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: [email protected]

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 [email protected].

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

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

Chapter 4: Installation & Wiring

4.6 Serial Communication Ports

The Multi-2 Unit has three usable serial RS232C and one RS422 communication ports. All of the
serial port settings and data format are fully configurable with the AFC User Console software.
When the optional “E” ethernet version is used, the PC & DATA-OUT2 ports are removed.

STANDARD VERSION PORT LAYOUT ETHERNET VERSION PORT LAYOUT
(Optional E Version)

RS-232C Signal Layout

1 DCD (Data Carrier Detect) Used only for DATA-IN*
2 RXD (Receive Data) Serial Data Input.
3 TXD (Transmit Data) Serial Data Output.
4 DTR (Data Terminal Ready) Output signal; active when the internal device is ready to link.
5 GND (Ground Signal)

6 DSR (Data Set Ready)

7 RTS (Request to Send)

8 CTS (Clear to Send)

9 RI (Ring Indicator) Not used

* All Multi-2 serial port connectors are MALE.

Input signal; indicates that the external device is ready to establish a
link. Can be connected directly to DTR for automatic data dump.
Output signal. Active when the internal device is ready to exchange
data.
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.

PAGE 4 - 7

Chapter 4: Installation & Wiring

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

4.6.1 PC Port

The “PC” port is for communicating with the AFC User Console Software PC. The connecting cable
is a standard RS232 Null-Modem cable and can be purchased through FEC (Part #FEB-1301) or
any cable supplier that carries standard 9-Pin Null Modem cables.

Note: This port is removed when using the Ethernet Version (Optional
Unit

RS-232 Pin Layout (Male)

1 DCD
2 RXD
3 TXD
4 DTR
5 GND
6 DSR
7 RTS
8 CTS
9 Not Used

Front View

Standard Null
Modem Cable

E

Version) Multi

PC running AFC

User Console Software

RS-232C PC CABLE

(Standard NULL MODEM Cable)

PAGE 4 - 8

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

Chapter 4: Installation & Wiring

4.6.2 DISPLAY Port

“DISPLAY” port is currently not used in the US Market.

RS-422 Pin Layout (Male)

1 TX+
2 TX-
3 RX+
4 RX-
5 GND
6 Not Used
7 Not Used
8 Not Used
9 Not Used

Front View

4.6.3 DATA-OUT (1) Port

“DATA-OUT(1)” is an output port for ASCII fastening data communication to external devices.
Information concerning available data and data format is shown in the following sections.

RS-232 Pin Layout (Male)

DCD

1
2 RXD
3 TXD
4 DTR
5 GND
6 DSR
7 RTS
8 CTS
9 Not Used

The following cable diagram shows connection for “dumping” data after a fastening cycle. The
output data configured (using the AFC Software) for the DATA-OUT 1 port will be reported
automatically after the fastening cycle ends.

Front View

RS-232C DATA-OUT 1 & 2 CABLE

PAGE 4 - 9

Chapter 4: Installation & Wiring

Basic

Fastening Data

Length in bytes

Extended Fastening Data

Length in bytes

Input Data*

Length in bytes

System Data

Length in bytes

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

4.6.3.1 Available Output Data (From DATA-OUT 1 Port)

The Multi-2 Unit is capable of outputting the fastening results data in an ASCII format to a serial
printer or other serial peripheral devices. The data is sent from the Multi-2 Unit’s RS232C “DATA
OUT - 1” port. The output data string format as well as port configuration can be configured using
the AFC User Console Software. As little as one data item or up to all items can be user
configured. ASCII Control Characters may also be implemented (Ex: Start of Text, End of Text,
etc.). Below is a list of data available and its byte length.

Peak Torque
Final Angle
First Time
Final Time
Cycle Time
First Torque Rate
Second Torque Rate
Third Torque Rate
Final Torque
Offset Torque
Judgment

Current (@ peak torque) 4
Angle (@ peak torque) 4
First Peak Torque 5
Second Peak Torque 5
First Torque Rate Increment Torque 5
First Torque Rate Increment Angle 4
Second Torque Rate Increment Torque 5
Second Torque Rate Increment Angle 4
Third Torque Rate Increment Torque 5
Third Torque Rate Increment Angle 4
Rundown revolutions 4
Cal Voltage Value 5
Zero Voltage Value 5
Judgment 2
Retry Flag 3 (ASCII “RTY”)

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

Date 10
Time 8
Spindle Number 2
Sequence Number 2
Parameter Number 2
Cycle Count Number 7

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

6
5
6
6
5
7
7
7
5
5
3

*Input Data is input to the Multi-2 Unit using the RS232C “DATA INPUT” port. This port is
configured 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.

PAGE 4 - 10

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

4.6.3.2 Output Data Format (From DATA-OUT 1 Port)

The example below shows the format of the DATA-OUT (1) port 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 as little as one output field to all available
data (see previous table for available data fields). Headers, footers & ASCII control characters are
all user configurable using the AFC User Console Software.

EXAMPLE ONLY – Actual data will depend on individual user set-up.

2007/09/26 09:17:57 SEQ01 [Input Data from DATA-IN if programmed here]
SP PA TORQUE ANGLE 1RATE 2RATE OFSET JUG Acceptable Fastening
01 01 0.50 2 0.000 0.005 0.00 O

2007/09/26 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

2007/09/26 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)

2007/09/26 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)

2007/09/26 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)

2007/09/26 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 4: Installation & Wiring

PAGE 4 - 11

Chapter 4: Installation & Wiring

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

4.6.4 DATA-OUT 2 Port

“DATA-OUT2” port is currently not used.

RS-232 Pin Layout (Male)

1 DCD

RXD

2
3 TXD
4 DTR
5 GND
6 DSR
7 RTS
8 CTS
9 Not Used

Note: This port is removed when using the Ethernet Version (Optional

Front View

E

Version) Multi

Unit

4.6.5 DATA-IN Port

The “DATA-IN” 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.

RS-232 Pin Layout (Male)

1 DCD
2 RXD
3 TXD
4 DTR
5 GND

Not Used

6
7 RTS
8 CTS
9 Not Used

Front View

RS-232C DATA-IN CABLE



* When using the DATA-IN port, PIN 1 (DCD) must be enabled for data input (Jumper pins 1 & 4).

 



PAGE 4 - 12

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

Base Pa

rt

1500MULTI2(E)

1500MULTI2(E)

*1500MULTI2E

1500MULTI2(E)

*1500MULTI2E

1500MULTI2(E)

*1500MULTI2E

1500MULTI2(E)

1500MULTI2(E)

®

1500MULTI2(E)

1500MULTI2(E)

1500MULTI2(E)

1500MULTI2(E)

®

1500MULTI2(E)

1500MULTI2(E)

Chapter 4: Installation & Wiring

4.7 PLC Input/Output (I/O) Interface

The Multi-2 Unit is able to operate under different Input/Output control structures through use of a
modular I/O interface board installed in the unit. Besides standard discrete “hardwired” interface
signals, the introduction of “Open” architecture communication networks known as “Fieldbus” made it
necessary for the direct interfacing to these networks. FEC integrated many Fieldbus interfaces
directly into our system through use of a modular I/O board interfacing these networks directly to our
I/O. (See Chapter 5 for available interfaces)

Interface Board

Discrete I/O interface shown above

4.7.1 Control Interfaces

The available I/O interfaces are shown in the chart below. 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. In addition to handling I/O signals, some Fieldbus types allow
resultant fastening data to be sent over the same connection to the host PLC (Described below as I/O
& Messaging)

Number

Suffix Description Special Requirements

-1 Discrete I/O (Sinking Type)

-2 Discrete I/O (Sourcing Type)

-3

DeviceNet-S® (for Toolsnet®)

-4 Profinet IO (I/O & Messaging)

-5

Interbus-S® (for Toolsnet®)

-6 Allen Bradley Remote I/O®

-7

Profibus® (for Toolsnet®)

-8

Modbus Plus®

-9

DeviceNet-S

-10 Ethernet I/P (I/O & Messaging)

-11

-12

-13

-14

-15 M-Net

Interbus-S®
Mitsubishi CC-Link® Ver. 2 (I/O & Messaging)
Profibus
Mitsubishi CC-Link Ver. 1® (I/O only)

(I/O & Messaging)

(I/O & Messaging)

Hardware V1.09 or later

Hardware V1.09 or later

Hardware V1.09 or later

Hardware V1.12 or later
Software V4.16 or later

Software V4.13 or later

*Toolsnet Interface available for Multi2E (optional ethernet) version only. See Toolsnet Interface
Manual for set up information. (Other interfaces available – Contact FEC)

PAGE 4 - 13

Chapter 4: Installation & Wiring

Sequence Select 1

Resetting the counter value requires

a 200~

500ms pulse.

BYPASS Spindle No.9

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

4.7.2 Input Signals

The list below contains a description of the Input signals available on the I/O interface. Further input
mapping can be found in the individual interface information (See Chapter 5).

Signal

Emergency Stop N.C.

Reset N.O.

Reverse N.O.

Start N.O.

Sequence Select 0 N.O.

Sequence Select 2 N.O.
Sequence Select 3 N.O.

Cycle Count Up N.O.

Cycle Count Clear N.O.

Self Check Disable N.O.
INPORT 1 N.O.

INPORT 2 N.O.
INPORT 3 N.O.
INPORT 4 N.O.

BYPASS Spindle No.1 N.O. Bypass’s spindle #1 - Spindle is ignored as if it does not exist.
BYPASS Spindle No.2 N.O. Bypass’s spindle #2 - Spindle is ignored as if it does not exist.
BYPASS Spindle No.3 N.O. Bypass’s spindle #3 - Spindle is ignored as if it does not exist.
BYPASS Spindle No.4 N.O. Bypass’s spindle #4 - Spindle is ignored as if it does not exist.
BYPASS Spindle No.5 N.O. Bypass’s spindle #5 - Spindle is ignored as if it does not exist.
BYPASS Spindle No.6 N.O. Bypass’s spindle #6 - Spindle is ignored as if it does not exist.
BYPASS Spindle No.7 N.O. Bypass’s spindle #7 - Spindle is ignored as if it does not exist.
BYPASS Spindle No.8 N.O. Bypass’s spindle #8 - Spindle is ignored as if it does not exist.

BYPASS Spindle No10 N.O. Bypass’s spindle #10 - Spindle is ignored as if it does not exist.
Data Select 0
Data Select 1 N.O.
Data Select 2
Input Signal Power

Input Signal Power Source Type +0V

Contact Description

Emergency Stop Input.
Signal MUST be Active to perform a fastening operation.
When this signal is inactive (off), all Multi-2 Unit operation ceases,
all spindles in motion will stop, and all communication ports &
input/outputs will be disabled.
Reset Input.
When active (on), this signal will clear all spindle 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
200~500ms. 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.
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-2 Unit.
Start Cycle Input.
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-2 Unit is set
up for AUTOMATIC Start input. If it is set up for DEADMAN
(hand-held operation) 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.

N.O.

N.O. Bypass’s spindle #9 - Spindle is ignored as if it does not exist.

Sequence Select Input.
These 5 inputs form a binary code which is capable of selecting
up to 16 different operation sequences. Refer to Table 1. (Can be
used for part model selection)

Cycle Count Input.
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-2 Unit. The Cycle Count input requires a pulse of 200~500
milliseconds to increment the counter. If the CYCLE COUNT UP
is set to AUTO, the cycle counter increments automatically at the
end of every fastening.
The internal cycle counter is reset when this signal is input.

Disables the Calibration & Zero Level check that automatically is
performed at the start of each cycle
External Sequence Input.
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.

These 3 inputs form a binary code to select up to 8 Output Data
Banks. Used for Digital I/O interfaces. NOTE: Not used for
Fieldbus interfaces. [See Table 3 on Page 5-12]

Common for input signal.

Sink Type +24V

PAGE 4 - 14

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

OFF ON OFF ON 6

ON ON OFF OFF 13

(Continued)

[Table 1 – Sequence Selection]

Sequence

Select 3

OFF OFF OFF OFF 1
OFF OFF OFF ON 2
OFF OFF ON OFF 3
OFF OFF ON ON 4
OFF ON OFF OFF 5

OFF ON ON OFF 7
OFF ON ON ON 8

ON OFF OFF OFF 9
ON OFF OFF ON 10
ON OFF ON OFF 11
ON OFF ON ON 12

ON ON OFF ON 14
ON ON ON OFF 15
ON ON ON ON 16

Sequence

Select 2

Sequence

Select 1

4.7.3 Output Signals

The list below contains a description of the output signals available on the I/O interface. Further
output mapping can be found in the individual interface information (See Chapter 5). The
Multi-2 Unit is capable of providing over 570 Output signals to indicate the status of the Multi-2
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 output bit.

Main Multi Unit Output Signals

Total Reject

Total Accept

Abnormal

Ready

Busy

End

Sequence 0
Sequence 1
Sequence 2
Sequence 3

Output when the fastening result is a REJECT. Indicates that one or more
spindles have 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 0~4 input selections.
Sequence bits are active according to what sequence is set from the
sequence select inputs. Used to confirm proper sequence before fastening
starts. Refer to Table 3.

Chapter 4: Installation & Wiring

Sequence

Select 0

Selected Sequence No.

PAGE 4 - 15

Chapter 4: Installation & Wiring

OFF OFF OFF ON 2

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

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

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 the high current 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. Typically used in conjunction with
Bank Outputs to monitor which Bank is selected.

