FEC AFC1500 User Manual

ELECTRIC SERVO NUTRUNNER

AFC1500 MULTI SYSTEM

MULTI-2 UNIT HARDWARE MANUAL

SECOND Edition March 2009

Automation Systems

51327 Quadrate Drive Phone: [phone]

Macomb, MI. 48042 Fax: [phone]

Web: www.fec-usa.com E-mail: [e-mail]

AFC1500E-HM2-2

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!

Any questions regarding the contents of this document or any related matter should be

directed to FEC INC. at [phone], faxed to [phone] or emailed to [e-mail].

The information set forth in the following document is the property of FEC INC.

This document shall not be released to or copied for any person and/or organization

without the expressed prior consent of FEC INC.

Unauthorized reproduction or distribution of this manual is strictly prohibited.

Please contact FEC INC. if you require additional copies.

ii

Revision

Revision affecting most chapters including minor fixes, revised

HS

DSP1500

FUSION

= DC Hand Tool

E

1 04/2008 Initial Release

Revision

Date

Revision History

2 3/2009

2.1 2/2010 Chapter 5 only- revised toolsnet version output format pg: 5-74 to 5-83

DSP1500 = Servo Press

AFC1500 = Nutrunner

AFC1500 = Nutrunner
FUSION = DC Hand Tool

= English Version

S = Spanish Version

*Japanese Version furnished by DDK

(uses DDK numbering convention)

= Servo Press

information and new items – Added Ethernet, Profinet & Toolsnet info.

Manual Numbering Convention

AFC1500E-HM2-2

Version Number
(Major Revision Level)

= SAN Unit Hardware

Operation Manual
HM2 = Multi2 / Main Unit
Hardware Operation Manual
HM-ENET = Ethernet Manual for
Multi / Main Unit
SW = Software Manual

iii

Introduction

Thank you for purchasing our Electric Servo Nutrunner - AFC1500 System.

This instruction manual describes the procedures for installation, wiring, handling and actions to
be taken in case of any failure.

◆

This instruction manual shall be delivered to the end user who operates the equipment.

◆

Read all instructions before use, and always keep this instruction manual with the equipment.

◆

Items not described in this instruction manual shall be considered “unavailable”.

◆

The product specification and appearance described in this instruction manual is subject to change

without notice.

◆

All rights reserved. Any disclosure, copying, distribution, or use of the information contained herein

for other than its intended purpose is strictly prohibited.

◆

Read all “Safety Precautions” before using the equipment, and understand and observe all

instructions and recommendations included in this manual.

◆

Read all instructions and recommendations included in this manual, understand the functions

and performance of this nutrunner and correctly use this machine.

◆

Wirings and parameter settings shall only be conducted by a qualified professional.

◆

Never conduct a withstand voltage test or insulation resistance test on this equipment.

◆

Only operate this equipment with FEC supplied controllers, tools & cables.

◆

All stated warranties become invalid if other components are used.

◆

This system may be sold as components to a manufacturer (other than FEC) of a complete

system. The manufacturer of the complete system is responsible for adhering to stated

operation and safety brought forth in this manual. It is agreed between the buyer and FEC

that it is the buyer’s responsibility to adhere to this manual.

◆

Indicate the following on all instruction manuals that use this equipment.

“

This equipment must be operated in accordance to FEC Supplied Manuals”

”This equipment is capable of high voltages hazardous to human life.”

Please confirm the followings when unpacking this equipment.

◆

Ensure that you received the correct model as ordered.

◆

Ensure that there are no missing parts.

◆

Check for any damage caused during transportation.

For the safety of operator and equipment

Points to check when unpacking

iv

Introduction

Warranty Period

Provisions of Warranty

Non - Warranty Items

FEC Inc. warrants that the equipment manufactured by it and delivered hereunder will be free of defects in

material and workmanship for a period of twelve (12) months from the date of placing the equipment in operation,

or eighteen (18) months from the date of shipment, or 500,000 machine cycles - whichever shall first occur.

Should any failure to conform to this warranty be reported in writing to the company within said period, the

company shall at its option, correct such nonconformity by suitable repair to such equipment or furnish a

replacement part from FEC or an FEC approved facility, provided the purchaser has stored, installed, maintained

and operated such equipment in accordance with good industry practices and has complied with specific

requirements & recommendations of the company. Accessories or equipment furnished by the company shall not

be liable for any repairs, replacements or adjustments to the equipment or any costs of labor performed by the

purchaser or others without the company's prior written approval.

The effects of corrosion, erosion and normal wear and tear are specifically excluded from the company's

warranty. Performance warranties are limited to those specifically stated within the company's proposal. Unless

responsibility for meeting such performance warranties are limited to specified shop or field tests, the company's

obligation shall be to correct in the manner and for a period of time provided above.

THE COMPANY MAKES NO OTHER WARRANTY OR REPRESENTATION OF ANY KIND WHATSOEVER,

EXPRESSED OR IMPLIED, EXCEPT THAT OF TITLE, AND ALL IMPLIED WARRANTIES, INCLUDING ANY

WARRANTY OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, ARE HEREBY

DISCLAIMED.

