FEC AFC1500 User Manual

AFC 1500 Multi Unit

1

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 [phone]

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 [phone]. Requests may be faxed to FEC INC. Product
Engineering at [phone].

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

Table of Contents

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

.

3

Table of Contents

Multi Unit Outline

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

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

3

7

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

9

10
10
10
10
10

11
12
13

15

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

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

25

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

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

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

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

26

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

49

50
50

AnyBus - DT Reference

5

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

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

Input / Output Signals & Fastening Data Outline

...

51
51

53

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

60

61

63

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Multi Unit Outline

Œ

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

8

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.

3

(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

9

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

10

Unit Description

PRINTER

S Win 98, NT, 2000, XP

NETWORK I/F UNI

T

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

11

Basic Dimensions

8

90

Shown with Discrete I/O board

Chapter 1: Multi Unit Outline

12

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

13

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

14

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

15

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

16

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

1

2

AFC1500

MULTI UNIT

3

Chapter 2: Setup and Wiring

17

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

18

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

1

2

Cable FEB-1268

UP TO 31 UNITS

3

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

19

Serial Communication Ports

The Multi Unit has three serial RS232C communication ports. All of these
port settings and data are fully configurable with the AFC User Console
software. COM1 is an output port for ASCII fastening data communication to
external devices. The COM2 port is for inputting ASCII data to the fastening
system for marriage to the fastening data. It is typically used for attaching part
serial number(s) to the fastening data for data storage birth history. COM3 is
reserved for a remote data display. The data format for these ports are
configurable using the AFC User Console software package.

1

6

PIN # SIGNAL NAME

DCD

1

2

RXD

3

TXD

4

DTR

5

GND

6

DSR

7

RTS

8

CTS

NOT USED

9

5

9

RS232C Pin Layout

Used only for Com 2 (input)*DCD Data Carrier Detect1
Serial Data Input.RXD Receive Data2
Serial Data Output.TXD Transmit Data3

DTR Data Terminal Ready4

Output signal; active when the internal device

is ready to link.
GND Ground Signal5
DSR Data Set Ready6

Input signal; indicates that the external device

is ready to establish a link. Can be connected

directly to DTR for automatic data dump.
RTS Request to Send7

Output signal. active when the internal device

is ready to exchange data.
CTS Clear to Send8

Input signal; indicates that the external device

is ready to exchange data. Can be connected

directly to RTS when no asynchronous data

flow is required.

Not usedRI Ring Indicator9

*When using Com2 (input) - Pin 1 DCD must be enabled for data
input.(Jumper pins 1 & 4)

Chapter 2: Setup and Wiring

20

RS232C COM1 port specifications (OUTPUT DATA)

Configurable (1200, 2400, 4800, 9600, 19,200)Speed
Configurable (7 or 8)Data bit
Configurable (1 or 2)Stop bits
Configurable (none, even or odd)Parity
Configurable (ASCII or PLC format1)Data Output format

RS232C COM2 port specifications (INPUT DATA)

Configurable (1200, 2400, 4800, 9600, 19,200)Speed
Configurable (7 or 8)Data bit
Configurable (1 or 2)Stop bits
Configurable (none, even or odd)Parity
Configurable (ASCII format)Data Input format

RS232C COM3 port specifications

Reserved for remote data display

1

PLC format adds STX (beginning of data) and ETX (end of data) control characters

Chapter 2: Setup and Wiring

21

Output Data Available

The Multi Unit is capable of outputting the fastening results data in an ASCII
format to a serial printer or other peripheral device. The data is sent from the
Multi Units RS232 COM1 port. The output data string as well as port
configuration can be configured by the AFC User Console Software. (Control
Characters may also be implemented ie; Start of Text, End of Text, etc.)
Below is a list of data available and its byte length.

Length in bytesBasic Fastening Data

6Peak Torque
5Final Angle
6First Time
6Final Time
5Cycle Time
7First Torque Rate
7Second Torque Rate
7Third Torque Rate
5Final Torque
5Offset Torque
3Judgement

Length in bytesExtended Fastening Data

4Current (@ peak torque)
4Angle (@ peak torque)
5First Peak Torque
5Second Peak Torque
5First Torque Rate Increment Torque
4First Torque Rate Increment Angle
5Second Torque Rate Increment Torque
4Second Torque Rate Increment Angle
5Third Torque Rate Increment Torque
4Third Torque Rate Increment Angle
4Rundown revolutions
5Cal Voltage Value
5Zero Voltage Value

Length in bytesInput Data*

RS232C data 1
RS232C data 2
RS232C data 3
RS232C data 4

Up to 128
This length is determined by the user
and dependent upon the length of data
input to these data areas.

Length in bytesSystem Data

10Date
8Time
2Spindle Number
2Sequence Number
2Parameter Number
7Cycle Count Number
3 (ASCII “RTY”)Retry Flag

*Input Data is input to the Multi Unit using RS232C Com2 port. This port
configuration is through the AFC User Console Software. The data must be
ASCII formatted data & is limited to 128 bytes in (4) separate data buffers.
The port must be configured for the input string which is to be received. The
data received can then be married with the resultant fastening data by selecting
the RS232 data in the output format. This function is typically used to marry a
part number with the resultant fastening data for production birth history.

Chapter 2: Setup and Wiring

22

Data Output Example

The example below shows the format of the COM1 output connected to a
printer. Actual data output format may vary depending on the configuration
and set-up of this port using the AFC User Console Software. The data field
is selectable from all the available output fields to as little as one output field.
(See previous table for available data fields) Headers, Footers & ASCII
control characters are all configurable using the AFC User Console Software.

2002/09/26 09:17:57 SEQ01
SP PA TORQUE ANGLE 1RATE 2RATE OFSET JUG Acceptable Fastening
01 01 0.50 2 0.000 0.005 0.00 O

2002/09/26 09:19:36 SEQ01
SP PA TORQUE ANGLE 1RATE 2RATE OFSET JUG Rejected Fastening
01 01 0.17L 0 0.000 0.000 0.00 X

2002/09/26 09:21:16 SEQ01
SP PA TORQUE ANGLE 1RATE 2RATE OFSET JUG Reset Cycle
01 01 0.23L 0 0.000 0.000 0.00 ! (Before fastening end)

2002/09/26 09:21:21 SEQ01
SP PA TORQUE ANGLE 1RATE 2RATE OFSET JUG Cycle Stopped
01 01 0.17L 0 0.000 0.000 0.00 ! (Before fastening end)

2002/09/26 09:21:34 SEQ01
SP PA TORQUE ANGLE 1RATE 2RATE OFSET JUG Abnormal
01 01 0.01 0 0.000 0.000 0.00 A05 (Showing abnormal code)

2002/09/26 09:21:21 SEQ01
SP PA TORQUE ANGLE 1RATE 2RATE OFSET JUG Spindle Bypassed
01 00 0. 0. 0. 0. 0.

Index

SEQ: Sequence 1RATE: 1st Rate H: High
SP: Spindle 2RATE: 2nd Rate L: Low
PA: Parameter OFSET: Offset Torque
ANGLE: Final Angle JUG: Judgment

Chapter 2: Setup and Wiring

23

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Chapter 2: Setup and Wiring

24

Control Interfaces

Ž

The Multi Unit has integrated a modular I/O

Interface to accommodate the use of fieldbus I/O

In this chapter

as well as discrete I/O making the unit

adaptable to changing I/O structures.

§Interface Board Setup

§Discrete I/O (24VDC)

§InterBus S

§DeviceNet

§Profibus

§CC Link

§Allen Bradley Remote I/O

§AnyBus-S Reference

§AnyBus-DT Reference

Chapter 3: Control Interfaces

25

Interface Board Setup

The Multi Unit is able to operate under different Input/Output control
structures through use of a modular I/O interface board installed in the unit.
With the introduction of “Open” communication networks known as
“Fieldbus”, the direct interfacing to these networks became necessary. FEC
integrated many of these Fieldbus directly into our system through use of a
modular I/O board interfacing these networks directly to our I/O.
The available interfaces are: Discrete I/O control (24VDC Sinking), InterBus
S, DeviceNet, Profibus, Mitsubishi CCLink & Allen Bradley Remote I/O.
The fieldbus interface boards are integrated directly to internal I/O signals
which eliminate associated I/O wiring thus reducing overall assembly labor.
In fieldbus systems, the communication is typically of the Master/Slave format
in which the FEC unit is a slave to the master CPU.
All I/O Motherboards have a DIP Switch SW1 (located at position 7D) which
has to be configured so the Multi Unit can identify the type of interface
installed.