[Table 2 – Sequence Select Output]

Sequence

Output 3

OFF OFF OFF OFF 1

Sequence

Output2

Sequence

Output1

Sequence

Output0

Selected Fastening

Sequence No.

OFF OFF ON OFF 3
OFF OFF ON ON 4



ON ON ON OFF 15
ON ON ON ON 16









PAGE 4 - 16

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

fastening cycle is complete and the READY signal is output.

value

.

Current Limit

Low

Chapter 4: Installation & Wiring

(Output Signals – Continued)

In addition to the main Multi unit output signals, individual spindles that are connected to the Multi unit
report status signals to the Multi Unit. These signals are available on a “per spindle” basis and can
be used or programmed using the AFC User Console software.

Available Individual Spindle Unit Output Signals (Per connected spindle)

Reject

Accept

Abnormal

Ready

Busy

Bypass

Parameter Select 1
Parameter Select 2
Parameter Select 3
Parameter Select 4
Time 1 Low Reject Output when 1st Time result is below the set 1st Time Low Limit value.
Time 1 High Reject Output when 1st Time result is above the set 1st Time High Limit value.
Time 2 Low Reject Output when Final Time result is below the set Final Time Low Limit value.
Time 2 High Reject Output when Final Time result is above the set Final Time High Limit value.

Peak Torque Low Reject

Peak Torque High Reject

Final Torque Low Reject

Final Torque High Reject

Angle Low Reject Output when Angle result is below the set Angle Low Limit value.
Angle Low Reject Output when Angle result is above the set Angle High Limit value.
Rate 1 Low Reject Output when Rate 1 result is below the set Rate 1 Low.
Rate 1 High Reject Output when Rate 1 result is above the set Rate 1 High.
Rate 2 Low Reject Output when Rate 2 result is below the set Rate 2 Low.
Rate 2 High Reject Output when Rate 2 result is above the set Rate 2 High.
Rate 3 Low Reject Output when Rate 3 result is below the set Rate 3 Low.
Rate 3 High Reject Output when Rate 3 result is above the set Rate 3 High.

Warning
Current Limit High
Warning

Combination Bits 1-8

Output when the fastening result is a REJECT. Indicates that the spindle 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 an ACCEPT. Indicates that the spindle is
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
spindle has detected an internal fault and can no longer proceed. The fault
maybe generated during a self-check function (see AFC1500 Operation
Manual for troubleshooting). The RESET signal clears the abnormal
condition.

Output when the spindle is in the READY condition. Indicates spindle 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 remains active until the

Signal is active when the spindle is bypassed either from San Unit bypass
input signal or from the San Unit bypass switch.

Output confirmation of PARAMETER SELECT 1~4 input selections.
Parameter Select bits are active according to what sequence is set from the
sequence select inputs.

Output when Peak Torque result is below the set Peak Torque Low Limit
value.

Output when Peak Torque result is above the set Peak Torque High Limit
value.

Output when Final Torque result is below the set Final Torque Low Limit

Output when Final Torque result is above the set Final Torque High Limit
value.

Output when the current is below acceptable Limits.

Output when the current is above acceptable Limits.
Used to create “special” outputs formed by using a combination of SAN Unit

outputs in “AND / OR” logic.

PAGE 4 - 17

Chapter 4: Installation & Wiring

OFF

ON

OFF

ON

OFF

ON

REVERSE

OFF

ON

Fastening

Fastening

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

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

4.7.4 Signal Timing Chart

STOP

Signal Timing

READY

RESET

START

FASTENING

A

A

Operation

Operation

BUSY

ACCEPT

REJECT

ABNORMAL

END

COUNT UP

A

200 ~ 500ms (A)

 Because the RESET input clears all fastening data and discrete outputs, it should only be activated

to clear a system Abnormal or to perform a Zero Level Check. The system will automatically reset
with each fastening start. A manual RESET activation between cycles could result in data loss.

 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 open (OFF), all

operations cease and all inputs / outputs become inactive.

 The START signal will not operate during RESET, REVERSE or ABNORMAL signal activation. A

pulse of 200~500 milliseconds is required for AUTO START mode. For DEADMAN mode (Used
mainly in handheld applications), the signal must be maintained for the complete fastening cycle
(until BUSY goes low).

 When the ABNORMAL signal is activated, the system must be RESET before normal operation will

resume.

 REJECT & ACCEPT signals are maintained until the start of the next cycle or on a RESET.
 READY indicates when the system is ready to start.
 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 approximately 5ms.

Seq. Sel. Bit 0

Seq. Sel. Bit 1
Seq. Sel. Bit 2

Sequence Select No. 6
(Multi-2 Inputs)

Seq. Sel. Bit 3

Bit 0 Selected

Bit 1 Selected
Bit 2 Selected

Bit 3 Selected

START

Allow 20ms to interlock the Sequence Select
Command and the associated result signal.

Sequence No. 6 Selected
(Multi-2 Outputs)

* No bit selected = Sequence No. 1

PAGE 4 - 18

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

Switch 1: I/O Enable / Disable Test Mode

Chapter 4: Installation & Wiring

4.7.5 External DIP Switch

FRONT

DIP SWITCH (Factory Setting)



(Located on bottom of unit)

No. OFF ON

4

Not Used

3

Not Used

Angle resolution: 0.1 Angle resolution: 1

2
1

EXT. I/O ENABLE EXT. I/O DISABLE

If Switch No.1 is turned ON, the Input / Output Module
will be bypassed and the STOP signal will be enabled
allowing Manual operations through the front panel
buttons for testing purposes. This is particularly
useful when Fieldbus interfaces are installed and
connection to the master device is not possible.

When finished testing the equipment, be sure to
turn Switch No. 1 OFF.
Do not change Switch No. 3 or 4.

Switch 2 : Angle Resolution

Normal angle resolution is 1.0 degree. Angle
resolution of 0.1 degree is available using this switch.
Note: SAN unit firmware version 3.3x is required and
the function enabled if using the AFC User Console for
monitoring purposes.

(Bottom View)

4.8 Setting Default TCP/IP Address

For Multi-2 units with firmware 1.16 or greater, the IP address for the User Console Ethernet Port can be
reset to the default setting by following the directions below.

1. Turn off power to the unit

2. Turn “ON” DIP Switch no. 1, 2 & 4

3. Depress and HOLD the RESET button (on front of unit) and turn the power back on

4. Hold the RESET button until the green ACC LED turns on solid

5. Turn power off and reset DIP Switch back to original setting

When power is reapplied, the TCP/IP settings will revert to the following default;

IP Address: 192.168.10.10
Subnet Mask: 255.255.255.0
Default Gateway: 192.168.10.1

4.9 Firmware Flash Connector

Upgrades or revisions to firmware are handled easily with the on board Flash Connector located on
the bottom of each Multi-2 Unit. There is no need to remove or disassemble the unit. A flash adapter
(CONTROLLER-ROM) containing the new firmware can be connected to connector CN8 with the
power off to the unit. The power is then cycled on until the ACCEPT LED is blinking indicating the
firmware upload is complete. Turn off power and remove the flash adapter. The firmware update is
now complete.

Note: This connector is for FEC use only and it is not recommended for use other than FEC.

Firmware Flash Connector (CN8)



User Console Ethernet Port

PAGE 4 - 19

Chapter 4: Installation & Wiring

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

(Blank Page)

PAGE 4 - 20

Chapter 5: Control Interfaces

Chapter 5: Control Interfaces

SW1

SW1

SW1

SW1

ON

ON

ON

ON

ON ON

ON

ON ON

ON ON

ON ON

ON ON ON

AFC1500 Multi-2 Unit Hardware Manual (Rev2.1)

5.1 I/O Interface Board

The Multi-2 unit interface board provides the interface between real world control signals and the
AFC1500 Fastening system I/O. Since there are many different I/O control structures in the industry
today, the Multi-2 unit has the ability to adapt to these through use of the I/O interface board. The
interface is available in many Fieldbus or “open architecture” configurations as well as standard
hardwired discrete I/O.

The Multi-2 unit I/O assumes control of the individual SAN unit I/O, thus eliminating the need to wire to
each individual spindle.

All I/O interface motherboards have a DIP Switch SW1 (located at position 7D) which has to be
configured so the Multi-2 Unit can identify the type of interface installed. The table below identifies the
switch set-up for configurable interface boards.

Interface Type

Discrete I/O (Sink Type – active true low )
Discrete I/O (Source Type – active true high)
DeviceNet-S® (for Toolsnet®)
Profinet IO
Interbus-S® (for Toolsnet®)
Allen Bradley Remote I/O
Profibus® (for Toolsnet®)
Modbus Plus®
DeviceNet-S®
Ethernet I/P
Interbus-S®
Mitsubishi CC-Link® Version 2 (I/O & Messaging)
Profibus®
Mitsubishi CC-Link® Version 1 (I/O only)
M-Net

1

ON OFF OFF OFF

OFF ON

ON

OFF OFF

ON OFF

OFF ON

ON

OFF OFF OFF ON

ON OFF OFF ON

OFF ON

ON

OFF OFF

ON OFF

OFF ON

ON

(Other interfaces available, contact FEC)

5.2 Interface Board DIP Switch Setup

Throughout this chapter, SW1 settings will be represented as follows:

- Represents switch position

Side View

––––

I/O Interface Circuit Board

2

3

OFF OFF
OFF OFF

OFF ON
OFF ON

4

OFF
OFF
OFF
OFF

PAGE 5 - 2

Discrete I/O (Sinking Type) Board Specifications

AFC1500 Multi-2 Unit Hardware Manual (Rev2.1)

Chapter 5: Control Interfaces

5.3 Discrete I/O Interface

The Discrete I/O Interface is commonly used for hardwire direct connect PLC applications. Two types
of Discrete I/O interfaces are available: 24VDC Sinking Type and 24VDC Sourcing Type. The standard
discrete I/O interface is the Sinking Type interface.

5.3.1 Sinking Type (NPN)

The Sinking Type I/O interface is standard with discrete I/O Multi Units. It connects to 24VDC True
Low type (NPN) PLC cards.

CN3

12

34

22

34

1

23

13

12

22

23

1

13

CN4

Operating Voltage 24 VDC

Maximum current (outputs) 200 ma

- Represents switch position

Logic True Low (Sinking)

Mating Connectors

PLC-IN
(Cable #FEB-1271)

PLC-OUT
(Cable #FEB-1272)

PAGE 5 - 3

Connector: Honda #MR-34F
Housing: Honda #MR-34L
Connector: Honda #MR-34M
Housing: Honda #MR-34L

Chapter 5: Control Interfaces

Input

Input

24VDC Power

AFC1500 Multi-2 Unit Hardware Manual (Rev2.1)

5.3.1.1 Discrete Signal Connection (Sinking Type)

AFC1500 MULTI-2 Unit Device PLC

Output

Output

PAGE 5 - 4

Discrete I/O (Sourcing Type) Board Specifications

AFC1500 Multi-2 Unit Hardware Manual (Rev2.1)

5.3.2 Sourcing Type (PNP)

The Sourcing Type I/O interface is optional with discrete I/O Multi Units. It connects to 24VDC True
High type (PNP) PLC cards. (This interface must be specified during ordering)

34

23

CN3

12

1

CN4

34

22

23

13

12

22

1

13

Operating Voltage 24 VDC

Maximum current (outputs) 200 ma

Chapter 5: Control Interfaces

- Represents switch position

Logic True High (Sourcing)

Mating Connectors

PLC-IN
(Cable #FEB-1271)

PLC-OUT
(Cable #FEB-1272)

PAGE 5 - 5

Connector: Honda #MR-34F
Housing: Honda #MR-34L
Connector: Honda #MR-34M
Housing: Honda #MR-34L

Chapter 5: Control Interfaces

AFC1500 Multi-2 Unit Hardware Manual (Rev2.1)

5.3.2.1 Discrete Signal Connection (Sourcing Type)

AFC1500 MULTI Unit Device PLC

Output signal

Input signal

PAGE 5 - 6

Contac

AFC1500 Multi-2 Unit Hardware Manual (Rev2.1)

5.3.3 Input Signals (PLC-IN) Connector

The Input Signals are provided on the PLC IN connector. Inputs are assigned in the order as
shown in the table below and cannot be changed. Pins designated as “Not Used” have no input
assigned to them.
NOTE: When using Discrete I/O, “Bypass Spindle” input signals assigned to the PLC IN
connector can only be used for up to 10 individual Spindles (from the Multi-2 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 Controllers using the SAN Unit’s PLC connector. (An alternative to
this is to use a fieldbus interface which has control of all spindle bypass signals from the
interface.)