Correction by the company of nonconformity's, whether patent or latent in the manner and for the period of time

provided above, shall constitute fulfillment of all liabilities of the company for such nonconformity's, whether based

on contract, warranty negligence, indemnity, strict liability or otherwise with respect to, or arising out of such

equipment.

The following are defined as non-warranty situations that are outside the scope of warranty provided:

•

Product is out of the warranty period as determined by FEC serial number tracking.

•

Any cause external to the equipment, including but not limited to any act of God, lighting or power surges, abuse,

negligence, accident or failure to maintain the proper operating environment.

•

Use of equipment or adjustments or devices not approved by the manufacturer and FEC.

•

Cosmetic damage to unit or any of the parts

•

Consumable parts - for example; sockets, rest/wear pads, bushings, etc.

•

Physical damage (example - damage caused by dropping, cut cables, etc.)

•

Field Service required on a Warranty Part - FEC warranty covers the parts and labor only onsite at FEC.

Extended warranties are available as an addition to the standard warranty period outlined above - for all FEC Inc.
systems. For extended warranties, contact FEC.

Warranty

v

ead all instructions before operating the

manual carefully

. Safety precautions in this manual are marked with two symbols

To prevent danger to the user and other persons as well as property damage

lly observed are marked with the symbols below.

This instruction manual uses the

be caused when the instruction is not observed.

nstructions that are marked with

marked with the above symbols are very

marked with the

the following additional

This symbol indicates that failure to observe instruction

with this symbol

This symbol indicates that failure to observe instruction marked

with this symbol

damage.

Safety Precautions

equipment safely and

the equipments functions, safety

nstruction

two symbols according to the degree of damage that may

may result in severe damage if they are not

instructions. For your safety, f

s that shall be observed.

may result in severe personal injury or death.

personal injury or

Caution:

High

Warning:

Pinch Point

Caution

R

Prior to use, read this instruction

precautions and instructions

and [Caution].

fu

◆

Even i

observed according to conditions.

Warning

Caution

equipment in order to use this

and fully understand

following

may result in minor

, i

correctly.

[Warning]

s that must be

marked

material

Contents

instructions and especially those

◆

This instruction manual uses

Warning:
Electric shock

Caution:
Fire

Prohibited

Required

important

se symbols.

symbols for instruction

Warning:
Fire

Caution:
Electric shock

Do not disassemble

Ground

ollow all

Temperature

vi

Never touch rotating devices or any part of the nutrunner

Make sure that no part of your body gets near any moving part of the tool.

The spindle may rotate unexpectedly, resulting in injury.

spindle may rotate and cause injury.

Do not repair, disassemble, or modify the equipment

this instruction may cause

Never operate the equipment

Failure to observe

Keep fingers away from the

the equipment is turned OFF.

operation and maintenance work shall be conducted by a

this instruction may cause

Turn OFF the power when conducting wiri

this instruction may cause

damage the cables, apply excess

Never use damaged cables.

this instruction may cause

3 grounding of FG terminals.

this instruction may cause

abnormal odor, noise, or operation error

source.

device

this instruction may cause

emergency stop circuit

Failure to observe

Keep away from the equipment

a

this instruction may cause

Safety Precautions

tool while it is rotating.

individual components of the system.

injury, electric shock, fire and malfunction.

for a while after

electric shock

professional.

the cables.

stop operation

injury and fire.

of equipment in order to stop

and

suddenly restart.

Warning

Do not remove the motors

The tool output

and gear cases of tools while power is applied.

Failure to observe

flammable gases.

Wiring

Failure to observe

Failure to observe

Never

Failure to observe

Use type-

Failure to observe

In case of an

and turn OFF the power

Install a Power shutdown

Failure to observe

Install an

promptly.

measures are conducted

Failure to observe

where it is exposed to water, near a corrosive

this instruction may cause fire.

connectors while the equipment is turned ON and

Failure to observe this instruction may cause

electric shock and injury.

ng operation and maintenance.

electric shock and injury.

stress to cables, or squeeze

electric shock and fire.

electric shock.

Failure to observe this instruction may cause

in order to ensure the safety of equipment.

injury.

on the outside

this instruction may cause injury.

during recovery from a temporary blackout

fter restarting the equipment. The equipment may

injury.

occurrence,

qualified

atmosphere or

.

immediately

operation

ensure safety

vii

Transport the equipment properly according to its weight.

this instruction may cause

The conditions when transporting the equipment by ship is as below.

Ambient temperature:

5

Package: Tight seal

Rust prevention measure: Apply grease or oil on tools.

this instruction may cause

Do not hold cables and output spindles when transpo

this instruction may cause

indictor on the

The indicator may come off and drop from the front panel.

this instruction may cause

The equipment shall be stored under the following conditions.

Ambient temperature:

Ambient humidity: 90% RH or lower

Indoors (Avoid direct sunlig

corrosive gases or flammable gases

No oil mist, dust, water, salt, iron powder

Avoid direct vibration or shocks

this instruction may cause

Transportation / Storage

Safety Precautions

Caution

Failure to observe

injury and malfunction.

◆

◆

Ambient humidity:

◆

◆

Failure to observe

-5°C～+55°C (Avoid freezing)

0% RH or lower (Avoid moisture)

earth leakage and malfunction.

Failure to observe

Do not hold the

front panel when transporting the AXIS Unit.

injury and malfunction.