To install an interface board:

1 Set the DIP Switch SW1 according to the table shown below.
2 Open the Multi Unit and mount the interface board.
3 Connect the ribbon cable from the Multi board CN2 to the interface board CN1.
4 Assemble the Multi Unit.

Chapter 3: Control Interfaces

26

SW1 DIP Switch setting for I/O board selection

Part #
Suffix

SW1

1

SW1

2

SW1

3

OFFOFFOFFON-1
OFFOFFONOFF-2
OFFOFFONON-3
OFFONOFFOFF-4
OFFONOFFON-5
OFFONONOFF-6
OFFONONON-7

INTERFACE TYPESW1

4

24VDC Sink Discrete I/O
24VDC Source Discrete I/O
DeviceNet - DT
DeviceNet(Estop) - DT
Interbus S - DT
Allen Bradley Remote I/O
Profibus - DT

ONOFFOFFOFF-8

Reserved

ONOFFOFFON-9

Devicenet - S

ONOFFONOFF-10

Reserved

ONOFFONON-11

Interbus S - S

ONONOFFOFF-12

Reserved

ONONOFFON-13

Profibus - S

ONONONOFF-14

CCLink* (Switches 5-8 NOT USED)

ONONONON-15

M-Net

Part # suffix refers to number added to Multi Unit Part number
(example: 1500Multi - 13 is a Multi unit with a Profibus -S interface board
installed)

-DT & -S boards refer to type of interface adapter installed.

-DT = Data transfer model(old model)

-S = Serial model (current model)
Devicenet (Estop) version is without Estop signal control

Chapter 3: Control Interfaces

27

Discrete I/O Interface

The Discrete I/O Interface is commonly used for direct connect PLC
applications. Although each individual AFC1500 Servo Controller can be
wired directly to a PLC through its own PLC I/O port (for individual control),
by using the Multi Unit , only the Multi Unit needs to be connected to the
PLC, eliminating the individual spindle I/O connection, thus reducing PLC
I/O quantities.

CN3 : PLC1 Connector (Inputs)
CN4 : PLC2 Connector (Outputs)

CN3

12

1

34

23

CN4

34

22

23

13

12

22

1

13

Connector Pin-out (View looking at connector) (Mating Connectors : Honda MR-34M & MR-34F)

Chapter 3: Control Interfaces

28

Input/Output Signals

Always ON / Always OFF

32

Data Select 2

32

Always ON / Always OFF

31

Data Select 1

31

As configured

29

Not Used

29

As configured

28

Not Used

28

As configured

27

Not Used

27

As configured

26

Bypass Spindle # 10

26

As configured

25

Bypass Spindle # 9

25

As configured

24

Bypass Spindle # 8

24

As configured

23

Bypass Spindle # 7

23

As configured

21

Bypass Spindle # 5

21

Spindle in By

pass (Any spindl

e)19Bypass Spindle # 3

19

Output (Connector PLC2)Input (Connector PLC1)

Pin No.SignalPin No.

Reject1Stop1
Accept2Reset2
Abnormal3Reverse3
Ready4Start4
Busy5Sequence Select 05
End6Sequence Select 16
Sequence 07Sequence Select 27
Sequence 18Sequence Select 38
Sequence 29Cycle Count Up9
Sequence 310Cycle Count Clear10
Out Port 111Not used11
Out Port 212Not used12
Out Port 313In Port 013
Out Port 414In Port 114
Out Port 515In Port 215
Out Port 616In Port 316
Out Port 717Bypass Spindle # 117
Out Port 818Bypass Spindle # 218

Current Limit Warning20Bypass Spindle # 420

Signal

2

As configured22Bypass Spindle # 622

Always ON / Always OFF30Data Select 030

Common (0 VDC)33Common (+24 VDC)33
Common (0 VDC)34Common (+24 VDC)34

Input Signals (Connector PLC1)

The Input Signals are provided on connector PLC1. Inputs are assigned in the
order to the above table. Pins designated as “Not Used” have no input
assigned to them.
NOTE: When using Discrete I/O, “Bypass Spindle” input signals assigned to
the PLC1 connector only can be used up to 10 individual spindles (From the
Multi Unit). When using Discrete I/O and you desire to connect this signal
from additional spindles, the signal must be wired from the individual SAN
Servo controllers using the SAN PLC connector. An alternative to this is to
use a Fieldbus interface which has control of all spindle bypass signals from
the interface.

2

This port is configurable by the User Console and the Data Select Input signals. See Chapter 4 for

further reference

Chapter 3: Control Interfaces

29

Output Signals (Connector PLC2)

The Multi Unit is capable of providing over 570 Output signals to indicate the
status of the Multi Unit and of all the AFC1500 SAN Controllers connected to
it (up to 31 controllers). These signals are user configurable using the AFC
User Console Software and may be programmed on any designated pin. Up to
8 separate output data “Banks” can be setup, each with 32 different output
signals. The Output “Bank” is then selected using the Data Select inputs.
(Data Sel 0, Data Sel 1, Data Sel 2) (The output setup listed above is an FEC
default setting)

Bank Select Outputs

When working with the Discrete I/O interface, the output signals are
programmed into “Banks” of 32 output signals in up to 8 output “Banks”
(Max. 256 outputs). If the required output signals from the Multi Unit exceeds
32 signals, then Bank 2 can be programmed with additional signals. If over 64
signals are required, Bank 3 can be programmed and so on. These Output
“Banks” can then be selected by the Data Select input signals. The Data Select
input signals 0, 1 & 2 together form a binary code to select up to eight (8)
different Data Banks. (See Chapter 4 for Bank Select Procedure)

Note: Bank Select inputs do not function with any interface except the
Discrete I/O interface. When using Bank selects, it is recommended that the
bank number be monitored to confirm actual output status of shared discrete
output points. This can be performed by using the “Always On/Off” bits
set-up in specific discrete output points when programming the output points
with the AFC User Console Software. For this function, program the “Always
On/Off” bits to mimic the Data Select input bits. “Always On” bits will turn
on the output in that particular Bank as soon as the bank is selected. “Always
Off” bits will turn off the output in the particular Bank which is selected.
Using different combinations of these bits programmed in a output in each
Bank will allow monitoring of which Bank is selected.
The number of discrete outputs used for this function depends on how many
Banks are required as shown below;

Number of Discrete Outputs RequiredNumber of Banks Required

0 or 11

22-4
35-8

Typically these “Always On / Off” bits are programmed in the last output
points (Pins 30 -32 as shown on previous page).

Chapter 3: Control Interfaces

30

Discrete Signal Connection

The Discrete I/O Interface operates with 24VDC Sink type (True Low)
connections as a default. (Contact FEC if 24VDC Source type (True High)
connections are desired) Typical configuration connection is shown in the
figure below;

Discrete I/O Port Specifications

24 VDCOperating Voltage
200 maMaximum current (outputs)
True Low (Sinking)Logic
CN3: Input Connector
CN4: Output

Chapter 3: Control Interfaces

31

Standard I/O Cable - Wire Color Code

The table below shows the color code of the standard FEC Discrete I/O cable
used for I/O connectors CN3 and CN4.
(FEC Cable Drawing FEB -1206)

Wire ColorPin No.