Chapter 5: Control Interfaces

Pin#

1 Emergency Stop N.C. Emergency Stop Input
2 Reset N.O. Reset Input
3 Reverse N.O. Reverse Spindle Rotation Input
4 Start N.O. Start Cycle Input
5 Sequence Select 0 N.O.
6 Sequence Select 1 N.O.
7 Sequence Select 2 N.O.
8 Sequence Select 3 N.O.
9 Cycle Count Up N.O. Cycle Count Input

10 Cycle Count Clear N.O.

11 Self Check Disable N.O. Disables automatic self check
12 Not Used
13 IN PORT 1 N.O.
14 IN PORT 2 N.O.
15 IN PORT 3 N.O.
16 IN PORT 4 N.O.
17 BYPASS Spindle No.1 N.O. Bypass’s spindle #1
18 BYPASS Spindle No.2 N.O. Bypass’s spindle #2
19 BYPASS Spindle No.3 N.O. Bypass’s spindle #3
20 BYPASS Spindle No.4 N.O. Bypass’s spindle #4
21 BYPASS Spindle No.5 N.O. Bypass’s spindle #5
22 BYPASS Spindle No.6 N.O. Bypass’s spindle #6
23 BYPASS Spindle No.7 N.O. Bypass’s spindle #7
24 BYPASS Spindle No.8 N.O. Bypass’s spindle #8
25 BYPASS Spindle No.9 N.O. Bypass’s spindle #9
26 BYPASS Spindle No.10 N.O. Bypass’s spindle #10
27 Not Used
28 Not Used
29 Not Used
30 Data Select 0
31 Data Select 1 N.O.
32 Data Select 2
33 Input Signal Power

34 Input Signal Power Source Type +0V

Note) NC: Normal Closed, NO: Normal Open

Signal

t

Sequence Select Input

External Sequence interface Input

Output Data Bank Select inputs

Common for input signal.

Description

Sink Type +24V

For Input Signal definition see Section 4.7.2.

PAGE 5 - 7

Chapter 5: Control Interfaces

Signal

Description

AFC1500 Multi-2 Unit Hardware Manual (Rev2.1)

5.3.4 Ouput Signals (PLC-OUT) Connector

The Multi-2 Unit is capable of providing over 570 Output signals to indicate the status of the
Multi-2 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 set up, each with 32 different
output signals. The Output “Bank” is then selected using the Data Select inputs (Data Select 0,
Data Select 1, Data Select 2).

FEC Standard* Output Layout

NO

1 Total Reject NO Output when the fastening result is a REJECT.
2 Total Accept NO Output when the fastening result is a ACCEPT.
3 Abnormal NO Output when an Abnormal condition occurs.
4 Ready NO Output when the system is in the READY condition.
5 Busy NO System is in cycle
6 End NO Output when a fastening cycle is complete.
7 Sequence Output 0 NO
8 Sequence Output 1 NO

9 Sequence Output 2 NO
10 Sequence Output 3 NO
11 Out Port 1 NO
12 Out Port 2 NO
13 Out Port 3 NO
14 Out Port 4 NO
15 Out Port 5 NO
16 Out Port 6 NO
17 Out Port 7 NO
18 Out Port 8 NO
19 Spindle in Bypass NO Output when any connected spindle is in Bypass
20 Current Limit Warning NO Active when the high current limit has been exceeded.
21

~

As Configured NO
29
30 Always ON / Always OFF NO See “Output Data Banks” on following page
31 Always ON / Always OFF NO See “Output Data Banks” on following page
32 Always ON / Always OFF NO See “Output Data Banks” on following page
33 Output Signal Power
34 Output Signal Power Source Type +24V

*

This “Standard” layout is only provided as a guide. Any signal may be programmed on any pin using the

AFC Software.

The layout above is programmed standard from FEC. It contains only “Multi” or system signals as shown,

however, individual spindle signals are available and may be programmed (Ex. Individual spindle accept or reject

– See 4.7.3 for complete list of signals that may be programmed on these pins)

** Type: NO = (Normally Open)

Type**

Output confirmation of SEQUENCE SELECT 0~4 input
selections.

These signals will output when the fastening sequence
reaches a step that has a [PLC OUTPUT] instruction
inserted.

Common for output signal.

Sink Type +0V

For Output Signal definition see Section 4.7.3.

PAGE 5 - 8

Number of Discrete Outputs Required

AFC1500 Multi-2 Unit Hardware Manual (Rev2.1)

5.3.4.1 Ouput Data Banks

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-2 Unit exceed 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 Table 3 below)

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 / Always 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 / Always 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 an output in each Bank will allow monitoring of which Bank is
selected.
The number of discrete outputs used for this monitoring function depends on how many
Banks are required as shown below:

Chapter 5: Control Interfaces

Number of Banks Required

1 (32 outputs) 0 or 1

2-4 (64 – 128 outputs) 2

5-8 (160 – 256 outputs) 3

for Monitoring Output Bank Status

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

[Table 3] Output Data (BANK) Selection

Data Select 2 Data Select 1 Data Select 0 Output Data Bank

OFF OFF OFF 0
OFF OFF ON 1
OFF ON OFF 2
OFF ON ON 3

ON OFF OFF 4
ON OFF ON 5
ON ON OFF 6
ON ON ON 7

PAGE 5 - 9

Chapter 5: Control Interfaces

Pin No.

Wire Color

AFC1500 Multi-2 Unit Hardware Manual (Rev2.1)

5.3.5 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 PLC IN and PLC OUT.
(FEC Cable Assemblies #FEB -1271 (PLC IN Cable), #FEB-1272 (PLC OUT Cable))

1 Black
2 Brown
3 Red
4 Orange
5 Yellow
6 Green
7 Blue
8 Violet

9 Gray
10 White
11 White/Black
12 White/Brown
13 White/Red
14 White/Orange
15 White/Yellow
16 White/Green
17 White/Blue
18 White/Violet
19 White/Gray
20 White/Black/Brown
21 White/Black/Red
22 White/Black/Orange
23 White/Black/Yellow
24 White/Black/Green
25 White/Black/Blue
26 White/Black/Violet
27 White/Black/Gray
28 White/Brown/Red
29 White/Brown/Orange
30 White/Brown/Yellow
31 White/Brown/Green
32 White/Brown/Blue
33 White/Brown/Violet
34 White/Brown/Gray

PAGE 5 - 10

2 Unit Hardware Manual (Rev2.1)

InterBus S from Phoenix Contact is a

transmitted in frames that provide simultaneous and predictable updates to all devices in the network.

version) has up to 512 bytes of assigned input data and 512 bytes of assigned

output data* (64bytes default). The 64 bytes of assigned I/O data allow a maximum of 512 inputs and

512 outputs per node. FEC I/O is assigned to the I/O points in these data are

designated spare). FEC Inputs match the

using the AFC User Console Software.

* When using Master boards where the PCP channel is NOT supported, the maximum number of I/O

20 output bytes.

S board manufactured by HMS Fieldbus Systems AB into the Multi

modular I/O board. For further technical information on the Interbus

Item

Application Connector

OUT Connector

Green if voltage is OK at Bus

Re

Green (flashing @

Green (flashing @

Red

Red

5

1

5

1

6

9

9

6

1

2

3

4

Control Interfaces

based, distributed device I/O network. I/O data is

as (some I/O will be

locations are

S interface go to the HMS website.

Description

ASIC and FLASH ROM check fault.

module initialized and running OK.

2

1

3

4

5

6

7

presents switch position

AFC1500 Multi-

5.4 Interbus S® Interface

This interface board (S -

n open-ring

Chapter 5:

will be 20 input bytes and

FEC integrates the Interbus

(www.hms.se)

discrete input layout. FEC Output

- Re

Daughter board

programmed

-2 Unit

1
2 BUS-IN Connector
3 BUS­4 Baud Rate Jumper
5 Status LEDs (4)
6 UL LED -

d - (flashing @ 2Hz) -

2Hz) - module not initialized.

7 Watchdog LED

1Hz) ­ (flashing @ 1Hz) - RAM check fault.
(flashing @ 4Hz) - DPRAM check fault.

PAGE 5 - 11

Chapter 5: Control Interfaces

AFC1500 Multi-2 Unit Hardware Manual (Rev2.1)

InterBus Specifications

Baud Rate 500K or 2M bits/sec.
Nodes 256
Distance 400 m
Cable Point to point twisted pair
Packet Size 1-256 words
Communication Type Master/Slave

Interface Specifications

Input data bytes (including free data) 512 (Default: 64 input data*)
Output data bytes (including free data) 512 (Default: 64 output data*)
Interface type Remote bus interface
Operating Voltage +5VDC / 200 ma
Data Width 4 words (1 word PCP, 3 words data)
ID Code F3 Hex
Output objects 6000H through 603FH
Input objects 6040H through 607FH

* Actual Input/Output data length is configurable using the AFC Software package.

PAGE 5 - 12

Bus IN

Signal

Description

(9 pin male D

-

sub)

Bus OUT

Pin No.

Signal

Description

(9 pin female D

-

sub)

*

5

1

9

6

1

5

6

9

AFC1500 Multi-2 Unit Hardware Manual (Rev2.1)

5.4.1 Component Descriptions

Fieldbus Interface Connectors

Housing

Pin No.

1
2
3
4
5
6
7
8
9

PE Protective Earth Ground
DO1 Data Output
DI1 Data Input
GND Signal Ground
NC ­NC ­/DO1 Inverted Data Output
/DI1 Inverted Data Input
NC ­NC -

Housing PE Protective Earth Ground
1 DO2 Data Output
2 DI2 Data Input
3 GND Signal Ground
4 NC ­ 5 GND Signal Ground
6 /DO2 Inverted Data Output
7 /DI2 Inverted Data Input
8 NC -

9 RBST

*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.

Baud Rate Switch

The module supports 2Mbit/s and 500Kbit/s operation. To select the
desired baud rate, just move the jumper cap to the corresponding location.

Baud rate must be selected before power is on and cannot be changed during operation.

Status LEDs

No. LED Color Description

1

CC/RC Green

2

3 RD Yellow

4 TR Green

BA Green

Chapter 5: Control Interfaces

Cable connection is good & master not in reset
Bus Active
Remote Bus Disabled
PCP - Communication active.

Hold Time = 500ms

PAGE 5 - 13

Chapter 5: Control Interfaces

AFC1500 Multi-2 Unit Hardware Manual (Rev2.1)

5.4.2 AFC User Console Software Settings

The Anybus board is set up by sending a Fieldbus Configuration File (*.fcf) containing initialization
messages from the Multi-2 Unit to the board during power up. This string of data initializes different
characteristics required for the board to communicate over the Interbus S network. In this string are
messages which set the length of I/O data as well as other messages. Since the board is only

initialized during power-up, the Multi-2 Unit MUST have the power cycled OFF/ON after the
“fcf” file is downloaded.

To download the fcf file, select “Field Bus Setup” from the “Multi” pull down menu. Select the
appropriate “Bus Type” and click “Browse” to locate the correct fcf file. After the file has been
selected, click “download” to send the file data to the Anybus board.

If no file exists (or if the settings need to be changed), after the Bus Type has been selected click on
the Setup Tab.

Select the desired settings from the pull downs. When finished, go back to the General Tab and
click “download” to send the file data to the Anybus board.

PAGE 5 - 14

AFC1500 Multi-2 Unit Hardware Manual (Rev2.1)

5.4.3 Input Signals Mapping (CH1 ~ CH16)

Inputs are assigned in the order as shown in the table below and cannot be changed. Bits
designated as “Unused” have no input assigned to them.

NOTE: If Interbus S TOOLSNET version is used – Input/Output Signal layout is different than
shown. See 5.12 for TOOLSNET I/O Layout

CH. No. Bit Signal

0bit Emergency Stop 1
1bit Reset 2
2bit Reverse 3
3bit Start 4
4bit Sequence Select 0 5
5bit Sequence Select 1 6

Input CH.

No.01

6bit Sequence Select 2 7
7bit Sequence Select 3 8
8bit Cycle Count Up 9

9bit Cycle Count Clear 10
10bit Self Check Disable 11
11bit Unused 12
12bit INPORT 1 13
13bit INPORT 2 14
14bit INPORT 3 15
15bit INPORT 4 16

CH. No. Bit Signal

BYPASS SP#11

0bit

BYPASS SP#12

1bit

BYPASS SP#13

2bit

BYPASS SP#14

3bit

BYPASS SP#15

4bit

BYPASS SP#16

5bit

BYPASS SP#17

Input CH.

No.03

6bit

7bit

8bit

9bit

10bit
11bit
12bit
13bit
14bit
15bit

BYPASS SP#18
BYPASS SP#19
BYPASS SP#20
BYPASS SP#21
BYPASS SP#22
BYPASS SP#23
BYPASS SP#24
BYPASS SP#25
BYPASS SP#26

The Channel Number at the Master Unit output side differs according to node address settings.
Please check before operating the unit.

Note: For signal definitions see Section 4.7.2

FEC Multi-2

Bit

FEC Multi-2

Bit
33

34
35
36
37
38
39
40
41
42
43
44
45
46
47
48

Chapter 5: Control Interfaces

CH. No. Bit Signal

BYPASS SP#1

0bit

BYPASS SP#2

1bit

BYPASS SP#3

2bit

BYPASS SP#4

3bit

BYPASS SP#5

4bit

BYPASS SP#6

5bit

BYPASS SP#7

Input CH.

No.02

CH. No. Bit Signal

Input CH.

No.04

6bit

BYPASS SP#8

7bit

BYPASS SP#9

8bit

BYPASS SP#10

9bit

10bit Unused 27

11bit Unused 28
12bit Unused 29
13bit Unused 30
14bit Unused 31
15bit Unused 32

0bit
1bit
2bit
3bit
4bit

BYPASS SP#27
BYPASS SP#28
BYPASS SP#29
BYPASS SP#30
BYPASS SP#31

5bit 54
6bit 55
7bit 56
8bit 57

9bit 58
10bit 59
11bit 60
12bit 61
13bit 62
14bit 63
15bit 64

FEC Multi-2

Bit
17
18

19
20
21
22
23
24
25
26

FEC Multi-2

Bit
49

50
51
52
53

PAGE 5 - 15

Chapter 5: Control Interfaces

FEC Multi

-2

Bank Bit

Sp

indle No.1 Accept

Spindle No.1 Reject

Spindle No.1 ABN.