Failure to observe

injury and malfunction.

◆

◆

◆

Atmosphere:

◆

Failure to observe

No

-5°C～+55°C (Avoid freezing)

(Avoid moisture)

ht)

earth leakage and malfunction.

rting the tools.

viii

where they can bear the maximum torque

this instruction may cause

this instruction may cause

Use the specified tool for the AXIS

this instruction may cause

nit shall

this instruction may cause

ventilation hole

from entering

this instruction may cause

The power source shall be provided with safety measures

Failure to observe

(S

this instruction may cause

get on the top of equipment or do not place heavy

this instruction may cause

equipment

this instruction may cause

and firmly

this instruction may cause

Operate the equipment within the specified power supply voltage

this instruction may cause

measures to

electrical

where the equipment is subjected to

high

this instruction may cause

Safety Precautions

Installation / Wiring

during operation.

such as breakers

on the top of equipment.

and malfunction.

injury, electric shock, fire and malfunction.

hen operating the in the following

magnetic field

injury, false operation, and malfunction.

Caution

Install all tools firmly

Failure to observe

Install the AXIS Unit firmly

Failure to observe

Failure to observe

The AXIS (SAN) U

Failure to observe

Do not block the

Avoid any foreign body

Failure to observe

protectors.

Do not use tools or AXIS

Failure to observe

Do not

Failure to observe

Do not subject the

Failure to observe

Apply proper wiring size

Failure to observe

Failure to observe

Take sufficient

conditions:

◆

Location where

◆

Location

◆

Location near a

Failure to observe

injury and malfunction.

inside the control panel using the specified screws.

malfunction.

(SAN) Unit.

fire and malfunction.

maintain the specified distance from other devices.

fire and malfunction.

of the AXIS (SAN) Unit.

inside the equipment.

fire and malfunction.

this instruction may cause fire and malfunction.

AN) Units that are damaged or missing parts.

fire, injury and malfunction.

injury and malfunction.

to excess shock and impact.

malfunction.

tighten all termination points.

injury, false operation

shield the equipment w

noise is generated

power wire.

objects

a strong electric field or

.

and circuit

ix

Never operate the equipment with wet hands

this instruction may cause electric shock.

Keep fingers away from the

is turned ON or for a while after the equipment is turned OFF.

this instruction may cause burns.

Use the equipment under the following conditions.

Ambient temperature: 0°C

Ambient humidity: 90% RH or lower

rs (Avoid direct sunlight)

corrosive gases or flammable gases

No oil mist, dust, water, salt, iron powder

Avoid direct vibration or shocks

this instruction may cause

ll parameters before operation

this instruction may cause injury,

adjustments or setting changes that may cau

this instruction may cause injury,

The equipment may restart suddenly

Always ensure that the start signal is OFF

instruction

Do not turn the equipment ON and OFF repeatedly.

instruction

equipment at torque higher than

Failure to observe this instruction may shorten

high temperature caused by overload.

In case any abnormality occurs,

Failure to observe this instruction may cause injury.

Safety Precautions

Operation

/ Adjustment

or while standing in a wet location

tool motors while the equipment

These parts may become very

in order to prevent unexpected movement

and malfunction.

se instability of

and malfunction.

is reset with the start signal ON.

.

or cause malfunction

remove the cause and ensure safety before resetting and

Caution

Failure to observe

AXIS (SAN) Unit radiating fin and

hot. Failure to observe

◆

◆

◆

Atmosphere: Indoo

◆

Failure to observe

Confirm and adjust a

of the equipment.

Failure to observe

No

Never conduct extreme

Failure to observe

Failure to observe this

～

+45°C (Avoid freezing)

when the equipment

may cause injury.

Failure to observe this

Do not use the

may cause malfunction.

(Avoid moisture)

earth leakage and malfunction.

false operation

false operation

before resetting the equipment.

the maximum torque capacity

equipment life

.

operation.

due to the

restarting the equipment.