Black1
Brown2
Red3
Orange4
Yellow5
Green6
Blue7
Violet8
Gray9
White10
White/Black11
White/Brown12
White/Red13
White/Orange14
White/Yellow15
White/Green16
White/Blue17
White/Violet18
White/Gray19
White/Black/Brown20
White/Black/Red21
White/Black/Orange22
White/Black/Yellow23
White/Black/Green24
White/Black/Blue25
White/Black/Violet26
White/Black/Gray27
White/Brown/Red28
White/Brown/Orange29
White/Brown/Yellow30
White/Brown/Green31
White/Brown/Blue32
White/Brown/Violet33
White/Brown/Gray34

Chapter 3: Control Interfaces

32

InterBus S Interface Board

InterBus S from Phoenix Contact is a open ring-based, distributed device I/O
network. I/O data is transmitted in frames that provide simultaneous and
predictable updates to all devices in the network. This interface board (S ­version) has up to 512 bytes of assigned input data and 512 bytes of assigned
output data* (64bytes default), two DB9 connectors and status LEDs. The 64
bytes of assigned I/O data allows a maximum of 512 inputs and 512 outputs
per node. FEC I/O is assigned to the I/O points in these data areas (some I/O
will be designated spare). FEC Inputs match the Discrete input layout. FEC
Output location is programmed using the AFC User Console Software.

* When using Master boards where the PCP channel is NOT supported, the
maximum number of I/O will be 20 input bytes/ 20 output bytes.

FEC integrates the Interbus-S board manufactured by HMS Fieldbus Systems
AB into the Multi-Unit modular I/O board. For further technical information
on the Interbus-S interface go to the HMS website. (www.hms.se)

InterBus Specifications

Interface Specifications

* Actual Input/Output data length is configurable using the AFC Software
package. (See AnyBus-S Reference at the end of this chapter for I/O Setting
example.)

500K baudSpeed
256Nodes
400 mDistance
Point to point twisted pairCable
1-256 wordsPacket Size
Master/SlaveCommunication Type

512 (Default: 64 input data*)Input data bytes (including free data)
512 (Default: 64 output data*)Output data bytes (including free data)
Remote bus interfaceInters Interface type
+5VDC / 200 maOperating Voltage
4 words (1 word PCP, 3 word data)Data Width
F3 HexID Code
3 LED’sStatus Indicator
6000H, 6001HOutput objects
6002H, 6003HInput objects

Chapter 3: Control Interfaces

33

RBC

Daughter board

DB9 Connector (male)

6

1

5

9

BA

RBDA/ERR

5

9

1

6

DB9 Connector

(female)

Indication LED

Status LEDs

Red when outgoing bus is disabledRBDA - Remote Bus Disable1
Green if PCP channel is carried on InterbusTR - Transmit/Receive2

CC - Cable Check3

Green if cable connection good & master not
in reset

Green when monitoring layer 2BA - Bus Active4
Green if voltage is OKUL - Voltage OK at bus5

Watchdog LED- There is one additional bicolor Watchdog LED on the
interface board (inside unit). After the module is initialized by the application,
the LED with flash in a 1 sec. interval if running properly. Prior to
initialization by the application then the LED with flash with a 2 second
interval.

InterBus connectors- BUS IN

Pin 4
Pin 5

Chapter 3: Control Interfaces

34

DO1TXD+Pin 1
DI1RXD+Pin 2
ISOGNDIsolated GroundPin 3

/DO1TXD-Pin 6
/DI1RXD-Pin 7
PEPE Earth GroundShield

InterBus connectors- BUS OUT

DO2TXD+Pin 1
DI2RXD+Pin 2
ISOGNDIsolated GroundPin 3,5

Pin 4

/DO2TXD-Pin 6
/DI2RXD-Pin 7
RBSTPin 9
PEPE Earth GroundShield

Termination

Always terminate RBST to ground if it is not the last module on the bus. If
the RBST is not connected to ground, the interface will automatically
terminate the bus.

Chapter 3: Control Interfaces

35

DeviceNet Interface board

The DeviceNet communication interface allows slave connection to an
industrial DeviceNet network. DeviceNet allows industrial devices to be
controlled over an open network architecture enabling device connection at
various locations in the field. This “Fieldbus” technology reduces
hardwiring/cabling & provides ease of installation. It uses a
broadcast-oriented protocol -the CAN (Controller Area Network)- that can
interface to many devices such as limit switches, sensors, directional valves,
motor starters, bar code readers, process sensors, frequency drives, etc. The
network can have up to 64 nodes. Its maximum communication baud rate is
500K baud with a maximum cable distance of 100 m., 250 K baud at a 250m
max. cable length or 125K baud with a maximum cable distance of 500m.
Node addressing (MAC ID) & baud rate is selectable using the baud/address
selection DIP switch. Module & Network status LED’s provide network
diagnostics. Maximum I/O data is 512 input bytes & 512 output bytes. FEC
Inputs match the Discrete input layout. FEC Output location is programmed
using the AFC User Console Software.
Note: The DeviceNet interface is implemented according to the ODVA
specification for a communications adapter (profile no.12). It is acting as a
“group two only server” on the DeviceNet network.

FEC integrates the DeviceNet board manufactured by HMS Fieldbus Systems
AB into the Multi-Unit modular I/O board. For further technical information
on the DeviceNet interface go to the HMS website. (www.hms.se)
Further DeviceNet information can be found through the Open DeviceNet
Vendors Association (ODVA). (www.ODVA.org)

DEVICENET
CONNECTOR

BAUD/MAC ID
SETTING

LED
INDICATORS

Chapter 3: Control Interfaces

36

Termination

Termination of the fieldbus requires a terminating resistor at each end of the
fieldbus. These resistors should have a value of 121 ohms.

EDS File

Each device on a DeviceNet network is associated with an EDS file containing
all necessary information about the device to be connected. The network
configuration program uses this file during configuration of the network.
The EDS file associated with the FEC device can be downloaded from the
FEC website. www.fec-usa.com (file: abs.eds)
Direct link:www.fec-usa.com/fecusacomnew/support/index.htm
(the file can also be downloaded directly from HMS - www.hms.se)

Note: The FEC system will appear in the network Vendor list as “HMS
Fieldbus Systems” and in the network as “Anybus-S Devicenet” adapter. This
is the manufacturer of the interface board which is integrated into the Multi
Unit.

DeviceNet Specifications

500K baud max.Speed
64Nodes
500m max.Distance

Cable

Twisted pair for signal and power

Allen Bradley or equivalent ;
Thin Cable #1485C-P1-C
Thick Cable # 1485C-P1-A
Master/SlaveCommunications Type

DeviceNet connector

BlackV-Pin 1
BlueCAN_LPin 2

Drain/ShieldPin 3

WhiteCAN_HPin 4
RedV+Pin 5

Interface Board Specifications

+5V, 200 maOperating Voltage
Board switches 1 & 2Baud rate configuration
Board switches 3 to 8MAC ID setting
512 max.*Output data bytes
512 max.*Input data bytes
4 LEDs for module and network statusStatus indicator
2 MaximumServers per group
Dual Port RAM or Serial InterfaceInterface type

* Typical configuration is 32 Bytes (256 I/O points) but can be altered using
the AFC Software package. (See AnyBus-S Reference at the end of this
chapter for I/O Setting example.)
See section 4 (I/O signals) for reference of typical fieldbus I/O layout.
Operation Note: The first 16 bits of I/O are used by Devicenet
communication. The first input must be set “ON” to enable communication.

Chapter 3: Control Interfaces

37

Indication LED

Status LEDs (#1 & 4 not used)

(#2)

(#3)

No PowerOffModule Status LED
Device Operational - no errorsGreen solid
Minor Recoverable faultRed flashing
Unrecoverable module faultRed solid
Not Powered / Not OnlineOffNetwork Status LED
On-line but not connected.Green flashing
On-line, link OK, connected.Green solid
Connection Time OutRed flashing
Critical Link FailureRed solid

MAC ID setting (Board switch)

SW-7SW-6SW-5SW-4SW-3

(LSB)

MAC IDSW-8

Address 0OFFOFFOFFOFFOFFOFF
Address 1ONOFFOFFOFFOFFOFF
Address 2OFFONOFFOFFOFFOFF

Address 3 ONONOFFOFFOFFOFF

.......

Address 61ONOFFONONONON
Address 62OFFONONONONON
Address 63ONONONONONON

This switch must be set before power is on, and cannot be changed during
operation.