Spindle No.1 BYP

Sp

indle No.2 Accept

Spindle No.2 Reject

Spindle No.2 ABN

Spindle No.2 BYP

Spindle No.3 Accep

t

Spindle No.3 Reject

Spindle No.3 ABN

Spindle No.3 BYP

Sp

indle No.4 Accept

Spindle No.4 Reject

Spindle

No.4 ABN.

Spindle No.4 BYP

Sp

indle No.5 Accept

Spindle No.

5 Reject

Spindle No.

5 ABN.

Spindle No.

5 BYP

Sp

indle No.6 Accept

Spindle No.

6 Reject

Spindle No.

6 ABN

Spindle No.

6 BYP

Spindle No.

7 Accep

t

Spindle No.

7 Reject

Spindle No.

7 ABN

Spindle No.

7 BYP

Sp

indle No.8 Accept

Spindle No.

8 Reject

Spindle No.

8 ABN.

Spindle No.

8 BYP

Sp

indle No.9 Accept

Spindle No.

9 Reject

Spindle No.

9 ABN.

Spindle No.

9 BYP

shown is only an EXAMPLE.

AFC1500 Multi-2 Unit Hardware Manual (Rev2.1)

5.4.4 Ouput Signals (CH1 ~ CH16)

The Multi-2 Unit is capable of providing over 570 Output signals to indicate the status of the Multi-2
Unit and of all the AFC1500 SAN Controllers connected to it (up to 31 controllers).

CH. No. Bit Signal

0bit Total Reject 1 1
1bit Total Accept 1 2
2bit Abnormal 1 3
3bit Ready 1 4
4bit Busy 1 5

Output CH.

No.01

Output CH.

No.02

Output CH.

No.03

：

CH. No. Bit Signal

Output CH.

No.16

5bit End 1 6
6bit Sequence Output 0 1 7
7bit Sequence Output 1 1 8
8bit Sequence Output 2 1 9

9bit Sequence Output 3 1 10
10bit Spindle in Bypass 1 11
11bit Current Warning 1 12
12bit

13bit
14bit
15bit

0bit

1bit

2bit

3bit

4bit

5bit

6bit

7bit

8bit

9bit
10bit
11bit
12bit
13bit
14bit
15bit

0bit

1bit

2bit

3bit

4bit

5bit

6bit

7bit

8bit

9bit
10bit
11bit
12bit
13bit
14bit
15bit

0bit 8 1

…

15bit 8 32

1 13
1 14
1 15
1 16
1 17
1 18
1 19
1 20
1 21
1 22
1 23
1 24
1 25
1 26
1 27
1 28
1 29
1 30
1 31
1 32
2 1
2 2
2 3
2 4
2 5
2 6
2 7
2 8
2 9
2 10
2 11
2 12
2 13
2 14
2 15
2 16

See Section 4.7.3 for available
output signals.

These Output signals are user

configurable using the AFC User

Console Software and may be

programmed on any designated

bit.

The Output signal mapping

The signals may be programmed

for placement in ANY bit

position.

The CH. No. at the Master input side differs according to node address settings.
Please check before operating the unit.

PAGE 5 - 16

Item

Description

2

1

3

4

5

AFC1500 Multi-2 Unit Hardware Manual (Rev2.1)

Chapter 5: Control Interfaces

5.5 DeviceNet® Interface

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 hard wiring/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.
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)

- Represents switch position

1 Application Connector
2 DeviceNet Connector
3 Configuration Switches
4 Status LEDs (4)

Red - (flashing @ 2Hz) - ASIC and FLASH ROM check fault.
Green (flashing @ 2Hz) - module not initialized.

5 Watchdog LED

Green (flashing @ 1Hz) - module initialized and running OK.
Red (flashing @ 1Hz) - RAM check fault.
Red (flashing @ 4Hz) - DPRAM check fault.

PAGE 5 - 17

Chapter 5: Control Interfaces

Twisted

AFC1500 Multi-2 Unit Hardware Manual (Rev2.1)

DeviceNet Specifications

Speed 125K, 250K and 500K baud
Nodes 64

500 meters at 125K baud

Maximum Distance

Cable

Communications Type Master/Slave

250 meters at 250K baud
100 meters at 500K baud

pair for signal and power

Allen Bradley or equivalent ;
Thin Cable #1485C-P1-C
Thick Cable # 1485C-P1-A

Interface Board Specifications

Operating Voltage +5V, 200 ma
Output data bytes 512 max.*
Input data bytes 512 max.*
Servers per group 2 Maximum
Interface type Dual Port RAM or Serial Interface

* 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.)

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.fec­usa.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-2 Unit.

NOTE: COMPATIBILITY ISSUE

There is a known compatibility issue using with OMRON C200HW-DRM21-V1

PLC’s and the Devicenet interface. This is an OMRON problem.

Omron suggests using CS1-DRM21-V1 PLC in its place.

PAGE 5 - 18

Pin No.

Signal

Wire Color

1 V-

Black

2 CAN_L

Blue

3 Drain/Shield

4 CAN_H

White

5 V+ Red

Baud

R

ate SW-1 SW-2

125K

OFF

OFF

250K

OFF

ON

500K

ON

OFF

Reserved

ON ON

Mac ID SW-3

(MSB)

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

8

(LSB)

Address 0

OFF

OFF

OFF

OFF

OFF

OFF

Address 1

OFF

OFF

OFF

OFF

OFF

ON

Address 2

OFF

OFF

OFF

OFF

ON

OFF

Address 3

OFF

OFF

OFF

OFF

ON ON

… … … … … … …

Address 61

ON ON ON ON

OFF

ON

Address 62

ON ON ON ON ON

OFF

Address 63

ON ON ON ON ON ON

ON

8

5

4

2

3

7

6

1

1

2 3

4

See “Termination”

AFC1500 Multi-2 Unit Hardware Manual (Rev2.1)

5.5.1 Component Descriptions

Fieldbus Interface Connections

Termination

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

Configuration Switches

On a DeviceNet network, each node must be assigned its own unique Mac ID. The Mac ID is a
value between 0 and 63 used to identify each node. The Mac ID and Baud Rate are set using the
DIP switches on the front of the module.

These switches must be set before power is on and cannot be changed during operation.

Baud Rate Settings

Chapter 5: Control Interfaces

Status LEDs

LED State Description

Mac ID Settings

1 - Reserved - Reserved for future use.

Off Not Powered / Not Online
Green solid Link OK, Online, Connected

2 - Network Status

Green flashing Online, Not connected
Red solid Critical Link Failure
Red flashing Connection Timeout
Off No power to device
Green solid Device operational

3 - Module Status

Green flashing Data size bigger than configured
Red solid Unrecoverable fault
Red flashing Minor fault

4 - Reserved - Reserved for future use.

PAGE 5 - 19

Chapter 5: Control Interfaces

AFC1500 Multi-2 Unit Hardware Manual (Rev2.1)

5.5.2 User Console Software Settings

The Anybus board is set up by sending a Fieldbus Configuration File (*.fcf) containing initialization
messages from the Multi-2 Unit to the board during power up. This string of data initializes different
characteristics required for the board to communicate over the DeviceNet network. In this string are
messages which set the length of I/O data as well as other messages. Since the board is only

initialized during power-up, the Multi-2 Unit MUST have the power cycled OFF/ON after the
“fcf” file is downloaded.

To download the fcf file, select “Field Bus Setup” from the “Multi” pull down menu. Select the
appropriate “Bus Type” and click “Browse” to locate the correct fcf file. After the file has been
selected, click “download” to send the file data to the Anybus board.

If no file exists (or if the settings need to be changed), after the Bus Type has been selected click on
the Setup Tab.

Select the desired settings from the pull downs. In I/O SETUP, select the “Input Data Length” and
“Output Data Length” as required by you application. (INPUT & OUTPUT in this screen refer to PLC
side I/O, INPUT = FEC Output size, OUTPUT = FEC Input size) When finished, go back to the
General Tab and click “download” to send the file data to the Anybus board.

The DeviceNet interface also has the ability to transfer fastening results data (message data). Refer
to the AFC1500 User Console Manual for message setup information.

See section 5.11.5 for message set-up example (reference only)

PAGE 5 - 20

AFC1500 Multi-2 Unit Hardware Manual (Rev2.1)

5.5.3 Input Signals (CH1 ~ CH16)

Inputs are assigned in the order as shown in the table below and cannot be changed. Bits
designated as “Not Used” have no input assigned to them.
Operation Note: The first 16 bits of I/O are used by DeviceNet communication. The first input must
be set “ON” to enable communication.

NOTE: If Devicenet TOOLSNET version is used – Input/Output Signal layout is different than
shown. See 5.12 for TOOLSNET I/O Layout

CH. No. Bit Signal

0bit Emergency Stop 1
1bit Reset 2
2bit Reverse 3
3bit Start 4
4bit Sequence Select 0 5
5bit Sequence Select 1 6

Input CH.

No.01

6bit Sequence Select 2 7
7bit Sequence Select 3 8
8bit Cycle Count Up 9

9bit Cycle Count Clear 10
10bit Self Check Disable 11
11bit Unused 12
12bit INPORT 1 13
13bit INPORT 2 14
14bit INPORT 3 15
15bit INPORT 4 16

CH. No. Bit Signal

BYPASS SP#11

0bit

BYPASS SP#12

1bit

BYPASS SP#13

2bit

BYPASS SP#14

3bit

BYPASS SP#15

4bit

BYPASS SP#16

5bit

BYPASS SP#17

Input CH.

No.03

6bit

7bit

8bit

9bit

10bit
11bit
12bit
13bit
14bit
15bit

BYPASS SP#18
BYPASS SP#19
BYPASS SP#20
BYPASS SP#21
BYPASS SP#22
BYPASS SP#23
BYPASS SP#24
BYPASS SP#25
BYPASS SP#26

The Channel Number at the Master Unit output side differs according to node address settings.
Please check before operating the unit.

Note: For signal definitions see Section 4.7.2

FEC Multi-2

Bit

FEC Multi-2

Bit
33

34
35
36
37
38
39
40
41
42
43
44
45
46
47
48

Chapter 5: Control Interfaces

CH. No. Bit Signal

BYPASS SP#1

0bit

BYPASS SP#2

1bit

BYPASS SP#3

2bit

BYPASS SP#4

3bit

BYPASS SP#5

4bit

BYPASS SP#6

5bit

BYPASS SP#7

Input CH.

No.02

CH. No. Bit Signal

Input CH.

No.04

6bit

BYPASS SP#8

7bit

BYPASS SP#9

8bit

BYPASS SP#10

9bit

10bit Unused 27

11bit Unused 28
12bit Unused 29
13bit Unused 30
14bit Unused 31
15bit Unused 32

0bit
1bit
2bit
3bit
4bit

BYPASS SP#27
BYPASS SP#28
BYPASS SP#29
BYPASS SP#30
BYPASS SP#31

5bit 54
6bit 55
7bit 56
8bit 57

9bit 58
10bit 59
11bit 60
12bit 61
13bit 62
14bit 63
15bit 64

FEC Multi-2

Bit
17
18

19
20
21
22
23
24
25
26

FEC Multi-2

Bit
49

50
51
52
53

PAGE 5 - 21

Chapter 5: Control Interfaces

FEC Multi

-2

Bank Bit

Sp

indle No.1 Accept

Spindle No.1 Reject

Spindle No.1 ABN.

Spindle No.1 BYP

Sp

indle No.2 Accept

Spindle No.2 Reject

Spindle No.2 ABN

Spindle No.2 BYP

Spindle No.3 Accep

t

Spindle No.3 Reject

Spindle No.3 A

BN

Spindle No.3 BYP

Sp

indle No.4 Accept

Spindle No.4 Reject

Spindle No.4 ABN.

Spindle No.4 BYP

Sp

indle No.5 Accept

Spindle No.

5 Reject

Spindle No.

5 ABN.

Spindle No.

5 BYP

Sp

indle No.6 Accept

Spindle No.

6 Reject

Spindle No.

6 ABN

Spindle No.

6 BYP

Spindle No.

7 Accep

t

Spindle No.

7 Reject

Spi

ndle No.

7 ABN

Spindle No.

7 BYP

Sp

indle No.8 Accept

Spindle No.

8 Reject

Spindle No.

8 ABN.

Spindle No.

8 BYP

Sp

indle No.9 Accept

Spindle No.

9 Reject

Spindle No

.9

ABN.

Spindle No.

9 BYP

AFC1500 Multi-2 Unit Hardware Manual (Rev2.1)

5.5.4 Ouput Signals (CH1 ~ CH16)

The Multi-2 Unit is capable of providing over 570 Output signals to indicate the status of the Multi-2
Unit and of all the AFC1500 SAN Controllers connected to it (up to 31 controllers).

CH. No. Bit Signal

0bit Total Reject 1 1
1bit Total Accept 1 2
2bit Abnormal 1 3
3bit Ready 1 4
4bit Busy 1 5

Output CH.

No.01

Output CH.

No.02

Output CH.

No.03

：

CH. No. Bit Signal

Output CH.