x

Table of Contents

Chapter 1: Outline

1.1 About this Manual......................................................................................... 1-2

1.2 Functions...............................…..……………………………………………… 1-3

1.3 Safety Precautions……….....…..………………………………………………. 1-4

Chapter 2: Specifications

2.1 Specifications.........................………………………………………………….. 2-2

2.2 Unit Dimensions……….................................…….…………………………… 2-3

Chapter 3: System Description

3.1 System Block Diagram...........………………………………………………….. 3-2

3.2 Unit Description…….....................................…….…………………………… 3-3

Chapter 4: Installation & Wiring

4.1 Installation…….............................................…….…………………………… 4-2

4.2 Power Wiring Reference........………………………………………………….. 4-3

4.3 Input Power Connection........………………………………………………….. 4-4

4.4 RS485 Connection…….........………………………………………………….. 4-4

4.5 User Console Ethernet Connection..………………………………………….. 4-5

4.5.1 Optional Ethernet Port – Data Communication………………………….. 4-6

4.6 Serial Communication Ports..………………………………………………….. 4-7

4.6.1 PC Port………............................………………………………………….. 4-8

4.6.2 Display Port…............................………………………………………….. 4-9

4.6.3 Data-Out (1) Port........................………………………………………….. 4-9

4.6.3.1 Available Output Data...........………………………………………….. 4-10

4.6.3.2 Output Data Format..............………………………………………….. 4-11

4.6.4 Data-Out (2) Port........................………………………………………….. 4-12

4.6.5 Data-In Port…............................………………………………………….. 4-12

4.7 PLC Interface Communication (I/O).………………………………………….. 4-13

4.7.1 Control Interfaces…....……………………………………………………... 4-13

4.7.2 Input Signals………………………………………………………………….. 4-14

4.7.3 Output Signals…………………………………………………………………4-15

4.7.4 Signal Timing Chart…………………………………………………………. 4-18

4.7.5 External DIP Switch Setting……………………………………………….. 4-19

4.8 Setting Default TCP/IP Address – User Console Port……………………….. 4-19

4.9 Firmware Flash Connector……………………………………………………... 4-19

xi

Table of Contents

Chapter 5: Control Interfaces

5.1 Interface Board ……......…….………………………………………………….. 5-2

5.2 Interface Board DIP Switch Setup................…….…………………………… 5-2

5.3 Discrete I/O Interface….........………………………………………………….. 5-3

5.3.1 Sinking Type (NPN)…................………………………………………….. 5-3

5.3.1.1 Discrete Signal Connection (Sinking Type)………………………….. 5-4

5.3.2 Sourcing Type (PNP)..................………………………………………….. 5-5

5.3.2.1 Discrete Signal Connection (Sourcing Type).……………………….. 5-6

5.3.3 Input Signals (PLC-IN)................………………………………………….. 5-7

5.3.4 Output Signals (PLC-OUT).........………………………………………….. 5-8

5.3.4.1 Output Data Banks.…...........………………………………………….. 5-9

5.3.5 Standard I/O Cable – Wire Color Code……………………………………. 5-10

5.4 Interbus S® Interface..…........………………………………………………….. 5-11

5.4.1 Component Descriptions............………………………………………….. 5-13

5.4.2 User Console Software Settings ………………………………………….. 5-14

5.4.3 Input Signals (Reference Layout)..……………………………………….. 5-15

5.4.4 Output Signals (Reference Layout)……………………………………….. 5-16

5.5 DeviceNet® Interface.…........………………………………………………….. 5-17

5.5.1 Component Descriptions...........………………………………………….. 5-19

5.5.2 User Console Software Settings ………………………………………….. 5-20

5.5.3 Input Signals (Reference Layout)..……………………………………….. 5-21

5.5.4 Output Signals (Reference Layout)……………………………………….. 5-22

5.6 Profibus® Interface.……........………………………………………………….. 5-23

5.6.1 Component Descriptions............………………………………………….. 5-25

5.6.2 User Console Software Settings ………………………………………….. 5-26

5.6.3 Input Signals (Reference Layout)..……………………………………….. 5-27

5.6.4 Output Signals (Reference Layout)……………………………………….. 5-28

5.7 Modbus Plus® Interface.........………………………………………………….. 5-29

5.7.1 Component Descriptions............………………………………………….. 5-31

5.7.2 User Console Software Settings ………………………………………….. 5-33

5.7.3 Input Signals (Reference Layout)..……………………………………….. 5-34

5.7.4 Output Signals (Reference Layout)……………………………………….. 5-35

5.8 CC-Link® Interface (Version 1)..……………………………………………….. 5-36

5.8.1 Component Descriptions........... ………………………………………….. 5-38

5.8.3 Input Signals (Reference Layout)..……………………………………….. 5-40

5.8.4 Output Signals (Reference Layout)……………………………………….. 5-41

5.9 CC-Link® Interface (Version 2)..……………………………………………….. 5-42

5.9.1 Component Descriptions............………………………………………….. 5-44

5.9.2 User Console Software Settings ………………………………………….. 5-46

5.9.3 Input Signals (Reference Layout)..……………………………………….. 5-47

5.9.4 Output Signals (Reference Layout)……………………………………….. 5-48

5.10 Allen-Bradley Remote I/O Interface………………………………………….. 5-49

5.10.1 Component Descriptions...........………………………………………….. 5-51

5.10.2 User Console Software Settings .……………………………………….. 5-52

5.10.3 Input Signals (Reference Layout).……………………………………….. 5-53

5.10.4 Output Signals (Reference Layout).…………………………………….. 5-54

xii

Table of Contents

5.11 Ethernet-I/P Interface…........………………………………………………….. 5-55

5.11.1 Component Descriptions...........………………………………………….. 5-56

5.11.2 User Console Software Settings. .……………………………………….. 5-57

5.11.3 Input Signals (Reference Layout).……………………………………….. 5-58

5.11.4 Output Signals (Reference Layout)..…………………………………….. 5-59

5.11.5 PLC Message Transfer Setup Example…..……………………………… 5-61

5.12 Profinet Interface……………………………………………………………….. 5-69

5.12.1 Component Descriptions………………………………………………….. 5-70

5.12.2 User Console Software Settings…………………………………………. 5-71

5.12.3 Input Signals (Reference Layout).……………………………………….. 5-72

5.12.4 Output Signals (Reference Layout)..…………………………………….. 5-73

5.13 Input / Output Signal Layout using Toolsnet Version………………………… 5-74

Chapter 6: Troubleshooting

6.1 Abnormals…………………….………………………………………………….. 6-2

xiii

Blank Page

xiv

Chapter 1: Outline

connection references

Chapter 1: Outline

AFC1500 Multi-2 Unit Hardware Manual (Rev. 2)

1.1 About this Multi-2 Unit Manual

This manual details the configuration, specifications and the operation of the AFC1500 Multi-2 Unit.