Baud rate setting (Board switch)

Baud rateSW-2SW-1

125KOFFOFF
250KONOFF
500KOFFON
ReservedONON

This switch must be set before power is on, and cannot be changed during
operation.

Chapter 3: Control Interfaces

38

Profibus Interface Board

The Profibus-DP communication interface allows slave connection to an
industrial Profibus-DP network. Profibus-DP allows industrial devices to be
controlled over an open network architecture enabling device connection at
various locations in the field. This “Fieldbus” technology reduces
hardwiring/cabling & provides ease of installation. It can interface to many
devices such as limit switches, sensors, directional valves, motor starters, bar
code readers, process sensors, frequency drives, etc. The network can have up
to 126 nodes. Its maximum communication baud rate is 12M baud and it’s
minimum baud rate is 9.6K baud.
Node addressing is selectable using the address selection switch. Baud rate is
auto detected from the master and no user setup is required. Module &
Network status LED’s provide network diagnostics. Maximum I/O data is
244 input bytes & 244 output bytes. FEC Inputs match the Discrete input
layout. FEC Output location is programmed using the AFC User Console
Software.
Note: The Profibus-DP interface is implemented according to the Profibus-DP
EN 50 170 (DIN 19245 Part 1) specification.

FEC integrates the Profibus-DP board manufactured by HMS Fieldbus
Systems AB into the Multi-Unit modular I/O board. For further technical
information on the Profibus-DP interface go to the HMS website.
(www.hms.se)
Further Profibus information can be found on the Profibus website at
www.profibus..com.

PROFIBUS
CONNECTOR

TERMINATION
SWITCH

ADDRESS
SETTING

LED
INDICATORS

Chapter 3: Control Interfaces

39

Termination

Termination of the fieldbus requires a terminating resistor at each end of the
fieldbus. A termination switch is provided on the Profibus-DP interface
board. Set the switch to “ON”, if termination is required. If external
terminators are used, the switch must be in the off position.

GSD File

Each device on a Profibus network is associated with an GSD file containing
all necessary information about the device to be connected. The network
configuration program uses this file during configuration of the network.
The GSD file associated with the FEC device can be downloaded from the
FEC website. www.fec-usa.com (File : hms_1003.gsd)
Direct link:www.fec-usa.com/fecusacomnew/support/index.htm
(the file can also be downloaded directly from HMS - www.hms.se)

Profibus Specifications

9.6K - 12M baud - autoselectedSpeed

Nodes

Distance

Cable

Maximum Cyclic I/O Size

Data transmission

126 Note:Node 126 is reserved for
commisioning purposes only

200m max. at 1.5Mbit/s extendable with
repeaters.
Shielded Copper Twisted Pair or fiber
optic
Master/Slave - EIA RS485Communications Type

Ver. 1.10Protocol Version
244bytes In, 244 bytes out max.
416 total bytes max.
The module only supports cyclic I/O
data transmission.

Profibus connector - D-Sub

Chapter 3: Control Interfaces

40

Not ConnectedPin 1
Not ConnectedPin 2

Positive RxD/TxD according to RS485 Spec.B- LinePin 3
Request to sendRTSPin 4
Isolated GND from RS 485 sideGND BusPin 5
Isolated +5V from RS 485 side+5V BusPin 6

Not connectedPin 7

Negative RxD/TxD according to RS485 Spec.A- LinePin 8

Not ConnectedPin 9

Connected to PEShieldHousing

Indication LED

Status LEDs

LED #4

LED #2

LED #3

LED #1- Not Used

Flashing Red ­1sec

Flashing Red ­2sec

Flashing Red ­4sec

Indicates faults on fieldbus sideRedFieldbus Diagnostics
Config. Error - in/out length set at
module intialize does not match
length in network config.
Error in user parameter data ­parameter length/content does not
match network length/content
Error in initialization of Profibus
communication ASIC
Module not onlineOffOn-Line
Module online and communication OKGreen
Module is not offline OffOff- Line
Module is offline on the fieldbusRed

Node Address

Before configuring the Profibus-DP module the node address has to be set.
This is done with two rotary switches on the module which can set the node
address 1-99 in decimal format. The Upper rotary switch (closest to the
D-sub) sets the “ten” digit (X 10), and the bottom rotary switch sets the single
digit. Example: To set node 37, place the “ten” switch on 3, and the single
digit switch on 7.
This switch must be set before power is on, and cannot be changed during
operation.

Configuration

FEC Profibus I/O configuration is programmable using the AFC User Console
software. I/O can be set as required by the application according to parameter
limits set forth by the GSD (Profibus) configuration file. The AFC Software
allows configuration of the number of I/O in the Multi Unit. Configuration of
the Profibus Master MUST match the configuration of the FEC Profibus
slave. In the Profibus Master set-up, input size and output size is set as “byte”

Chapter 3: Control Interfaces

41

ordering. (Do not use “word” ordering. This will inverse the I/O location)
When setting the Profibus Master configuration, PLC input size refers to FEC
output size (ie. Accept, Reject, Busy, etc.) and PLC output size refers to FEC
inputs (ie. Start, Stop, Reset, etc.). FEC will show up as 2 modules. Module
1 is inputs, module 2 is outputs. (See AnyBus-S Reference at the end of this
chapter for I/O Setting example.)

Chapter 3: Control Interfaces

42

Mitsubishi CC-Link

The Mitsubishi CC-Link communication interface allows slave connection to
an industrial Mitsubishi CC-Link network. FEC has a partner license with
Mitsubishi for the AFC1500 system for connection on the CC-Link network.
Mitsubishi CC-Link allows industrial devices to be controlled over an open
network architecture enabling device connection at various locations in the
field. This “Fieldbus” technology reduces hardwiring/cabling & provides ease
of installation. It can interface to many devices such as limit switches,
sensors, directional valves, motor starters, bar code readers, process sensors,
frequency drives, etc. The network can have up to 64 stations. Its maximum
communication baud rate is 10M baud and it’s minimum baud rate is 156K
baud.
Station addressing is selectable using the Station selection switch as well as
the number of occupied (32bit) stations using another selection DIP switch.
Baud rate is DIP switch selectable. Module & Network status LED’s provide
diagnostics. Maximum I/O data is 128 inputs & 128 outputs.

NOTE: The FEC CC-Link module is configured as a “Remote Device
Station” when setting up the parameters in the PLC program.
For detailed information on the Mitsubishi CC-Link Network, see the
Mitsubishi User Manual # 13J872 Control & Communication - Link System
Master / Local Module.

LED
INDICATORS

BAUD RATE
SETTING

LOCAL NUMBER
SETTING

CC-LINK
CONNECTOR

OCCUPIED STATION
SETTING

Chapter 3: Control Interfaces

43

Termination

Termination of the CCLink requires a terminating resistor at each end of the
fieldbus. Connect 120 ohm resistor between the DA & DB terminals if this is
the last connection. (Remember that the CCLink master also needs to be
terminated)

CC Link Specifications

156K - 10M baud - selectableSpeed
64 Max.Stations

Distance

Cable

Maximum Cyclic I/O Size

I/O Configuration*

1200m max. at 156K baud / 50m max.
at 10Mbit/s
Shielded Copper Twisted Pair
Mitsubishi BA1SJ61-(m) m=Meters
Belden 8102 or equivilent
Master/Slave - EIA RS485Communications Type

HDLC StandardTransmission Format
128 inputs, 128 outputs max. Size set
in groups of 32 I/O (Occupied Stations)
I/O addressing set by PLC TO / FROM
commands in Logic

* Actual I/O addressing must be assigned in the PLC logic. See the
Mitsubishi User Manual # 13J872 Control & Communication - Link System
Master / Local Module for logic reference. (Ref. Section 10)

CC-Link connector

Communication LineDAPin 1
Communication LineDBPin 2
Digital GroundDGPin 3
Connect cable shieldSHIELDPin 4
Field GroundFGPin 5

Connector: 5.08mm BU04/5 Hartmann or Equivalent

Wiring of the CC-Link network should be performed by using the cable listed
above in the CC-Link Specifications. The three twisted conductors should be
wired in series to each CC-Link device, using a terminating resistor at the
Master end and on the last Remote/Local device between the DA & DB
terminals. Connection should be DA to DA, DB to DB, DG to DG with the
cable shield connected to the SHIELD terminal. The field ground (FG) should
be connected to earth ground.