No.16

5bit End 1 6
6bit Sequence Output 0 1 7
7bit Sequence Output 1 1 8
8bit Sequence Output 2 1 9

9bit Sequence Output 3 1 10
10bit Spindle in Bypass 1 11
11bit Current Warning 1 12
12bit

13bit
14bit
15bit

0bit

1bit

2bit

3bit

4bit

5bit

6bit

7bit

8bit

9bit
10bit
11bit
12bit
13bit
14bit
15bit

0bit

1bit

2bit

3bit

4bit

5bit

6bit

7bit

8bit

9bit
10bit
11bit
12bit
13bit
14bit
15bit

0bit 8 1

…

15bit 8 32

1 13
1 14
1 15
1 16
1 17
1 18
1 19
1 20
1 21
1 22
1 23
1 24
1 25
1 26
1 27
1 28
1 29
1 30
1 31
1 32
2 1
2 2
2 3
2 4
2 5
2 6
2 7
2 8
2 9
2 10
2 11
2 12
2 13
2 14
2 15
2 16

See Section 4.7.3 for available

output signals.

These Output signals are user

configurable using the AFC User

Console Software and may be

programmed on any designated

bit.

The Output signal mapping

shown is only an EXAMPLE.

The signals may be programmed

for placement in ANY bit

position.

The CH. No. at the Master input side differs according to node address settings.
Please check before operating the unit.

PAGE 5 - 22

Item

Description

2

1

4

5

6

3

AFC1500 Multi-2 Unit Hardware Manual (Rev2.1)

Chapter 5: Control Interfaces

5.6 Profibus® Interface

The Profibus-DP communication interface allows slave connection to an industrial Profibus 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 its minimum baud rate is 9.6K baud.
Node addressing is selectable using the address selection switches. 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 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 interface go to the HMS website.
(www.hms.se)
Further Profibus information can be found on the Profibus website at www.profibus.com.

- Represents switch position

1 Application Connector
2 Profibus Connector
3 Terminator Switch
4 Address Switches
5 Status LEDs (4)

Red - (flashing @ 2Hz) - ASIC and FLASH ROM check fault.
Green (flashing @ 2Hz) - module not initialized.

6 Watchdog LED

Green (flashing @ 1Hz) - module initialized and running OK.
Red (flashing @ 1Hz) - RAM check fault.
Red (flashing @ 4Hz) - DPRAM check fault.

PAGE 5 - 23

Chapter 5: Control Interfaces

AFC1500 Multi-2 Unit Hardware Manual (Rev2.1)

Profibus Specifications

Speed 9.6K - 12M baud - auto selected
Nodes 126 Note: Node 126 is reserved for commissioning purposes only
Distance 200m max. at 1.5Mbit/s extendable with repeaters.
Cable Shielded Copper Twisted Pair or fiber optic
Communications Type Master/Slave - EIA RS485
Protocol Version Ver. 1.10
Maximum Cyclic I/O Size 244bytes In, 244 bytes out max. 416 total bytes max.
Data transmission The module only supports cyclic I/O data transmission.

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 setup, input size and output size is set as “byte” 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.)

GSD File

Each device on a Profibus network is associated with a 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.fec­usa.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)

PAGE 5 - 24

5

1

9

6

1

2 3

4

AFC1500 Multi-2 Unit Hardware Manual (Rev2.1)

5.6.1 Component Descriptions

Fieldbus Interface Connection

Pin No. Signal Description

1 N.C.
2 N.C.
3 B- Line Positive RxD/TxD according to RS485 Spec.
4 RTS Request to send
5 GND Bus Isolated GND from RS 485 side
6 +5V Bus Isolated +5V from RS 485 side
7 N.C.
8 A- Line Negative RxD/TxD according to RS485 Spec.

9 N.C.

(9 pin female D-sub) Housing Shield Connected to PE

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.

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 “tens”
digit (10x), and the bottom rotary switch sets the “ones” digit (1x). Example: To set

node 37, place the “tens” digit switch on 3 and the “ones” digit switch on 7.

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

Status LEDs

LED Status Description

1 - Not Used

2

3

4

Fieldbus

Diagnostics

Off Module not on-line
Green Module is on-line and data exchange is possible.
Off Module is not off-line

Red

Off No diagnostics present.

Red flashing at 1
second intervals

Red flashing at 1/2
second intervals

Red flashing at 1/4
second intervals

Chapter 5: Control Interfaces

Module is off-line and data exchange is not
possible.

Error in configuration: IN and/or OUT length set
during initialization of the module is not equal to
the length set during configuration of the
network.

Error in user parameter data: The
length/contents of the User Parameter data set
during initialization of the module is not equal to
the length/contents set during configuration of
the network.
Error in initialization of the PROFIBUS
communication ASIC.

PAGE 5 - 25

Chapter 5: Control Interfaces

AFC1500 Multi-2 Unit Hardware Manual (Rev2.1)

5.6.2 User Console Software Settings

The Anybus board is set up by sending a Fieldbus Configuration File (*.fcf) containing initialization
messages from the Multi-2 Unit to the board during power up. This string of data initializes different
characteristics required for the board to communicate over the Profibus network. In this string are
messages which set the length of I/O data as well as other messages. Since the board is only

initialized during power-up, the Multi-2 Unit MUST have the power cycled OFF/ON after the
“fcf” file is downloaded.

To download the fcf file, select “Field Bus Setup” from the “Multi” pull down menu. Select the
appropriate “Bus Type” and click “Browse” to locate the correct fcf file. After the file has been
selected, click “download” to send the file data to the Anybus board.

If no file exists (or if the settings need to be changed), after the Bus Type has been selected click on
the Setup Tab.

Select the desired settings from the pull downs. When finished, go back to the General Tab and
click “download” to send the file data to the Anybus board.

PAGE 5 - 26

AFC1500 Multi-2 Unit Hardware Manual (Rev2.1)

5.6.3 Input Signals (Word 01 ~ Word 16)

Inputs are assigned in the order as shown in the table below and cannot be changed. Bits
designated as “Unused” have no input assigned to them.

NOTE: If Profibus TOOLSNET version is used – Input/Output Signal layout is different than
shown. See 5.12 for TOOLSNET I/O Layout

CH. No. Bit Signal

0bit Emergency Stop 1
1bit Reset 2
2bit Reverse 3
3bit Start 4
4bit Sequence Select 0 5
5bit Sequence Select 1 6

Input Word

No.01

6bit Sequence Select 2 7
7bit Sequence Select 3 8
8bit Cycle Count Up 9

9bit Cycle Count Clear 10
10bit Self Check Disable 11
11bit Unused 12
12bit INPORT 1 13
13bit INPORT 2 14
14bit INPORT 3 15
15bit INPORT 4 16

CH. No. Bit Signal

BYPASS SP#11

0bit

BYPASS SP#12

1bit

BYPASS SP#13

2bit

BYPASS SP#14

3bit

BYPASS SP#15

4bit

BYPASS SP#16

5bit

BYPASS SP#17

Input Word

No.03

6bit

7bit

8bit

9bit

10bit
11bit
12bit
13bit
14bit
15bit

BYPASS SP#18
BYPASS SP#19
BYPASS SP#20
BYPASS SP#21
BYPASS SP#22
BYPASS SP#23
BYPASS SP#24
BYPASS SP#25
BYPASS SP#26

Note: For signal definitions see Section 4.7.2

FEC Multi-2

Bit

FEC Multi-2

Bit
33

34
35
36
37
38
39
40
41
42
43
44
45
46
47
48

Chapter 5: Control Interfaces

CH. No. Bit Signal

BYPASS SP#1

0bit

BYPASS SP#2

1bit

BYPASS SP#3

2bit

BYPASS SP#4

3bit

BYPASS SP#5

4bit

BYPASS SP#6

5bit

BYPASS SP#7

Input Word

No.02

CH. No. Bit Signal

Input Word

No.04

6bit

BYPASS SP#8

7bit

BYPASS SP#9

8bit

BYPASS SP#10

9bit

10bit Unused 27

11bit Unused 28
12bit Unused 29
13bit Unused 30
14bit Unused 31
15bit Unused 32

0bit
1bit
2bit
3bit
4bit

BYPASS SP#27
BYPASS SP#28
BYPASS SP#29
BYPASS SP#30
BYPASS SP#31

5bit 54
6bit 55
7bit 56
8bit 57

9bit 58
10bit 59
11bit 60
12bit 61
13bit 62
14bit 63
15bit 64

FEC Multi-2

Bit
17
18

19
20
21
22
23
24
25
26

FEC Multi-2

Bit
49

50
51
52
53

PAGE 5 - 27

Chapter 5: Control Interfaces

FEC Multi

-2

Bank Bit

Sp

indle No.1 Accept

Spindle No.1 Re

ject

Spindle No.1 ABN.

Spindle No.1 BYP

Sp

indle No.2 Accept

Spindle No.2 Reject

Spindle No.2 ABN

Spindle No.2 BYP

Spindle No.3 Accep

t

S

pindle No.3 Reject

Spindle No.3 ABN

Spindle No.3 BYP

Sp

indle No.4 Accept

Spindle No.4 Reject

Spindle No.4 ABN.

Spindle No.4 BYP

Sp

indle No.5 Accept

Spindl

e No.5

Reject

Spindle No.

5 ABN.

Spindle No.

5 BYP

Sp

indle No.6 Accept

Spindle No.

6 Reject

Spindle No.

6 ABN

Spindle No.

6 BYP

Spindle No.

7 Accep

t

Spindle No.

7 Reject

Spindle No.

7 ABN

Spindle No.

7 BYP

Sp

indle No.8 Accept

Spindle No.

8 Reject

Spindle No.

8 ABN.

Spindle No.

8 BYP

Sp

indle No.9 Accept

Spindle No.

9 Reject

Spindle No.

9 ABN.

Spindle No.

9 BYP

shown is only an EXAMPLE.

AFC1500 Multi-2 Unit Hardware Manual (Rev2.1)

5.6.4 Ouput Signals (Word 01 ~ Word 16)

The Multi-2 Unit is capable of providing over 570 Output signals to indicate the status of the Multi-2
Unit and of all the AFC1500 SAN Controllers connected to it (up to 31 controllers).
See Section 4.7.3 for available output signals.

Word No. Bit Signal

0bit Total Reject 1 1
1bit Total Accept 1 2
2bit Abnormal 1 3
3bit Ready 1 4
4bit Busy 1 5

Output

Word

No.01

Output

Word

No.02

Output

Word

No.03

：

CH. No. Bit Signal

Output CH.

No.16

5bit End 1 6
6bit Sequence Output 0 1 7
7bit Sequence Output 1 1 8
8bit Sequence Output 2 1 9

9bit Sequence Output 3 1 10
10bit Spindle in Bypass 1 11
11bit Current Warning 1 12
12bit

13bit
14bit
15bit

0bit

1bit

2bit

3bit

4bit

5bit

6bit

7bit

8bit

9bit
10bit
11bit
12bit
13bit
14bit
15bit

0bit

1bit

2bit

3bit

4bit

5bit

6bit

7bit

8bit

9bit
10bit
11bit
12bit
13bit
14bit
15bit

0bit 8 1

…

15bit 8 32

1 13
1 14
1 15
1 16
1 17
1 18
1 19
1 20
1 21
1 22
1 23
1 24
1 25
1 26
1 27
1 28
1 29
1 30
1 31
1 32
2 1
2 2
2 3
2 4
2 5
2 6
2 7
2 8
2 9
2 10
2 11
2 12
2 13
2 14
2 15
2 16

These Output signals are user

configurable using the AFC User

Console Software and may be

programmed on any designated

bit.

The Output signal mapping

The signals may be programmed

for placement in ANY bit

position.

PAGE 5 - 28

Item

Description

2

1

3

4

5

6

AFC1500 Multi-2 Unit Hardware Manual (Rev2.1)

Chapter 5: Control Interfaces

5.7 Modbus Plus® Interface

Modbus Plus is a local area network system designed for industrial control and monitoring applications
developed by Modicon Inc. The network enables programmable controllers, host computers and other
devices to communicate throughout the plant. Modbus Plus is normally used in industrial automation to
transfer fast data (up to 1Mbit/sec.) for motor controllers, MMI, I/O units and other industrial equipment.
This interface board has up to 16 words of assigned input data and 16 words of assigned output data
(256 inputs / 256 outputs). 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 locations are programmed
using the AFC User Console Software.

FEC integrates the Modbus Plus board manufactured by HMS Fieldbus Systems AB into the Multi-2
Unit’s modular I/O board. For further technical information on the Modbus Plus interface go to the HMS
website. (www.hms.se)

Daughter board

- Represents switch position

1 Application Connector
2 Modbus Plus Connector
3 Node ID Switch
4 Source ID Switch
5 Status LEDs (4)

Red - (flashing @ 2Hz) - ASIC and FLASH ROM check fault.
Green (flashing @ 2Hz) - module not initialized.

6 Watchdog LED

Green (flashing @ 1Hz) - module initialized and running OK.
Red (flashing @ 1Hz) - RAM check fault.
Red (flashing @ 4Hz) - DPRAM check fault.

PAGE 5 - 29

Chapter 5: Control Interfaces

AFC1500 Multi-2 Unit Hardware Manual (Rev2.1)

Modbus Plus Specifications

Baud Rate 1M bits/sec.
Max. Nodes 32 (with repeaters - 64)
Max. Distance 2000m (with repeaters)
Max. Bus Cable Length 500m
Cable RS-485 twisted pair (1-pair + Shield)
Communication Type Master/Slave

Interface Specifications

Input data 16 words (256 bits)*
Output data 16 words (256 bits)*
Interface type token bus interface
Operating Voltage +5VDC / 200 ma
Data Width 8 bits

* Actual Input/Output data length is configurable using the AFC Software package.