The following table outlines the contents of each chapter.

Chapter

1 Outline

2 Specifications General specifications of the AFC1500 Multi-2 Unit.

3 System Description Description of standard and optional system components.

4 Installation and Wiring

5 Control Interfaces

6 Troubleshooting Description of Abnormal conditions.

Any questions regarding the contents of this document or any related matter should be
directed to FEC Inc. at [phone] or faxed to [phone].

The Information set forth in the following document is the property of FEC Inc. This
document shall not be released to or copied for any person and/or organization without
the expressed prior consent of FEC Inc.
Unauthorized reproduction or distribution of this manual is strictly prohibited. Please
contact FEC Inc. if additional copies are required.

Related Documentation

Title Contents

Basic characteristics and requirements of the AFC1500
Multi-2 Unit.

Mounting requirements, wiring
including communication port specifications.
Description of standard Discrete I/O and optional Fieldbus I/O
PLC Interfaces.

AFC User Console Manual AFC1500E-SW-*
AFC1500 Operation Manual AFC1500E-HS-*

PAGE 1 - 2

AFC1500 Multi-2 Unit Hardware Manual (Rev. 2)

Chapter 1: Outline

1.2 Functions

The Multi-2 Unit is a complimentary controller device to enhance the AFC1500 SAN Unit 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-2 Unit, the Multi-2 Unit assumes control (over these spindles) of the following
functions:



Input / Output (I/O) connection (including Fieldbus interfaces)



Sequence Control



Parameter Programming



Fastening Data Monitoring & Communication



General Status Indication

♦

Input / Output (I/O) Connection

The Multi-2 Unit assumes control of the control signals (Ex.: STOP, START, REVERSE,
BYPASS, etc.) to all of the AFC1500 Servo (SAN) Controllers connected to it via the RS485
communication port, thus eliminating direct connection & control to the individual spindles
saving costly I/O connection. 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-2 Unit or I/O (Input/Output) signals from a PLC and / or PC Based Controller.
Additionally, a multitude of (direct connect) Fieldbus interfaces are available when using a
Multi2 Unit.

♦

♦

Sequence Control

♦♦

The Multi-2 Unit controls the fastening sequencing eliminating the need for external control
devices (PLC) to perform complicated spindle control sequencing. All fastening sequencing is
handled by the Multi-2 Unit. This built in feature allows the Multi-2 Unit to control a variety of
complex sequencing strategies including; incremental fastening steps, spindle grouping,
reject (reverse) strategies, wait timing, multiple starts, etc. Also available are sequence
Input / Output interfaces which allow external control of sequence starting / stopping with
outside automation while in sequence.

♦

♦

Parameter Programming

♦♦

A Windows® compatible computer running the AFC User Console software package can be
connected to the Multi-2 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-2 Unit can monitor and process the fastening results collected by the AFC1500 Servo
(SAN) Controllers connected to it. It has four (4) 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-2 Unit stores previous fastening data in RAM (non-volatile) for
uploading at another time. The number of cycles stored is based on the number of spindles
connected (see chart on page 2-2). The data can be uploaded using the AFC User Console
software package.
Additionally, the Multi -2 comes standard with an dedicated ethernet port to connect to a
computer running the AFC User Console Software package making it easier to connect to most
computers without serial convertors. As an option, the Multi - 2E comes with an additional
ethernet port for reporting of resultant fastening data to host systems.

♦

♦

General Status Indication

♦♦

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

PAGE 1 - 3

Chapter 1: Outline

AFC1500 Multi-2 Unit Hardware Manual (Rev. 2)

1.3 Safety Precautions

To ensure the most effective and extended use of all equipment, adhere to the following precautions:

 Wiring

• Use only the specified cables for all system connections.

• Do not use a high voltage circuit as a frame ground (FG). Also, the frame ground should be

separate from the power ground. The use of a grounding rod located as close as possible to
the enclosure housing the AFC1500 Multi-2 Unit is preferable.

• Circuit breakers or fuses are required on branch circuit power feeds to the Multi-2 Unit.

• PLC I/O cables must be run separate from any high voltage sources or cabling, and must not

exceed 50 feet.

 Installation Environment

• The AFC1500 Multi-2 Unit should be placed in a NEMA 12 enclosure.

• Using the equipment in the following locations may lead to malfunction or breakdown. Avoid

using in these areas or use an air conditioner.

 Areas under direct sunlight or if the environmental temperature is out of the 32~122



0~50) range.

 Areas where relative humidity is out of the 20-90% range, the temperature change is

drastic or where the area is exposed to mist and water drops.

• Do not use at the following locations. (Contact FEC Inc. if necessary for clarification)

 Areas where conductive powder, oil, mist, salt or organic solvents exist.
 Areas that have corrosive or combustible gases.
 Areas that have strong electric or magnetic fields.
 Areas where strong vibration or shock could be transmitted directly to a Multi 2 Unit.