Chapter 3: Control Interfaces

44

Station Number Setting (SW1)

SW-8SW-7SW-6SW-5SW-4SW-3SW-2SW-1

Station

#

1OFFOFFOFFOFFOFFOFFOFFON
2OFFOFFOFFOFFOFFOFFONOFF

.........

10OFFOFFOFFONOFFOFFOFFOFF

.........

47OFFONOFFOFFOFFONONON

.........

64OFFONONOFFOFFONOFFOFF

Station Number sets the address in the CC-Link network. Max. number of
stations is 64. No two devices may share the same address. Switch setting
format is Binary Coded Decimal (BCD) Switch 1-4 is Least Significant Byte
(LSB). Switch 5-8 is Most Significant Byte (MSB). This switch must be set
before power is on, and cannot be changed during operation.

Baud rate setting (SW2)

Baud rateSW-4SW-3SW-2SW-1

156KOFFOFFOFFOFF
625KOFFOFFOFFON

2.5MOFFOFFONOFF
5MOFFOFFONON
10MOFFONOFFOFF

This setting MUST match the setting of the Master module. This switch must
be set before power is on, and cannot be changed during operation.

Number of Occupied Stations (SW3)

SW-4SW-3SW-2SW-1Number of Stations

OFFONONON1 (32 In/32 Out)
OFFONOFFON2 (64 In/64 Out)
OFFONONOFF3 (96 In/96 Out)
OFFONOFFOFF4 (128 In/128 Out)

Occupied Stations setting determines the number of 32 bit station buffer
memory locations that will be allocated for this station in the Master buffer
memory. This sets the number of total I/O available for the station. Each
memory bit has a designated input AND output buffer. So a setting of (1) 32
station actually allocates 32 input & 32 output locations for a total of 64 total
points. This switch must be set before power is on, and cannot be changed
during operation.
NOTE: See FEC Electrical Controls drawings for actual setting required as
this may vary per application.

Chapter 3: Control Interfaces

45

Indication LED

Status LEDs

Watchdog Timer errorOFFRUN
Module is Normal - RunningON
NormalOFFERR
Communication error at all StationsON - Steady
Communication error at StationON - Flashing
Module Sending DataSend DataSD
Module Reading DataRead DataRD

Configuration

Configuration of the CCLink system is done in the PLC Logic. It is essential
that this configuration matches the Dip Switch settings of the FEC CCLink
slave. FEC is considered a “Remote Device” in the PLC configuration. The
number of “Occupied Stations” set in the PLC must also match the Dip Switch
set-up. (Note: The last 16 output addresses are used by the CCLink
communication & cannot be used by the user) Below is an example of the
PLC configuration setting for the FEC Node in the CCLink network;

Command
[MOV H1306 D19]

Description

MOV = Move command
H = Hex number being used
1 = Remote Device (0= Remote I/O Station, 2= Intelligent Device)
3 = 3 Occupied Stations (3 x 32I/O = 96 Inputs & Outputs, (4 is max.))
06 = Station #6 (CCLink address, 64 max.)
D19 = PLC register which stores the configuration (could be any register #)

Note: This is only an example of the station setting configuration. Other
configuration must be completed in the PLC logic for proper operation. The
PLC configuration MUST match the settings of the FEC Dip Switches. The
communication link will not be established and the red “ERR” LED will be lit
if these settings do not match. Please review the Mitsubishi CCLink manual
#13J872 for further information.

Chapter 3: Control Interfaces

46

Allen Bradley Remote I/O Interface board

The Allen Bradley (AB) Remote I/O communication interface allows slave
connection to an AB Remote I/O network. FEC has licensed (Lic.
#199906006) the use of the AB Remote I/O interface board (through HMS
Fieldbus Systems). AB Remote I/O is a proprietary Fieldbus of Allen Bradley.
AB - RIO allows industrial devices to be controlled over a network
architecture enabling device connection at various locations in the field. This
“Fieldbus” technology reduces hardwiring/cabling & provides ease of
installation. The network can have up to 240 nodes with valid rack addresses
of 0-59. Its maximum communication baud rate is 230K baud with two other
settings of 115K & 57.6K baud.
Rack addressing & baud rate is selectable using the baud/address selection
DIP switch. Module status LED’s provide network diagnostics. Maximum
I/O data is 128 inputs & 128 outputs (Full Rack). 1/4, 1/2, 3/4 & Full rack
configuration is supported. (Default config. is 1/2 Rack 64In/64Out)

FEC integrates the AB Remote I/O board manufactured by HMS Fieldbus
Systems into the Multi-Unit modular I/O board. For further technical
information on the AB Remote I/O interface see the AnyBus -DT reference
found at the end of this chapter or go to the HMS website. (www.hms.se)
Further AB Remote I/O information can be found through Allen Bradley’s
website. (www.ab.com)

BAUD/ADDRESS
SETTING

LED
INDICATION

TERMINATION
SWITCH

REMOTE I/O
CONNECTOR

Chapter 3: Control Interfaces

47

Termination

Termination of the RIO network requires a terminating resistor at each end of
the network. If this is the last module on the network, turn “ON” the
terminating switch located on the interface board.

AB Remote I/O Specifications

57.6, 115, 230K baud - SelectableSpeed
0-59Rack Addresses
up to 240 1/4 racksNodes
1/4, 1/2 (Default), 3/4, Full Rack Configuration supported*

Distance

Cable

57.6k - 3048 meter
115K - 1524 meter
230K - 762 meter

78 ohm Twinax
Belden #9463 or equivalent
Master/SlaveCommunications Type

*Rack Config. set by AFC User Console software. Contact FEC for other
setting.

AB Remote I/O connector

BlueCOM linePin 1
ShieldGNDPin 2
ClearCOM linePin 3

Indication LED

Status LEDs

Normal OperationOFFError
Bus off / ErrorON - Red
No CommunicationOFFActive
Communication ActiveON - Green
Power OffOFFPower
Power OnON - Green

Chapter 3: Control Interfaces

48

Address setting (DIP switch)

MAC IDSW-8SW-7SW-6SW-5SW-4SW-3

(LSB)

Address 0*OFFOFFOFFOFFOFFOFF
Address 1OFFOFFOFFOFFOFFON
Address 2OFFOFFOFFOFFONOFF

Address 3 OFFOFFOFFOFFONON

.......

Address 57ONONONOFFOFFON
Address 58ONONONOFFONOFF
Address 59ONONONOFFONON

This switch must be set before power is on, and cannot be changed during
operation.
*Address should be set to “0” if this is the only device on the network.

Baud rate setting (Board switch)

Baud rateSW-2SW-1

57.6KOFFOFF
115KOFFON
230KONOFF
ReservedONON

Baud rate must match the settings of the Remote I/O scanner.
This switch must be set before power is on, and cannot be changed during
operation.

Fieldbus I/O Assignment

See Input/Output Signal & Fastening Data Outline Section (4) for a
description of the I/O and it’s assignment location.

Chapter 3: Control Interfaces

49

ANYBUS-S Reference

AnyBus S Initialization

FEC incorporates the ANYBUS module as the interface to various fieldbus
communication devices. (manufactured by HMS, www.hms.se) It is intialized
by the AFC 1500 Multi Unit which sets certain parameters including the size
of the Input / Output tables to be used for the particular fieldbus. All
fieldbus’s except for the Allen Bradley Remote I/O use the “-S” type of
AnyBus Card. This provides interchangeability between the cards while
minimizing software changes. This also allows FEC to set parameters to all
the different types of fieldbus cards with the same parameter set-up software.
The AFC User Console has the function included to set the parameters, mainly
Input / Output size, to the Anybus card. Below is an example of the
command structure. The “Message Data” area near the bottom is where the
I/O size is set.

NOTE: FEC sets this at the Factory, and does not recommend setting this
by the end user. This information is provided for reference only.