PAGE 5 - 30

Pin No.

Signal

Description

(9 pin female D

-

sub)

Function

SW-

1

(MSB)

SW-2 SW-3 SW-4 SW-5 SW-6

(LSB)

Address

1 ON ON ON ON ON ON

Addr

ess 2 ON ON ON ON ON OFF

Address

3 ON ON ON ON OFF ON

Address

4 ON ON ON ON OFF OFF

… … … … … … …

Address 6

2 OFF OFF OFF OFF ON OFF

Address 6

3 OFF OFF OFF OFF OFF ON

Address 6

4 OFF OFF OFF OFF OFF OFF

Function

SW-

1

(MSB)

SW-2 SW-3 SW-4 SW-5 SW-6

(LSB)

Address

1 ON ON ON ON ON ON

Address

2 ON ON ON ON ON OFF

Address

3 ON ON ON ON OFF ON

Address

4 ON ON ON ON OFF OFF

… … … … … … …

Address 6

2 OFF OFF OFF OFF ON OFF

Address 6

3 OFF OFF OFF OFF OFF ON

Address 6

4 OFF OFF OFF OFF OFF OFF

5

1

9

6

AFC1500 Multi-2 Unit Hardware Manual (Rev2.1)

5.7.1 Component Descriptions

Fieldbus Interface Connector

Housing PE Protective Earth Ground
1 Shield Cable Shield
2 MBP Line B Modbus Plus Line B
3 MBP Line A Modbus Plus Line A
4 NC ­ 5 NC ­ 6 NC ­ 7 NC ­ 8 NC -

9 NC -

Node ID & Source ID Switches

(S1) Node ID Settings

Chapter 5: Control Interfaces

(S2) Source ID Settings

S1 and S2 settings must be made before power is on and cannot be changed during
operation.

PAGE 5 - 31

Chapter 5: Control Interfaces

1

2 3

4

AFC1500 Multi-2 Unit Hardware Manual (Rev2.1)

Status LEDs

LED Status Description

1 - Not Used
2

ERROR

3

MBP

Active

4

MBP Init

Red Communication is not OK.

Green flashing
every 160ms; on
80ms; off 80ms

Green flashing at
1 second intervals
Green - 2 flashes,
on 160ms then off
480ms.
Green - 3 flashes,
on 160ms, off
240ms then off

1.6sec.
Green - 4 flashes,

on 160ms, off
240ms then off

1.2sec.

Green Peer interface is initialized.

Node working normal, receiving and passing
token.

Node is in MONITOR_OFFLINE state.

Node is in MAC_IDLE never-getting-token state.

Node is not hearing any other nodes.

Node has detected duplicate node address.

PAGE 5 - 32

AFC1500 Multi-2 Unit Hardware Manual (Rev2.1)

5.7.2 User Console Software Settings

The Anybus board is set up by sending a Fieldbus Configuration File (*.fcf) containing initialization
messages from the Multi-2 Unit to the board during power up. This string of data initializes different
characteristics required for the board to communicate over the Modbus Plus network. In this string
are messages which set the length of I/O data as well as other messages. Since the board is only

initialized during power-up, the Multi-2 Unit MUST have the power cycled OFF/ON after the
“fcf” file is downloaded.

To download the fcf file, select “Field Bus Setup” from the “Multi” pull down menu. Select the
appropriate “Bus Type” and click “Browse” to locate the correct fcf file. After the file has been
selected, click “download” to send the file data to the Anybus board.

If no file exists (or if the settings need to be changed), after the Bus Type has been selected click on
the Setup Tab.

Select the desired settings from the pull downs. When finished, go back to the General Tab and
click “download” to send the file data to the Anybus board.

Chapter 5: Control Interfaces

PAGE 5 - 33

Chapter 5: Control Interfaces

AFC1500 Multi-2 Unit Hardware Manual (Rev2.1)

5.7.3 Input Signals (Word 01 ~ Word 16)

Inputs are assigned in the order as shown in the table below and cannot be changed. Bits
designated as “Unused” have no input assigned to them.

Since Modbus Plus sends I/O signals 8 bits at a time, and trying to use the data as a word, all
bits and bytes are transferred backwards.

Word No. Bit Signal

0bit Sequence Select 3 8
1bit Sequence Select 2 7
2bit Sequence Select 1 6
3bit Sequence Select 0 5
4bit Start 4
5bit Reverse 3

Input Word

No.01

6bit Reset 2
7bit Emergency Stop 1
8bit INPORT 4 16
9bit INPORT 3 15

10bit INPORT 2 14

11bit INPORT 1 13
12bit Unused 12
13bit Self Check Disable 11
14bit Cycle Count Clear 10
15bit Cycle Count Up 9

Word No. Bit Signal

BYPASS SP#18

0bit

BYPASS SP#17

1bit

BYPASS SP#16

2bit

BYPASS SP#15

3bit

BYPASS SP#14

4bit

BYPASS SP#13

5bit

BYPASS SP#12

Input Word

No.03

6bit
7bit
8bit

9bit
10bit
11bit
12bit
13bit
14bit
15bit

BYPASS SP#11
BYPASS SP#26
BYPASS SP#25
BYPASS SP#24
BYPASS SP#23
BYPASS SP#22
BYPASS SP#21
BYPASS SP#20
BYPASS SP#19

Note: For signal definitions see Section 4.7.2

FEC Multi-2

Bank Bit

FEC Multi-2

Bank Bit

40
39
38
37
36
35
34
33
48
47
46
45
44
43
42
41

Word No. Bit Signal

BYPASS SP#8

0bit

BYPASS SP#7

1bit

BYPASS SP#6

2bit

BYPASS SP#5

3bit

BYPASS SP#4

4bit

BYPASS SP#3

5bit

BYPASS SP#2

Input Word

No.02

6bit

BYPASS SP#1

7bit
8bit Unused 32

9bit Unused 31
10bit Unused 30
11bit Unused 29
12bit Unused 28
13bit Unused 27
14bit
15bit

BYPASS SP#10
BYPASS SP#9

Word No. Bit Signal

0bit
1bit
2bit

BYPASS SP#31

3bit

BYPASS SP#30

4bit

BYPASS SP#29

5bit

BYPASS SP#28

Input Word

No.04

6bit

BYPASS SP#27

7bit
8bit 64
9bit 63

10bit 62

11bit 61
12bit 60
13bit 59
14bit 58
15bit 57

FEC Multi-2

Bank Bit

24
23
22
21
20
19
18
17

26
25

FEC Multi-2

Bank Bit

56
55
54
53
52
51
50
49

PAGE 5 - 34

FEC Multi-2

Bank Bit

Spindle No.1 BYP

Spi

ndle No.1 ABN.

Spindle No.1 Reject

Sp

indle No.1 Accept

Spindle No.

3 BYP

Spindle No.

3 ABN.

Spindle No.

3 Reject

Sp

indle No.3 Accept

Spindle No.

2 BYP

Spindle No.

2 ABN.

Spindle No.

2 Reject

Sp

indle No.2 Accept

Spindle No.

5 BYP

Spindle No.

5 ABN.

Spindle No.

5 Reject

Sp

indle No.5 Accept

Spindle No.

4 BYP

Spindle No.

4 ABN.

Spindle No.

4 Reject

Sp

indle No.4 Accept

Spindle No.

7 BYP

Spindle No.

7 ABN.

Spindle No.

7 Reject

Sp

indle No.7 Accept

Spindle No.

6 BYP

Spindle No.

6 ABN.

Spindle No.

6 Reject

Sp

indle No.6 Ac

cept

Spindle No.

9 BYP

Spindle No.

9 ABN.

Spindle No.

9 Reject

Sp

indle No.9 Accept

Spindle No.

8 BYP

Spindle No.

8 ABN.

Spindle No.

8 Reject

Sp

indle No.8 Accep

t

shown is only an EXAMPLE.

AFC1500 Multi-2 Unit Hardware Manual (Rev2.1)

5.7.4 Ouput Signals (Word 01 ~ Word 16)

The Multi-2 Unit is capable of providing over 570 Output signals to indicate the status of the Multi-2
Unit and of all the AFC1500 SAN Controllers connected to it (up to 31 controllers).
See Section 4.7.3 for available output signals.

Since Modbus Plus sends I/O signals 8 bits at a time, and trying to use the data as a word, all
bits and bytes are transferred backwards.

Word No. Bit Signal

0bit Sequence Output 1 1 8
1bit Sequence Output 0 1 7
2bit End 1 6
3bit Busy 1 5
4bit Ready 1 4

Output

Word

No.01

Output

Word

No.02

Output

Word

No.03

：

CH. No. Bit Signal

Output CH.

No.16

5bit Abnormal 1 3
6bit Total Accept 1 2
7bit Total Reject 1 1
8bit

9bit
10bit
11bit
12bit Current Warning 1 12

13bit Spindle in Bypass 1 11
14bit Sequence Output 3 1 10
15bit Sequence Output 2 1 9

0bit

1bit

2bit

3bit

4bit

5bit

6bit

7bit

8bit

9bit
10bit
11bit
12bit
13bit
14bit
15bit

0bit

1bit

2bit

3bit

4bit

5bit

6bit

7bit

8bit

9bit
10bit
11bit
12bit
13bit
14bit
15bit

0bit 8 1

…

15bit 8 32

1 16
1 15
1 14
1 13

1 24
1 23
1 22
1 21
1 20
1 19
1 18
1 17
1 32
1 31
1 30
1 29
1 28
1 27
1 26
1 25
2 8
2 7
2 6
2 5
2 4
2 3
2 2
2 1
2 16
2 15
2 14
2 13
2 12
2 11
2 10
2 9

Chapter 5: Control Interfaces

These Output signals are user

configurable using the AFC User

Console Software and may be

programmed on any designated

bit.

The Output signal mapping

The signals may be programmed

for placement in ANY bit

position.

PAGE 5 - 35

Chapter 5: Control Interfaces

Item

Description

3

5

1

4

2

AFC1500 Multi-2 Unit Hardware Manual (Rev2.1)

5.8 CC-Link® Interface (Version 1)

The Mitsubishi CC-Link communication interface allows slave connection to an industrial Mitsubishi CC­Link 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. Maximum I/O data is 128 inputs & 128 outputs
(actual usable I/O is 112).

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.

- Represents switch position

OCCUPIED STATION
SETTING

1 CC-Link Connector
2 Station Number Setting Switch
3 Baud Rate Setting Switch
4 Occupied Station Setting Switch
5 Status LEDs (4)

PAGE 5 - 36

AFC1500 Multi-2 Unit Hardware Manual (Rev2.1)

CC-Link Specifications

Speed 156K - 10M baud - selectable
Stations 64 Max.
Distance 1200m max. at 156K baud / 50m max. at 10Mbit/s
Cable Shielded Copper Twisted Pair

Mitsubishi BA1SJ61-(m) m=Meters

Belden 8102 or equivalent
Communications Type Master/Slave - EIA RS485
Transmission Format HDLC Standard
Maximum Cyclic I/O Size 128 inputs, 128 outputs max. Size set in groups of 32 I/O

(4 Occupied Stations)
I/O Configuration* 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)

Configuration

Configuration of the CC-Link system is done in the PLC Logic. It is essential that this configuration
matches the Dip Switch settings of the FEC CC-Link 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 CC-Link communication &
cannot be used by the user) .

Chapter 5: Control Interfaces

PAGE 5 - 37

Chapter 5: Control Interfaces

8

5

4

2

3

7

6

1

ON

4

2

3

1

See

AFC1500 Multi-2 Unit Hardware Manual (Rev2.1)

5.8.1 Component Descriptions

Fieldbus Interface Connection

Pin 1 DA Communication Line
Pin 2 DB Communication Line
Pin 3 DG Digital Ground
Pin 4 SHIELD Connect cable shield
Pin 5 FG Field Ground

“Termination”

Mating Connector: Allows in-line “series” connection

Manufacturer：Phoenix Contact
Model Name ：TMSTBP 2.5/5-ST-5.08

*Connector is attached.

Wiring of the CC-Link network should be performed by using the cable listed 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.

Termination

Termination of the CC-Link 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)

Station Number Setting (SW1)

Station Number switch 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).

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

ON OFF OFF OFF OFF OFF OFF OFF 1

OFF ON OFF OFF OFF OFF OFF OFF 2

. . . . . . . . .

OFF OFF OFF OFF ON OFF OFF OFF 10

. . . . . . . . .

ON ON ON OFF OFF OFF ON OFF 47

. . . . . . . . .

OFF OFF ON OFF OFF ON ON OFF 64

Station #

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

Baud Rate Setting (SW2)

Baud rate SW-1 SW-2 SW-3 SW-4

156K OFF OFF OFF OFF
625K ON OFF OFF OFF

2.5M OFF ON OFF OFF
5M ON ON OFF OFF
10M OFF OFF ON OFF

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.

PAGE 5 - 38

ON

4

2

3

1

AFC1500 Multi-2 Unit Hardware Manual (Rev2.1)

Number of Occupied Stations (SW3)

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.

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

1 (32 In/32 Out) ON ON ON OFF
2 (64 In/64 Out) ON OFF ON OFF
3 (96 In/96 Out) OFF ON ON OFF
4 (128 In/128 Out) OFF OFF ON OFF

Status LEDs

RUN OFF Watchdog Timer error

ON Module is Normal - Running

ERR OFF Normal

ON - Steady Communication error at all

ON - Flashing Communication error at Station
SD Send Data Module Sending Data
RD Read Data Module Reading Data

Chapter 5: Control Interfaces

Stations

PAGE 5 - 39

Chapter 5: Control Interfaces

AFC1500 Multi-2 Unit Hardware Manual (Rev2.1)

5.8.2 Input Signals

Inputs are assigned in the order as shown in the table below and cannot be changed. Bits
designated as “Unused” have no input assigned to them.