 Static Electricity

• The AFC1500 Multi-2 Unit incorporates many electronic Surface Mounted Devices (SMD). It
is advisable to strictly adhere to practices for safe electrostatic discharge in order to prevent
damage to the system components when handling them.

 Cleaning

• Do not use any organic solvents, such as thinner, to clean a Multi-2 Unit. The solvent could
melt the surface paint, or penetrate inside and cause damage. A cloth dampened with alcohol
or warm water should be used to lightly wipe the components.

 Electrical Noise Prevention

• Multi-2 Units must be located a minimum of 600mm from high transient voltage sources such
as transformers, motor starters, AC inverters and AC contactors. If it cannot be avoided, the
unit must be shielded.

• If high powered devices are used inside the enclosure, they must use a surge suppression
device.

• Make sure that the power supply lines and cables for connecting the unit and tool are not run
together inside the same duct.

 Handling and Shipping

• It is critical that AFC1500 System components are properly handled and shipped in order to
maintain the system’s integrity. Adhere to the following requirements for shipping and
handling:

 Loose AFC1500 Multi-2 Units must be individually packaged and shipped in anti-static

containers or wrap to prevent damage from electrostatic discharge.

 If the Multi Unit is to be shipped in an enclosure, tighten all mounting screws to prevent

the unit from being dislodged.

 Do not ship or store the unit in environments where the temperature is out of the

23~131 (-5~55) range or where the humidity is above 90%.



PAGE 1 - 4

Chapter 2: Specifications

®

Additional Interfaces a

lso available:

Chapter 2: Specifications

AFC1500 Multi-2 Unit Hardware Manual (Rev.2)

2.1 Specifications

Power Supply Voltage 100 to 220 VAC±15%, 1-phase, 50/60 Hz.
Power Consumption 9 Watt/Hour
In rush current Less than 160 mA
CPU NEC V53A
Data Communication RS232C (User Console PC) (N/A with Ethernet Data Option)
RS232C (Data Output #1 / Data Output)
RS232C (Data Input)
RS232C (Data Output #2) (N/A with Ethernet Data Option)
RS422 (External Remote Display)
RS485 Servo Units Programming/Control
Ethernet - User Console (User Console PC)
Ethernet - Network Communication (OPTIONAL 2E Version Only)
Control Interfaces Discrete I/O (24Vdc Sink)
Discrete I/O (24Vdc Source)
DeviceNet

Profibus®

(Includes data messaging capability)

Profinet IO

Ethernet I/P
Mitsubishi CC Link® 1

(Includes data messaging capability)

Allen Bradley Remote I/O 1

Modbus Plus®
CC Link® Version 2
Interbus-S®

(Includes data messaging capability)

M-Net

Contact FEC for special fieldbus requirements

Fastening Sequence
Programming Steps
Fastening
Control Methods

100
(99 plus “End” Step)
Torque Control / Angle Control

Optional Yield Control (Requires SAN Ver. 2.39)
Max. No. of spindles 31 per Multi-2 Unit
Fastening Parameters 16
Fastening Sequences 16
Torque Rate
monitoring areas

Data Storage
(Non-volatile RAM)

Based on the number of
spindles connected.2

3

st

(1

, 2nd and 3rd Rate areas)

Stored

# of

Spdls.

Cycles

# of

Spdls.
1 7878
2 6032
3 4888
4 4108
5 3536
6 3120
7 2782
8 2496

Stored
Cycles

9 2288
10 2080
11 1924
12 1794
13 1690
14 1586
15 1482
16 1404

# of

Spdls.

Stored
Cycles

# of

Spdls.
17 1326
18 1248
19 1196
20 1144
21 1092
22 1040
23 1014
24 962

Stored
Cycles

25 936
26 910
27 858
28 832
29 806
30 780
31 754

Installation requirement NEMA12 Enclosure
Operation Temperature 0º to 50 ºC (32 º to 122 ºF)
Operation Humidity 20% to 90%

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

2) The number of cycles stored will be reduced if RS232C - DATA IN data is stored with the
fastening data.

PAGE 2 - 2

AFC1500 Multi-2 Unit Hardware Manual (Rev.2)

2.2 Unit Dimensions

Mounting: Top (1) place #8-32 screw
Bottom (2) places #8-32 screw

Weight: 1.4 kg

Chapter 2: Specifications

Note: Unit Dimensions are the same whether a Multi 2 unit (as shown), or a Multi 2E (Ethernet) version.

Chapter 2: Specifications

AFC1500 Multi-2 Unit Hardware Manual (Rev.2)

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Chapter 3: System Description

Chapter 3: System Description

AFC1500 Multi-2 Unit Hardware Manual (Rev.2)

3.1 System Block Diagram

The diagram below shows how the AFC1500 Multi-2 Unit can be connected to a single unit or combined
in a multiple spindle configuration. The use of a Multi-2 Unit provides one set of PLC I/O for controlling
multiple spindle fastening operations. Along with discrete 24VDC (sinking or sourcing) I/O, various
fieldbus interfaces are also available for direct connection to networks such as Profibus, AB remote I/O,
CCLink, DeviceNet, etc.
The AFC1500 Multi-2 Unit also provides an interface for connection to the User Console PC, serial
printers, barcode readers, display units, etc.