Command Layout

Register Name Command
Message ID 000A
Message Info 4001
Command 0002
Data size 0012
Frame Count 0001
Frame Number 0001
Offset High 0000
Offset Low 0000
Extended word 1 ­Extended word 2 ­Extended word 3 ­Extended word 4 ­Extended word 5 ­Extended word 6 ­Extended word 7 ­Extended word 8 - Example
Message Data word 1 IN I/O Length 0010 (16 bytes 128 inputs)
Message Data word 2 IN DRAM Length 0010 (FEC outputs)
Message Data word 3 IN Total Length 0010
Message Data word 4 OUT I/O Length 0008 (8 bytes 64 outputs)
Message Data word 5 OUT DRAM Length 0008 (FEC Inputs)
Message Data word 6 OUT Total Length 0008
Message Data word 7 Module Status 0002
Message Data word 8 Interrupt Notification 0003
Message Data word 9 Watchdog Counter 0000

In the AFC User console Multi-fieldbus setup, the (S Type) setup menu is
used to input/download this data. Other commands are required to transfer
this data, but the command “000A” is the command which sets the I/O size.

Chapter 3: Control Interfaces

50

AnyBus - DT Reference (Allen Bradley Remote I/O)

AnyBus DT Initialization

FEC incorporates the ANYBUS module as the interface to various fieldbus
communication devices. (manufactured by HMS, www.hms.se) It is intialized by the
AFC 1500 Multi Unit which sets certain parameters including the size of the Input /
Output tables to be used for the particular fieldbus. The DT model is only used for
the FEC Allen Bradley Remote I/O interface. The AFC User Console software
package is able to configure setup parameters for Allen Bradley Remote I/O as
shown below. (The (DT Type) setup menu is used to input/download this data.)

NOTE: FEC sets this at the Factory, and does not recommend setting this by
the end user. This information is provided for reference only.

DT Address Name Description
3D0h RIO Data Rate 0: 57.6 kbits/sec

1: 115.2 kbits/sec
2: 230.4 kbits/sec
3-255 Not valid (set at 2)
Default value read from Dip Switch

3D1h RIO Rack Address 0x00 - 0x3b valid rack address

0x3c - 0xff invalid setting, set at 0x3b
Default value read from Dip Switch

3D2h RIO Rack Size 0: 1/4 rack

1: 1/2 rack (default)
2: 3/4 rack
3: Full rack
4-255: Not Valid, (set to 3)

3D3h RIO Start Quarter 0: 1st (default)

1: 2nd
2: 3rd
3: 4th
4-255: not valid (set to 3)

Only 0 is valid in block transfer mode

3D4h RIO Last Rack 0: Not last rack (default)

1: Last Rack
2-255: Not valid (set to 1)

3D5h RIO Restart Lockout 0: module reintializes on

communication fault (default)
1: Module locks out, restart with power
down
2-255: Not valid (Set at 1)

3D6h Not used

3D7h RIO IO Mode 0: Mixed mode

1: Mixed mode- IO start at byte 2
2: Only Block transfer
3: Only discrete data (default)
4-255: not valid (set at 3)

Chapter 3: Control Interfaces

51

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Chapter 3: Control Interfaces

52

Input / Output Signals and

•

Fastening Data Outline

In this chapter

§Input Signals

This chapter provides a description of all input

and output control signals, typical I/O layout

(for fieldbus) and Fastening output data

available in the Multi Unit.

§Output Signals

§Signal Timing

§SAN Output Signals

§I/O Layout

§Abnormal Code

Multi Unit Input Signals

Multi Unit Input Signals

1

Stop

2

Reset

3

Reverse

4

Start

5

Seq 0

6

Seq 1

7

Seq 2

8

Seq 3

9

Cycle Count Up

10

Cycle Count
Clear

13

In Port 0

14

In Port 1

15

In Port 2

16

In Port 3

Emergency Stop Input (Normally Closed).
Signal MUST be Active to perform fastening.
When this signal is inactive (off), all Multi Unit operation
ceases, all spindles in motion will stop, and all
communication ports & input/outputs will be disabled.
Reset Input (Normally Open).
When active (on), this signal will clear all fastening
data, and discrete outputs. A Zero Check of all torque
transducers will be completed. During the Zero Check,
the CHECK lamp will illuminate, the READY signal will
turn OFF, and the ACCEPT or REJECT lamp will light
to indicate the result of the Zero Check. If the System
has been disabled by an Abnormal output, the System
will not return to normal operation until the Abnormal
condition has been corrected, and this signal has been
input for 200~500 ms. Do not input this signal between
cycles, as part of an automatic cycle due to the
potential for fastening data loss.

Reverse Spindle Rotation Input (Normally Open). All
spindles will rotate in an opposite direction (of
fastening) for as long as this signal is activated (on) and
maintained. The Reverse input functions the same as
the reverse pushbutton on the front of the Multi Unit.
Start Cycle Input (Normally Open).
The Start input automatically resets the previous cycle,
clears all data to zero, and initiates the next fastening
cycle. The Start input requires a pulse of 200~500
milliseconds if the Multi Unit is set up for AUTOMATIC
Start input. If it is set up for DEADMAN (hand-held
operations) input, the Start input must be maintained
"on" for the entire cycle. Typically, this signal is held on
until confirmation of the “Busy” signal is received.
Sequence Select Input (Normally Open).
These 4 inputs form a binary code which is capable of
selecting up to 16 different operation sequences. Refer
to Sequence Select Table.

Cycle Count Input (Normally Open).
The System cycle counter will increment each time this
signal is input if the CYCLE COUNT UP is set to PLC
SIGNAL in the Multi Unit. The Cycle Count input
requires a pulse of at least 50 ms to increment the
counter. If the CYCLE COUNT UP is set to AUTO, the
cycle counter increments automatically at the end of
every fastening.
Sets the cycle count to Zero.

External Sequence Input (Normally Open)
These four (4) signals are external inputs to the
fastening sequence. When a [PLC INPUT WAIT]
instruction is programmed in the fastening sequence, it
will stop until the designated external input is active.

Chapter 4: I/O & Output Data

54

Multi Unit Input Signals

30

Data Select 0

31

Data Select 1

32

Data Select 2

17*

Bypass Spindle
#1

26*

Bypass Spindle
#10

35*

Bypass Spindle
#11

55*

Bypass Spindle
#31

* Spindle Bypass signals can only be used with a Fieldbus interface (except
spindle 1-10 is available in discrete I/O) . If using the Discrete I/O interface
the spindle bypass signals are wired from the SAN Unit PLC connector (if you
have more than 10 spindles) . See I/O layout for input location in fieldbus.

These lines form a binary code to select up to 8 Output
Data Banks. Used for Digital I/O interfaces. NOTE: Not
Used for Fieldbus interfaces.

Bypass’s spindle #1 - Spindle is ignored as if it does not
exist.

...

Bypass’s spindle #10 - Spindle is ignored as if it does
not exist.

Bypass’s spindle #11 - Spindle is ignored as if it does
not exist.

...

Bypass’s spindle #31 - Spindle is ignored as if it does
not exist.

1
2
3
4
5
6
7
8

9
10
11
12
13
14
15
16

Sequence Select Table

Sequences are selected using the Sequence Select Bits 0-3. Using these four
bits in a binary fashion, 16 sequences can be selected. With all bits “OFF”,
sequence #1 is selected and with all bits “ON”, sequence #16 is selected. The
Sequence must be set before the start signal is received. It is recommended
when using multiple sequences that the Sequence Output signals (SEQ. 0-3)
be used to confirm which sequence is selected BEFORE starting the cycle.