Address Signal

RY(n+0)0 Emergency Stop 1
RY(n+0)1 Reset 2
RY(n+0)2 Reverse 3
RY(n+0)3 Start 4
RY(n+0)4 Sequence Select 0 5
RY(n+0)5 Sequence Select 1 6
RY(n+0)6 Sequence Select 2 7
RY(n+0)7 Sequence Select 3 8
RY(n+0)8 Cycle Count Up 9
RY(n+0)9 Cycle Count Clear 10
RY(n+0)A Self Check Disable 11
RY(n+0)B Unused 12
RY(n+0)C INPORT 1 13
RY(n+0)D INPORT 2 14
RY(n+0)E INPORT 3 15
RY(n+0)F INPORT 4 16

Address Signal

RY(n+2)0
RY(n+2)1
RY(n+2)2
RY(n+2)3
RY(n+2)4
RY(n+2)5
RY(n+2)6
RY(n+2)7
RY(n+2)8

RY(n+2)9
RY(n+2)A
RY(n+2)B
RY(n+2)C
RY(n+2)D
RY(n+2)E
RY(n+2)F

BYPASS SP#11
BYPASS SP#12
BYPASS SP#13
BYPASS SP#14
BYPASS SP#15
BYPASS SP#16
BYPASS SP#17
BYPASS SP#18
BYPASS SP#19
BYPASS SP#20
BYPASS SP#21
BYPASS SP#22
BYPASS SP#23
BYPASS SP#24
BYPASS SP#25
BYPASS SP#26

Note: For signal definitions see Section 4.7.2

FEC Multi-2
Bank Bit

FEC Multi-2

Bank Bit

33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48

Address Signal

RY(n+1)0
RY(n+1)1
RY(n+1)2
RY(n+1)3
RY(n+1)4
RY(n+1)5
RY(n+1)6
RY(n+1)7
RY(n+1)8
RY(n+1)9

BYPASS SP#1
BYPASS SP#2
BYPASS SP#3
BYPASS SP#4
BYPASS SP#5
BYPASS SP#6
BYPASS SP#7
BYPASS SP#8
BYPASS SP#9
BYPASS SP#10

RY(n+1)A Unused 27
RY(n+1)B Unused 28
RY(n+1)C Unused 29
RY(n+1)D Unused 30
RY(n+1)E Unused 31

RY(n+1)F Unused 32

Address Signal

RY(n+3)0
RY(n+3)1
RY(n+3)2
RY(n+3)3
RY(n+3)4

BYPASS SP#27
BYPASS SP#28
BYPASS SP#29
BYPASS SP#30
BYPASS SP#31

RY(n+3)5 Unused 54
RY(n+3)6 Unused 55
RY(n+3)7 Unused 56
RY(n+3)8 Unused 57
RY(n+3)9 Unused 58
RY(n+3)A Unused 59
RY(n+3)B Unused 60
RY(n+3)C Unused 61
RY(n+3)D Unused 62
RY(n+3)E Unused 63
RY(n+3)F Unused 64

FEC Multi-2

Bank Bit

17
18
19
20
21
22
23
24
25
26

FEC Multi-2

Bank Bit

49
50
51
52
53

PAGE 5 - 40

FEC Multi

-2

Bank Bit

Sp

indle No.1 Accept

Spindle No.1 Reject

Spindle No.1 ABN.

Spindle No.1 BYP

Sp

indle No.2 Accept

Spindle No.2 Reject

Spindle No.2 ABN

Spindle

No.2 BYP

Spindle No.3 Accep

t

Spindle No.3 Reject

Spindle No.3 ABN

Spindle No.3 BYP

Sp

indle No.4 Accept

Spindle No.4 Reject

Spindle No.4 ABN.

Spindle No.4 BYP

Sp

indle No.5 Accept

Spindle No.

5 Reject

Spindle No.

5 ABN.

Spindle No.

5 BYP

Sp

indle No.6 Accept

Spindle No.

6 Reject

Spindle No.

6 ABN

Spindle No.

6 BYP

Spindle No.

7 Accep

t

Spindle No.

7 Reject

Spindle No.

7 ABN

Spindle No.

7 BYP

Sp

indle No.8 Accept

Spindle No.

8 Reject

Spin

dle No.

8 ABN.

Spindle No.

8 BYP

Sp

indle No.9 Accept

Spindle No.

9 Reject

Spindle No.

9 ABN.

Spindle No.

9 BYP

only an EXAMPLE.

AFC1500 Multi-2 Unit Hardware Manual (Rev2.1)

5.8.4 Output Signals

The Multi-2 Unit is capable of providing over 570 Output signals to indicate the status of the Multi-2
Unit and of all the AFC1500 SAN Controllers connected to it (up to 31 controllers).
See Section 4.7.3 for available output signals.

Address Signal

RX(n+0)0 Total Reject 1 1
RX(n+0)1 Total Accept 1 2
RX(n+0)2 Abnormal 1 3
RX(n+0)3 Ready 1 4
RX(n+0)4 Busy 1 5
RX(n+0)5 End 1 6
RX(n+0)6 Sequence Output 0 1 7
RX(n+0)7 Sequence Output 1 1 8
RX(n+0)8 Sequence Output 2 1 9
RX(n+0)9 Sequence Output 3 1 10
RX(n+0)A Spindle in Bypass 1 11
RX(n+0)B Current Warning 1 12
RX(n+0)C

RX(n+0)D
RX(n+0)E
RX(n+0)F
RX(n+1)0
RX(n+1)1
RX(n+1)2
RX(n+1)3
RX(n+1)4
RX(n+1)5
RX(n+1)6
RX(n+1)7
RX(n+1)8
RX(n+1)9
RX(n+1)A
RX(n+1)B
RX(n+1)C
RX(n+1)D
RX(n+1)E
RX(n+1)F
RX(n+2)0
RX(n+2)1
RX(n+2)2
RX(n+2)3
RX(n+2)4
RX(n+2)5
RX(n+2)6
RX(n+2)7
RX(n+2)8
RX(n+2)9
RX(n+2)A
RX(n+2)B
RX(n+2)C
RX(n+2)D
RX(n+2)E
RX(n+2)F

：

Address Signal Description

For

CC-Link

Comm.

Only

RX(n+x)0 Unusable

… …

RX(n+x)F Unusable

1 13
1 14
1 15
1 16
1 17
1 18
1 19
1 20
1 21
1 22
1 23
1 24
1 25
1 26
1 27
1 28
1 29
1 30
1 31
1 32
2 1
2 2
2 3
2 4
2 5
2 6
2 7
2 8
2 9
2 10
2 11
2 12
2 13
2 14
2 15
2 16

Communication only, regardless of how many

Chapter 5: Control Interfaces

These Output signals are user

configurable using the AFC User

Console Software and may be

programmed on any designated

bit.

The Output signal mapping

shown is

The signals may be programmed

for placement in ANY bit

position.

The last 16 bits are reserved for CC-Link

stations are set.

PAGE 5 - 41

Chapter 5: Control Interfaces

Item

Description

3

2

5

1

6

4

AFC1500 Multi-2 Unit Hardware Manual (Rev2.1)

5.9 CC-Link® Interface (Version 2)

FEC integrates the CC-Link board (Version 2 setting) manufactured by HMS Fieldbus Systems AB into
the Multi-2 Unit’s modular I/O board when CC-link must send both I/O and Message Data. For further
technical information on the CC-Link (Version 2) interface go to the HMS website. (www.hms.se)

NOTE: The FEC CC-Link (V2) 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.

- Represents switch position

Daughter board

1 Application Connector
2 CC-Link Connector
3 Baud Rate Setting Switch
4 Station Number Setting Switches (2)
5 Status LEDs (4)

Red - (flashing @ 2Hz) - ASIC and FLASH ROM check fault.
Green (flashing @ 2Hz) - module not initialized.

6 Watchdog LED

Green (flashing @ 1Hz) - module initialized and running OK.
Red (flashing @ 1Hz) - RAM check fault.
Red (flashing @ 4Hz) - DPRAM check fault.

PAGE 5 - 42

AFC1500 Multi-2 Unit Hardware Manual (Rev2.1)

CC-Link Specifications

Speed 156K - 10M baud - selectable
Stations 64 Max.
Distance 1200m max. at 156K baud / 50m max. at 10Mbit/s
Cable Shielded Copper Twisted Pair

Mitsubishi BA1SJ61-(m) m=Meters

Belden 8102 or equivalent
Communications Type Master/Slave - EIA RS485
Transmission Format HDLC Standard
Maximum Cyclic I/O Size 896 inputs, 896 outputs max. Size set in groups of 256 I/O

(Occupied Stations)
I/O Configuration* 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)

Configuration

Configuration of the CC-Link system is done in the PLC Logic. It is essential that this configuration
matches the Dip Switch settings of the FEC CC-Link slave. FEC is considered a “Remote Device”
in the PLC configuration. The number of “Occupied Stations” set in the PLC must also match the
settings in the AFC User Console set-up. (Note: The last 16 output addresses are used by the
CC-Link communication & cannot be used by the user)

FEC CC-Link (Version 2) 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 CC-Link
System Profile (CSP file). The AFC Software allows configuration of the number of Occupied
Stations and Extended Cyclic Settings in the Multi Unit. Configuration of the CC-Link Master MUST
match the configuration of the FEC CC-Link slave.

CSP File

To simplify network configuration, CC-Link devices may be associated with a CC-Link System
Profile, also known as a CSP-file. This file contains a description of the device and can be used by
some CC-Link system utilities to simplify the configuration process.
The CSP file associated with the FEC device can be downloaded directly from HMS - www.hms.se.

Chapter 5: Control Interfaces

PAGE 5 - 43

Chapter 5: Control Interfaces

See

AFC1500 Multi-2 Unit Hardware Manual (Rev2.1)

5.9.1 Component Descriptions

Fieldbus Interface Connection

Pin 1 DA Communication Line
Pin 2 DB Communication Line
Pin 3 DG Digital Ground
Pin 4 SHIELD Connect cable shield
Pin 5 FG Field Ground

“Termination”

Mating Connector: Allows in-line “series” connection

Manufacturer：Phoenix Contact
Model Name ：TMSTBP 2.5/5-ST-5.08

*Connector is attached.

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.

Termination

Termination of the CC-Link 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)

Baud Rate Switch

This rotary switch is used to specify the baud rate of the module.
This can also be specified in the FB_INIT mailbox command. In this
case, the switch must be set to “9”.

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.

Station Number Switches

These two rotary switches are used to specify the station number of the module
(Two digit decimal). The Upper rotary switch (closest to the Baud Rate Switch) sets
the “tens” digit (10x), and the bottom rotary switch sets the “ones” digit (1x). Valid
settings range from 1 up to 641.

Example: To set station number 24, place the “tens” digit switch on 2 and the
“ones” digit switch on 4.

This can also be specified in the FB_INIT mailbox command. In this case, the
switches must be set to “99”.

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

1) If more than one station is occupied by the module, the highest possible station number is
reduced by the number of occupied stations minus one.

PAGE 5 - 44

1

2 3

4

AFC1500 Multi-2 Unit Hardware Manual (Rev2.1)

Status LEDs

LED Color State Description

1
(RUN)

2
(ERRL)

3
(RDLED)

4
(SDLED)

Green

Red

Green

Green

ON Normal Operation

OFF

ON

OFF

ON Data being received

OFF

ON Data being transmitted

OFF

Network non-participating or timeout status
No power on module
CRC error detection
Illegal station number or illegal baud rate selected

Normal Operation
No power on module

No data reception
No power on module

No data transmission
No power on module

Chapter 5: Control Interfaces

PAGE 5 - 45

Chapter 5: Control Interfaces

AFC1500 Multi-2 Unit Hardware Manual (Rev2.1)

5.9.2 User Console Software Settings

The Anybus board is set up by sending a Fieldbus Configuration File (*.fcf) containing initialization
messages from the Multi-2 Unit to the board during power up. This string of data initializes different
characteristics required for the board to communicate over the CC-Link network. In this string are
messages which set the length of I/O data as well as other messages. Since the board is only
initialized during power-up, the Multi-2 Unit MUST have the power cycled OFF/ON after the “fcf” file
is downloaded.

To download the fcf file, select “Field Bus Setup” from the “Multi” pull down menu. Select the
appropriate “Bus Type” and click “Browse” to locate the correct fcf file. After the file has been
selected, click “download” to send the file data to the Anybus board.

If no file exists (or if the settings need to be changed), after the Bus Type has been selected click on
the Setup Tab.

Select the desired settings from the pull downs. When finished, go back to the General Tab and
click “download” to send the file data to the Anybus board.

The CC-Link (Version 2) interface also has the ability to transfer message data. Refer to the
AFC1500 User Console Manual for message setup information.

PAGE 5 - 46

AFC1500 Multi-2 Unit Hardware Manual (Rev2.1)

5.9.3 Input Signals

Inputs are assigned in the order as shown in the table below and cannot be changed. Bits
designated as “Unused” have no input assigned to them.