PAGE 3 - 2

AFC1500 Multi-2 Unit Hardware Manual (Rev.2)

Chapter 3: System Description

3.2 Unit Description

AFC MULTI – 2 Standard Version

The standard version of the Multi-2 unit includes both an RS232 port (PC Port) and Ethernet
port (Ethernet U/C Port) for communicating to a computer running the AFC User Console
Software. (Only one may be used at a time)

(RS232C) PC Port

(RS422) Display Port

(RS232C) Data-Out Port #1

(RS232C) Data-Out Port #2

(RS232C) Data-In Port

Ethernet U/C
Status LED

Power ON LED

Busy LED

Accept LED

Reject LED

Interface Board

Abnormal LED
Reset Button

Start Button

Reverse Button

Power Connector

Calibration Button

RS485 Port

Ethernet U/C Port

* Discrete I/O Interface Board Shown. (RS232C)Data-Out 2 and (RS422) Data-In are not used.

AFC MULTI – 2E Ethernet Version (Optional)

The optional ethernet version of the Multi – 2 unit adds the functionality of an additional ethernet
port for FASTENING DATA COMMUNICATION protocols to external systems as well as User
Console connectivity. Existing protocols include; QDAS, ToolsNet®, FECNet as well as custom
Protocols. The RS232 PC Port and Data-Out 2 port are removed using this configuration.

Ethernet Network Port

Ethernet Reset Button

(RS232C) Data-Out Port

(RS232C) Data-In Port

(RS422) Display Port

Ethernet U/C

Status LED

PAGE 3 - 3

Chapter 3: System Description

Multi

-

2 Unit

Panel Description

RS232C

– Data Out Port #2

Not Used

etc.)

Power On LED Indicates when power is applied to the Multi-2 Unit.
Busy LED Lights when the unit is performing a self check, return, fastening

operation or is downloading/uploading data to the AFC User Console
software package.

Accept LED Lights if a fastening cycle or a self check test falls within acceptable

parameters. (This LED indicates status for ALL connected spindles)

Reject LED Lights if a fastening cycle or a self check test is outside of acceptable

parameters. (This LED indicates status for ALL connected spindles)

Abnormal LED Lights when a system abnormal condition is detected in the control

system of any connected spindle. (Does NOT indicate a spindle 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 Operation Manual for Abnormal Troubleshooting)

RS485 Port RJ45 style connector used to connect to all AFC1500 Servo (SAN)

Units included in the system.

Ethernet U/C Port Communication port for the AFC Software User Console PC.

Red (TX) Transmitting Data

Ethernet U/C Status LEDs

Reset Button Resets all signal and communication buffers to “clear” conditions.

Start Button Starts the fastening cycle. Requires a pulse of 0.1 to 0.5 sec. for

Reverse Button Turns the spindles in the opposite direction of the preset fastening

Cal Button Performs the Torque Transducer shunt calibration test. When pressed,

Power Connector Connects to incoming power: 100 to 220VAC (auto-sensing), Single

Interface Board (I/O) Allocation socket for input/output signal Interface boards. Options

RS232C – PC Port Communication port for the User Console PC.
RS232C – Data Out Port #1
(RS232C – Data Out Port)

RS232C – Data In Port Communication port for ASCII data input from peripheral devices. (Ex:

Yellow 10/100 Link
Green (RX) Receiving Data

Clears the Abnormal signal and performs the Torque Transducer Zero
Level Check.

“Normal” start selection or must be maintained during complete cycle
for “Deadman” start selection.

direction while the button is held active.

the Servo (SAN) Units will display either a green accept LED or red
reject LED indicating status of the individual Calibration test.

phase, 50/60 Hz.

available are Discrete I/O (Sink or Source), Interbus-S®, DeviceNet®,
Profibus®, CC-Link® (Version 1 or 2), Modbus Plus®, Allen Bradley

Remote I/O (Rockwell License #199906006) or Ethernet-I/P

Communication port for fastening result data output to any external
device, i.e.: host computer, serial printer, etc. Data output format is
configured using the User Console (AFC) Software package.

bar code readers, RF tag, etc.) Allows external ASCII data to be merged
with fastening result data.

AFC1500 Multi-2 Unit Hardware Manual (Rev.2)

RS422 – Display Port Not Used
Ethernet Network Port*

Ethernet Reset Button* For resetting the Network Ethernet Port IP address to default setting.

*On Ethernet Version only.

for network connectivity (Toolsnet®, QDAS®, SQL, Custom Protocol,

(IP: 192.168.10.40 Subnet Mask: 255.255.255.0 Gateway:

192.168.10.1)
To reset port to default IP address, power down Multi Unit. Depress
reset button and hold it depressed while powering on the Multi Unit until
green Accept LED illuminates.

PAGE 3 - 4



Chapter 4: Installation & Wiring



Chapter 4: Installation & Wiring

RS485 port specifications

(RJ45)

Protocol

Proprietary

2

1

8

AFC1500 Multi-2 Unit Hardware Manual (Rev. 2)

4.3 Input Power Connection

An auto sensing power supply allows for input power in the range of 100 ~ 220VAC single phase,
50/60 hertz. Adequate circuit protection must be provided. Recommended conductor size should be
a minimum of #18AWG.