Seq Select 3Seq Select 2Seq Select 1Seq Select 0Sequence

offoffoffoff
offoffoffon
offoffonoff
offoffonon
offonoffoff
offonoffon
offononoff
offononon
onoffoffoff
onoffoffon
onoffonoff
onoffonon
ononoffoff
ononoffon
onononoff
onononon

Chapter 4: I/O and Output Data

55

Multi Unit Output Signals

The Multi Unit is capable of providing over 570 Output signals to indicate the
status of the Multi Unit and all of the AFC1500 SAN Servo Controllers
connected to it (up to 31 controllers). By using the AFC User Console
Software, it is possible to select the signals to be output and set them in a
specific address location. The output layout must be programmed and in
effect there is no assigned outputs. However, FEC sets output signals in a
typical layout but keep in mind that every application could be different.
Refer to the specific applications Electrical Controls drawings for the exact
layout.
When working with the Discrete I/O interface, additional output signals
required beyond 32 outputs are realized using the “BANK” select function.
Up to 8 banks of 32 outputs can be selected, each programmable from the
User Console Software. If the Interface is for a Fieldbus application, Bank
selecting is not necessary. All outputs required can be programmed to specific
fieldbus addresses.

Bank Select Procedure

When using a discrete I/O interface, the output signals can be arrayed in
groups called data “banks” which are selected by the Data Select input signals.
The Data Select signals 0, 1 & 2 form together a binary code to select up to
eight (8) different Data Banks of 32 outputs as shown below;

Output Data BankData Select 2Data Select 1Data Select 0

Bank 1offoffoff
Bank 2offoffon
Bank 3offonoff
Bank 4offonon
Bank 5onoffoff
Bank 6onoffon
Bank 7ononoff
Bank 8ononon

See Chapter 3 : Bank Select Outputs for more information on Bank Selects.

Chapter 4: I/O & Output Data

56

Multi Unit Output Signals

Each data bank is configurable to contain any of the Multi or AFC1500 SAN
Servo Controllers signals listed below

Multi Unit Output Signals

1

2

3

4

5

6

7
8

9
10
11
12
13
14
15
16
17
18
19

20

21

22

Reject

Accept

Abnormal

Ready

Busy

End

Sequence 0
Sequence 1
Sequence 2
Sequence 3
Out Port 1
Out Port 2
Out Port 3
Out Port 4
Out Port 5
Out Port 6
Out Port 7
Out Port 8
Spindle in
Bypass

Current
Limit
Warning

Always
ON / OFF

Combination

Bits 1-8

Output when the fastening result is a REJECT. Indicates
that one or more spindles has failed achieving the fastening
limits. This output remains active until the START signal or
RESET signal is input.
Output when the fastening result is a ACCEPT. Indicates all
spindles are within fastening limits. This output remains
active until the START signal or RESET signal is input.

Output when an Abnormal condition occurs. This signal
indicates that the System has detected an internal fault, and
can no longer proceed. The fault maybe generated from a
connected spindle during a self-check function. Check the
individual spindle status to identify which spindle is reporting
the abnormal condition. (see AFC1500 Operation Manual
for troubleshooting) The spindle reporting an abnormal may
be bypassed to resume normal operation, however, the
bypassed spindle will be ignored and not run while in
bypass. An Abnormal condition must be corrected before
the System will resume normal operation. The RESET
signal clears the abnormal condition.
Output when the system is in the READY condition.
Indicates system is ready to operate, and inputs are
enabled. This signal is inactive (off) when the BUSY output
is active (on).
Output after a START signal is received, and active until the
fastening cycle is complete and the READY signal is output.

Output when a fastening cycle is complete. Remains active
until the START, RESET or REVERSE signal is input.
Output confirmation of SEQUENCE SELECT 0~3 input
selections. Sequence bits are active according to what
sequence is set from the sequence select inputs. Used to
confirm proper sequence before fastening start.

These signals will output, when the fastening sequence
reaches a step that has a [PLC OUTPUT] instruction
inserted. Used to provide sequence operation status to
external PLC’s and/or control outputs for slide motion, lights,
& buzzers, etc without the use of a PLC. (The AFC User
Console Software can set these outputs on and off in the
fastening sequence)

Signal is active when any of the connected spindles are
bypassed either from San Unit bypass input signals or from
the San Unit bypass switch.
Active when high current warning limit has been exceeded.
This can be used to identify potential motor failure before
total failure occurs by identifying high current draws over
what the typical current draw is for the application.

Can be used to set outputs ON or OFF . Mainly used in
conjunction with Bank Outputs to monitor which Bank is
selected
Used to create “special” outputs formed by using a
combination of SAN Unit outputs in “And / Or” logic.

Chapter 4: I/O and Output Data

57

Signal Timing

The chart below shows basic Multi Unit signal timing.

STOP

RESET

START

REVERSE

FASTENING

BUSY

READY

ACCEPT

REJECT

ABNORMAL

OFF

OFF

OFF

OFF

ON

ON

OFF

OFF

OFF

ON

ON

OFF

OFF

ON

OFF

ON

OFF

ON

§ Because the RESET input clears all fastening data, and discrete outputs, it
should be activated only to clear a system Abnormal or to perform a Zero
Level Check. The System will automatically reset with each fastening,
and a Manual RESET activation between cycles could result in data loss.
The RESET signal requires a pulse of 200~500 milliseconds.

§ The REVERSE signal must be maintained for the duration of the desired
REVERSE function.

§ The STOP input is Normally Closed, and enables all other functions.
When STOP is Open (off), all operations cease and all inputs / outputs
become inactive.

§ The START signal will not operate during RESET, REVERSE, or
ABNORMAL signal activation. The START signal requires a pulse of
200~500 milliseconds for the AUTO START mode. For the DEADMAN
mode (Used mainly in handheld applications), the signal must be
maintained during the complete fastening cycle.

§ When the ABNORMAL signal is active, The system must be RESET
before normal operation will resume.

§ REJECT / ACCEPT signals are maintained until the start of the next cycle.

§ READY will indicate when the system is ready to start.

Chapter 4: I/O & Output Data

58

Sequence Select Timing

This example shows the sequence select timing for selecting sequence #6.

INPUTS

OUTPUTS

SEQUENCE SELECT 0

SEQUENCE SELECT 1

SEQUENCE SELECT 2

SEQUENCE SELECT 3

SEQUENCE SELECT 0

SEQUENCE SELECT 1

SEQUENCE SELECT 2

SEQUENCE SELECT 3

START

OFF

ON

OFF

OFF

ON

OFF

OFF

ON

OFF

OFF

ON

OFF

OFF

ON

5ms

It is recommended when changing sequences that the Sequence Select outputs
be used to verify that the sequence has been changed before issuing a start
signal. Delay from Sequence Select input to Sequence Select output is
approx. 5ms.

Chapter 4: I/O and Output Data

59

Output signals from the SAN Servo Controllers

The output signals listed below are signals available from the individual
spindle controller (SAN) Unit and only indicate status from that particular
spindle. They do not indicate status from any other spindle or group of
spindles. These are typically used for individual spindle status display.
The number in the tables below are only for reference showing total number of
signals available per spindle. (Total number of available signals from the SAN
Units: 31 Spindles X 28 Signals = 868 signals)

AFC1500 SAN Servo Controller Output Signals

RejectREJ1
AcceptACC2
AbnormalABN3
In BypassBYP4
ReadyRDY5
BusyBUSY6
Parameter Select 1 bitP SEL 17
Parameter Select 2 bitP SEL 28
Parameter Select 3 bitP SEL 39
Parameter Select 4 bitP SEL 410
Time 1 Reject LowTM1 LO11
Time 1 Reject HighTM1 HI12
Time 2 Reject LowTM2 LO13
Time 2 Reject HighTM2 HI14
Final Torque Low RejectFT LO15
Final Torque High RejectFT HI16
Peak Torque Low RejectPT LO17
Peak Torque High RejectPT HI18
Angle Low RejectAN LO19
Angle High RejectAN HI20
Torque Rate 1 Low RejectTR1 LO21
Torque Rate 1 High RejectTR1 HI22
Torque Rate 2 Low RejectTR2 LO23
Torque Rate 2 High RejectTR2 HI24
Torque Rate 3 Low RejectTR3 LO25
Torque Rate 3 High RejectTR3 HI26
Current Warning LowAMP LO27
Current Warning HighAMP HI28

Chapter 4: I/O & Output Data

60

Typical I/O Layout (Fieldbus)

The following I/O layout map is provided as a typical reference of the bit
addressing for FIELDBUS systems. This is only a reference and NOT
intended for any particular application or fieldbus type. See your application’s
Electrical Control Schematic drawings for your actual I/O layout.
Note: The inputs are permanently set in the location shown and cannot be
changed. However, the Output locations are programmable and may not
reside in the locations shown.