Wiring Chart

4
3
2
1

Pin Description

4
3 100 ~ 220VAC +/-15%

100 ~ 220VAC +/-15%

No Connection **
Frame Ground

Mating Connector

Manufacture: Amp
Housing Part No.: 1-178128-4
Contact Part No.: 1-175218-3 (Qty.-3)

** To standardize components, FEC cable part
#FEB-1260 may be used due to the fact that
pin #2 is not connected internally.

4.4 RS485 Connection

The Multi-2 Unit uses an RS485 port to perform the communication operations with the AFC1500
Servo (SAN) Controllers. This port has two channels CH1 and CH2. CH1 is dedicated to handle 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.

Speed 9600, 19200, 38400 baud
Cable Std Cat 5 Ethernet
Maximum number of
connected devices

31

Operating Voltage RS485 Standard

RS485 Wiring

NO Signal Name Channel
1 TX+ / RX+ CH1
2 TX- / RX- CH1
3 RX+ CH2
4 TX- CH2
5 TX+ CH2
6 RX- CH2
7 GND
8 GND

PAGE 4 - 4

AFC1500 Multi-2 Unit Hardware Manual (Rev. 2)

Ethernet

port specifications (RJ45)

8

Chapter 4: Installation & Wiring

4.5 User Console Ethernet Connection

The “User Console Ethernet” port is a dedicated TCP/IP ethernet port for communicating with the
AFC User Console Software in a Windows® based PC. Similar to the serial RS232 (PC) port
dedicated for the AFC Software connection, this port allows connection in an ethernet environment vs.
using the standard serial port connection in previous versions of the Multi Unit. This port allows the
user to set-up, monitor, save data, display and print fastening data and setup parameters using the
AFC User Console software. The ethernet connection allows connection to multiple Multi-2 units
using an ethernet switch or hub. (Different IP addresses must be configured for multiple connection).

NOTE: An additional ethernet port is available for communicating fastening resultant data to
external data collection systems (ie. QDas
custom protocols). This is an OPTIONAL ethernet port and can be ordered by adding the

E

option to the Multi-2 Unit. (Part #1500Multi2E-x)

The default IP address is set at FEC or it can be configured by the user using the AFC User Console
software. If connection cannot be established using the default IP address, the IP address may
have been changed. The default IP address can be re-established by resetting it. See section

4.8.1 for resetting the IP address back to the default setting. The Multi-2 IP address may also be
uploaded, viewed and modified using the AFC software PC connected serially. (RS232 PC Port or
RS485 SAN UNIT connection) Once the current IP address configuration is verified using a serial
connection, then connection may be attempted using the Ethernet port.

Default IP Address of Multi 2 unit
IP Address: 192.168.10.10
Subnet Mask: 255.255.255.0
Default Gateway: 192.168.10.1

Note: Set-up the TCP/IP properties in the computer that will connect to the Multi-2 unit prior to
attempting ethernet port connection. The actual IP address setup in the computer must be a different
number than the Multi-2 unit IP address. Example: Using the default IP address above, set the PC
IP address to 192.168.10.50. Use the same Subnet & Gateway settings)

Note: Only one AFC Software connection method may be used at any given time whether
serial connection or Ethernet connection. The AFC Software can only be configured for one
connection port at a time. If more than one connection is required at the same time (to
additional Multi Units), additional AFC software may be installed and run at the same time,
each set-up with different communication connections.

The connecting cable is a standard Ethernet Crossover cable if connected directly to a PC (FEC
Part #FEB-1331-6). If connected through an Ethernet switch, a standard ethernet CAT5 or CAT5e
may be used (FEC Part Number FEB-1258-6).



, ToolsNet



, FECNet



, SQL Servers or other

Speed 10/100Mbps (auto select)
Cable Std Cat 5 Ethernet
Protocol Proprietary
Operating Voltage Ethernet Standard

Ethernet Wiring

Pin Signal Name
1 Tx+
2 Tx­ 3 Rx+
4 ­ 5 ­ 6 Rx­ 7 ­ 8 -

PAGE 4 - 5

Chapter 4: Installation & Wiring

AFC1500 Multi-2 Unit Hardware Manual (Rev. 2)

4.5.1 Optional Ethernet Port – Data Communication

As an option, an additional ethernet port is available for sending fastening resultant data over an
ethernet TCP/IP connection. This port can be configured using a standard web browser for
communication to Atlas Copco Toolsnet networks, FEC NET or custom protocols. Additionally,
once configured, the AFC User console software can also communicate over this port.

NOTE: Only one ethernet port may be used to communicate to the AFC software. Either the
dedicated User Console Ethernet port (located in the lower right corner of the front face) or the
optional Ethernet port.

Default IP Address of the Multi 2 Optional Ethernet Port
IP Address: 192.168.10.40
Subnet Mask: 255.255.255.0
Default Gateway: 192.168.10.1

If communication cannot be established using these settings, the settings may have been changed
in the Ethernet Port. To reset the setting back to these default settings, press the RESET
pushbutton located beside the ethernet port while powering on the unit.

See the MULTI 2E SETUP PROCEDURE document for more information when using this port.
(Contact FEC)

Optional Ethernet Port

Default Reset Button

PAGE 4 - 6