Inputs

InputBitInputBitInputBit

Not Used65Spindle Bypass 1133Stop1
Not Used66Spindle Bypass 1234Reset2
Not Used67Spindle Bypass 1335Reverse3
Not Used68Spindle Bypass 1436Start4
Not Used69Spindle Bypass 1537Seq. Select 05
Not Used70Spindle Bypass 1638Seq. Select 16
Not Used71Spindle Bypass 1739Seq. Select 27
Not Used72Spindle Bypass 1840Seq. Select 38
Not Used73Spindle Bypass 1941Cycle Count - Up9
Not Used74Spindle Bypass 2042Cyc. Count Reset10
Not Used75Spindle Bypass 2143Not Used11
Not Used76Spindle Bypass 2244Not Used12
Not Used77Spindle Bypass 2345Input Port 013
Not Used78Spindle Bypass 2446Input Port 114
Not Used79Spindle Bypass 2547Input Port 215
Not Used80Spindle Bypass 2648Input Port 316
Not Used81Spindle Bypass 2749Spindle Bypass 117
Not Used82Spindle Bypass 2850Spindle Bypass 218
Not Used83Spindle Bypass 2951Spindle Bypass 319
Not Used84Spindle Bypass 3052Spindle Bypass 420
Not Used85Spindle Bypass 3153Spindle Bypass 521
Not Used86Not Used54Spindle Bypass 622
Not Used87Not Used55Spindle Bypass 723
Not Used88Not Used56Spindle Bypass 824
Not Used89Not Used57Spindle Bypass 925
Not Used90Not Used58Spindle Bypass 1026
Not Used91Not Used59Not Used27
Not Used92Not Used60Not Used28
Not Used93Not Used61Not Used29
Not Used94Not Used62Data Sel. 0 (N/A)30
Not Used95Not Used63Data Sel. 1 (N/A)31
Not Used96*Not Used64Data Sel. 2 (N/A)32

*Note: The number of data bits reserved for inputs varies with the type of
fieldbus interface. It varies between 16 & 256 (or more), even though the
number of inputs are limited to this list. See your applications Electrical
Drawings for this information.

Chapter 4: I/O and Output Data

61

Outputs

OutputBitOutputBitOutputBit

Spdl. 22 Reject97Spdl. 10 Reject49Reject (Total)1
Spdl. 22 Accept98Spdl. 10 Accept50Accept (Total)2
Spdl. 22 Abnormal99Spdl. 10 Abnormal51Abnormal3
Spdl. 22 Bypassed100Spdl. 10 Bypassed52Ready4
Spdl. 23 Reject101Spdl. 11 Reject53Busy5
Spdl. 23 Accept102Spdl. 11 Accept54End6
Spdl. 23 Abnormal103Spdl. 11 Abnormal55Seq. 0 Selected7
Spdl. 23 Bypassed104Spdl. 11 Bypassed56Seq. 1 Selected8
Spdl. 24 Reject105Spdl. 12 Reject57Seq. 2 Selected9
Spdl. 24 Accept106Spdl. 12 Accept58Seq. 3 Selected10
Spdl. 24 Abnormal107Spdl. 12 Abnormal59Spdl. in Bypass11
Spdl. 24 Bypassed108Spdl. 12 Bypassed60Current Warning12
Spdl. 25 Reject109Spdl. 13 Reject61Spdl. 1 Reject13
Spdl. 25 Accept110Spdl. 13 Accept62Spdl. 1 Accept14
Spdl. 25 Abnormal111Spdl. 13 Abnormal63Spdl. 1 Abnormal15
Spdl. 25 Bypassed112Spdl. 13 Bypassed64Spdl. 1 Bypassed16

Spdl. 26 Reject113Spdl. 14 Reject65Spdl. 2 Reject17
Spdl. 26 Accept114Spdl. 14 Accept66Spdl. 2 Accept18
Spdl. 26 Abnormal115Spdl. 14 Abnormal67Spdl. 2 Abnormal19
Spdl. 26 Bypassed116Spdl. 14 Bypassed68Spdl. 2 Bypassed20
Spdl. 27 Reject117Spdl. 15 Reject69Spdl. 3 Reject21
Spdl. 27 Accept118Spdl. 15 Accept70Spdl. 3 Accept22
Spdl. 27 Abnormal119Spdl. 15 Abnormal71Spdl. 3 Abnormal23
Spdl. 27 Bypassed120Spdl. 15 Bypassed72Spdl. 3 Bypassed24
Spdl. 28 Reject121Spdl. 16 Reject73Spdl. 4 Reject25
Spdl. 28 Accept122Spdl. 16 Accept74Spdl. 4 Accept26
Spdl. 28 Abnormal123Spdl. 16 Abnormal75Spdl. 4 Abnormal27
Spdl. 28 Bypassed124Spdl. 16 Bypassed76Spdl. 4 Bypassed28
Spdl. 29 Reject125Spdl. 17 Reject77Spdl. 5 Reject29
Spdl. 29 Accept126Spdl. 17 Accept78Spdl. 5 Accept30
Spdl. 29 Abnormal127Spdl. 17 Abnormal79Spdl. 5 Abnormal31
Spdl. 29 Bypassed128Spdl. 17 Bypassed80Spdl. 5 Bypassed32

Spdl. 30 Reject129Spdl. 18 Reject81Spdl. 6 Reject33
Spdl. 30 Accept130Spdl. 18 Accept82Spdl. 6 Accept34
Spdl. 30 Abnormal131Spdl. 18 Abnormal83Spdl. 6 Abnormal35
Spdl. 30 Bypassed132Spdl. 18 Bypassed84Spdl. 6 Bypassed36
Spdl. 31 Reject133Spdl. 19 Reject85Spdl. 7 Reject37
Spdl. 31 Accept134Spdl. 19 Accept86Spdl. 7 Accept38
Spdl. 31 Abnormal135Spdl. 19 Abnormal87Spdl. 7 Abnormal39
Spdl. 31 Bypassed136Spdl. 19 Bypassed88Spdl. 7 Bypassed40
Spare137Spdl. 20 Reject89Spdl. 8 Reject41
Spare138Spdl. 20 Accept90Spdl. 8 Accept42
Spare139Spdl. 20 Abnormal91Spdl. 8 Abnormal43
Spare140Spdl. 20 Bypassed92Spdl. 8 Bypassed44
Spare141Spdl. 21 Reject93Spdl. 9 Reject45
Spare142Spdl. 21 Accept94Spdl. 9 Accept46
Spare143Spdl. 21 Abnormal95Spdl. 9 Abnormal47
Spare144Spdl. 21 Bypassed96Spdl. 9 Bypassed48

Note:These outputs are programmable & may not reflect this layout in your
application.

Chapter 4: I/O & Output Data

62

Abnormal Code

The Multi Unit is capable of giving unit fault status to the AFC 1500 User
Console in the form of a code number. This number can be read and
displayed by the User Console software. (See the User Console manual for
more information where to access this function) These codes are only
available on Multi Firmware version 3.34 or later.

Number

Description Abnormal

1

2

3

4

7

8

9

An Axis unit was not in Ready status when the Multi Unit attempted
to start - confirm all axis status
The connected spindles do not match with spindles called from
fastening sequence - confirm fastening sequence
Fastening sequence does not have spindle numbers assigned ­confirm fastening sequence
Fastening sequence selected does not exist - confirm fastening
sequence.
No End command in the fastening sequence5
Fastening sequence abnormal 6
An Axis unit was not in Ready status when the Multi Unit attempted
to send 1st step command - confirm all axis status
An Axis unit was not in Ready status when the Multi Unit attempted
to send 2nd step command - confirm all axis status
Input / Output port number error - input port number over 4 or
Output port number over 8 is set

Chapter 4: I/O and Output Data

63