Address Signal

RY(n+0)0 Emergency Stop 1
RY(n+0)1 Reset 2
RY(n+0)2 Reverse 3
RY(n+0)3 Start 4
RY(n+0)4 Sequence Select 0 5
RY(n+0)5 Sequence Select 1 6
RY(n+0)6 Sequence Select 2 7
RY(n+0)7 Sequence Select 3 8
RY(n+0)8 Cycle Count Up 9
RY(n+0)9 Cycle Count Clear 10
RY(n+0)A Self Check Disable 11
RY(n+0)B Unused 12
RY(n+0)C INPORT 1 13
RY(n+0)D INPORT 2 14
RY(n+0)E INPORT 3 15
RY(n+0)F INPORT 4 16

Address Signal

RY(n+2)0
RY(n+2)1
RY(n+2)2
RY(n+2)3
RY(n+2)4
RY(n+2)5
RY(n+2)6
RY(n+2)7
RY(n+2)8
RY(n+2)9
RY(n+2)A
RY(n+2)B
RY(n+2)C
RY(n+2)D
RY(n+2)E
RY(n+2)F

BYPASS SP#11
BYPASS SP#12
BYPASS SP#13
BYPASS SP#14
BYPASS SP#15
BYPASS SP#16
BYPASS SP#17
BYPASS SP#18
BYPASS SP#19
BYPASS SP#20
BYPASS SP#21
BYPASS SP#22
BYPASS SP#23
BYPASS SP#24
BYPASS SP#25
BYPASS SP#26

Note: For signal definitions see Section 4.7.2

FEC Multi-2

Bank Bit

FEC Multi-2

Bank Bit

33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48

Chapter 5: Control Interfaces

Address Signal

RY(n+1)0
RY(n+1)1
RY(n+1)2
RY(n+1)3
RY(n+1)4
RY(n+1)5
RY(n+1)6
RY(n+1)7
RY(n+1)8
RY(n+1)9

BYPASS SP#1
BYPASS SP#2
BYPASS SP#3
BYPASS SP#4
BYPASS SP#5
BYPASS SP#6
BYPASS SP#7
BYPASS SP#8
BYPASS SP#9
BYPASS SP#10

RY(n+1)A Unused 27
RY(n+1)B Unused 28
RY(n+1)C Unused 29
RY(n+1)D Unused 30
RY(n+1)E Unused 31
RY(n+1)F Unused 32

Address Signal

RY(n+3)0
RY(n+3)1
RY(n+3)2
RY(n+3)3
RY(n+3)4

BYPASS SP#27
BYPASS SP#28
BYPASS SP#29
BYPASS SP#30
BYPASS SP#31

RY(n+3)5 54
RY(n+3)6 55
RY(n+3)7 56
RY(n+3)8 57

RY(n+3)9 58
RY(n+3)A 59
RY(n+3)B 60
RY(n+3)C 61
RY(n+3)D 62
RY(n+3)E 63
RY(n+3)F 64

FEC Multi-2

Bank Bit

17
18
19
20
21
22
23
24
25
26

FEC Multi-2

Bank Bit

49
50
51
52
53

PAGE 5 - 47

Chapter 5: Control Interfaces

FEC Multi

-2

Bank Bit

Sp

indle No.1 Accept

Spindle No.1 Reject

Spindle No.1 ABN.

Spindle No.1 BYP

Sp

indle No.2 Accept

Spindle No.2 Reject

Spindle No.2 ABN

Spindle No.2 BYP

Spindle No

.3 Accep

t

Spindle No.3 Reject

Spindle No.3 ABN

Spindle No.3 BYP

Sp

indle No.4 Accept

Spindle No.4 Reject

Spindle No.4 ABN.

Spindle No.4 BYP

Sp

indle No.5 Accept

Spindle No.

5 Reject

Spindle No.

5 ABN.

Spindle No.

5 BYP

Sp

indle No.6 Accept

Spindle No.

6 Reject

Spindle No.

6 ABN

Spindle No.

6 BYP

Spindle No.

7 Accep

t

Spindle No.

7 Reject

Spindle No.

7 ABN

Spindle No.

7 BYP

Sp

indle No.8 Accept

Spindle No.

8 Reject

Spindle No.

8 ABN.

Spindl

e No.8

BYP

Sp

indle No.9 Accept

Spindle No.

9 Reject

Spindle No.

9 ABN.

Spindle No.

9 BYP

shown is only an EXAMPLE.

AFC1500 Multi-2 Unit Hardware Manual (Rev2.1)

5.9.4 Ouput Signals

The Multi-2 Unit is capable of providing over 570 Output signals to indicate the status of the Multi-2
Unit and of all the AFC1500 SAN Controllers connected to it (up to 31 controllers).
See Section 4.7.3 for available output signals.

Address Signal

RX(n+0)0 Total Reject 1 1
RX(n+0)1 Total Accept 1 2
RX(n+0)2 Abnormal 1 3
RX(n+0)3 Ready 1 4
RX(n+0)4 Busy 1 5
RX(n+0)5 End 1 6
RX(n+0)6 Sequence Output 0 1 7
RX(n+0)7 Sequence Output 1 1 8
RX(n+0)8 Sequence Output 2 1 9
RX(n+0)9 Sequence Output 3 1 10
RX(n+0)A Spindle in Bypass 1 11
RX(n+0)B Current Warning 1 12
RX(n+0)C

RX(n+0)D
RX(n+0)E
RX(n+0)F
RX(n+1)0
RX(n+1)1
RX(n+1)2
RX(n+1)3
RX(n+1)4
RX(n+1)5
RX(n+1)6
RX(n+1)7
RX(n+1)8
RX(n+1)9
RX(n+1)A
RX(n+1)B
RX(n+1)C
RX(n+1)D
RX(n+1)E
RX(n+1)F
RX(n+2)0
RX(n+2)1
RX(n+2)2
RX(n+2)3
RX(n+2)4
RX(n+2)5
RX(n+2)6
RX(n+2)7
RX(n+2)8
RX(n+2)9
RX(n+2)A
RX(n+2)B
RX(n+2)C
RX(n+2)D
RX(n+2)E
RX(n+2)F

：

Bit Signal Description

For

CC-Link

Comm.

Only

RX(n+x)0 Unusable

… …

RX(n+x)F Unusable

1 13
1 14
1 15
1 16
1 17
1 18
1 19
1 20
1 21
1 22
1 23
1 24
1 25
1 26
1 27
1 28
1 29
1 30
1 31
1 32
2 1
2 2
2 3
2 4
2 5
2 6
2 7
2 8
2 9
2 10
2 11
2 12
2 13
2 14
2 15
2 16

These Output signals are user

configurable using the AFC User

Console Software and may be

programmed on any designated

bit.

The Output signal mapping

The signals may be programmed

for placement in ANY bit

position.

The last 16 bits are reserved for CC-Link

Communication only regardless of how many

stations are set.

PAGE 5 - 48

Item

Description

5

3

2

1

6

4

AFC1500 Multi-2 Unit Hardware Manual (Rev2.1)

Chapter 5: Control Interfaces

5.10 Allen-Bradley Remote I/O Interface

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. 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)

- Represents switch position

1 Application Connector
2 Remote I/O Connector
3 Baud Rate / Station Number Setting Switch
4 Terminator Switch
5 Status LEDs (3)

Red - (flashing @ 2Hz) - ASIC and FLASH ROM check fault.
Green (flashing @ 2Hz) - module not initialized.

6 Watchdog LED

Green (flashing @ 1Hz) - module initialized and running OK.
Red (flashing @ 1Hz) - RAM check fault.
Red (flashing @ 4Hz) - DPRAM check fault.

PAGE 5 - 49

Chapter 5: Control Interfaces

AFC1500 Multi-2 Unit Hardware Manual (Rev2.1)

AB Remote I/O Specifications

Speed 57.6, 115, 230K baud - Selectable
Rack Addresses 0-59
Nodes up to 240 1/4 racks
Rack Configuration supported* 1/4, 1/2 (Default), 3/4, Full
Distance 57.6k - 3048 meter

115K - 1524 meter
230K - 762 meter

Cable 78 ohm Twinax

Belden #9463 or equivalent

Communications Type Master/Slave

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

PAGE 5 - 50

Baud

R

ate SW-1 SW-2

57.6K

OFF

OFF

115K ON OFF

230K OFF ON

Reserved

ON ON

Address 0

OFF

OFF

OFF

OFF

OFF

OFF

Address 1

ON OFF

OFF

OFF

OFF

OFF

Address 2

OFF

ON OFF

OFF

OFF OFF

Address 3

ON ON

OFF

OFF

OFF OFF

… … … … … … …

Address

57 ON OFF OFF ON ON ON

Address

58 OFF ON OFF ON ON ON

Address

59 ON ON OFF ON ON ON

ON

8

5

4

2

3

7

6

1

AFC1500 Multi-2 Unit Hardware Manual (Rev2.1)

5.10.1 Component Descriptions

Fieldbus Interface Connection

Pin No. Color Description
1 Blue COM Line
2 Clear Ground
3 Shield COM Line

Termination

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

Configuration Switches

On an A-B Remote I/O network, each node must be assigned its own unique Rack Address. The
Rack Address is a value between 0 and 59 used to identify each node. The Rack Address and Baud
Rate are set using the DIP switches on the front of the module.

These switches must be set before power is on and cannot be changed during operation.

Baud Rate Settings

Chapter 5: Control Interfaces

Rack Address Settings

Rack

Address

SW-3

(MSB)

SW-4 SW-5 SW-6 SW-7 SW-8

Status LEDs

LED State Description

Error OFF Normal Operation

ON - Red Bus off / Error

Active OFF No Communication

ON - Green Communication Active

Power OFF Power Off

ON - Green Power On

(LSB)

PAGE 5 - 51

Chapter 5: Control Interfaces

AFC1500 Multi-2 Unit Hardware Manual (Rev2.1)

5.10.2 User Console Software Settings

The Anybus board is set up by sending a Fieldbus Configuration File (*.fcf) containing initialization
messages from the Multi-2 Unit to the board during power up. This string of data initializes different
characteristics required for the board to communicate over the Allen-Bradley Remote I/O network. In
this string are messages which set the length of I/O data as well as other messages. Since the
board is only initialized during power-up, the Multi-2 Unit MUST have the power cycled OFF/ON
after the “fcf” file is downloaded.

To download the fcf file, select “Field Bus Setup” from the “Multi” pull down menu. Select the
appropriate “Bus Type” and click “Browse” to locate the correct fcf file. After the file has been
selected, click “download” to send the file data to the Anybus board.

If no file exists, (or if the settings need to be changed) after the Bus Type has been selected click on
the Setup Tab.

Select the desired settings from the pull downs. When finished, go back to the General Tab and
click “download” to send the file data to the Anybus board.

PAGE 5 - 52

AFC1500 Multi-2 Unit Hardware Manual (Rev2.1)

5.10.3 Input Signals (CH1 ~ CH16)

Inputs are assigned in the order as shown in the table below and cannot be changed. Bits
designated as “Not Used” have no input assigned to them.

CH. No. Bit Signal

0bit Emergency Stop 1
1bit Reset 2
2bit Reverse 3
3bit Start 4
4bit Sequence Select 0 5
5bit Sequence Select 1 6

Input CH.

No.01

6bit Sequence Select 2 7
7bit Sequence Select 3 8
8bit Cycle Count Up 9
9bit Cycle Count Clear 10

10bit Self Check Disable 11

11bit Unused 12
12bit INPORT 1 13
13bit INPORT 2 14
14bit INPORT 3 15
15bit INPORT 4 16

CH. No. Bit Signal

BYPASS SP#11

0bit

BYPASS SP#12

1bit

BYPASS SP#13

2bit

BYPASS SP#14

3bit

BYPASS SP#15

4bit

BYPASS SP#16

5bit

BYPASS SP#17

Input CH.

No.03

6bit
7bit
8bit
9bit

10bit

11bit

12bit
13bit
14bit
15bit

BYPASS SP#18
BYPASS SP#19
BYPASS SP#20
BYPASS SP#21
BYPASS SP#22
BYPASS SP#23
BYPASS SP#24
BYPASS SP#25
BYPASS SP#26

The Channel Number at the Master Unit output side differs according to rack address settings.
Please check before operating the unit.

FEC Multi-2

Bank Bit

FEC Multi-2

Bank Bit

33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48

Chapter 5: Control Interfaces

CH. No. Bit Signal

BYPASS SP#1

0bit

BYPASS SP#2

1bit

BYPASS SP#3

2bit

BYPASS SP#4

3bit

BYPASS SP#5

4bit

BYPASS SP#6

5bit

BYPASS SP#7

Input CH.

No.02

CH. No. Bit Signal

Input CH.

No.04

6bit

BYPASS SP#8

7bit

BYPASS SP#9

8bit

BYPASS SP#10

9bit
10bit Unused 27
11bit Unused 28
12bit Unused 29
13bit Unused 30
14bit Unused 31
15bit Unused 32

BYPASS SP#27

0bit

BYPASS SP#28

1bit

BYPASS SP#29

2bit

BYPASS SP#30

3bit

BYPASS SP#31

4bit
5bit 54
6bit 55
7bit 56
8bit 57
9bit 58

10bit 59
11bit 60
12bit 61
13bit 62
14bit 63
15bit 64

FEC Multi-2

Bank Bit

17
18
19
20
21
22
23
24
25
26

FEC Multi-2

Bank Bit

49
50
51
52
53

PAGE 5 - 53

Chapter 5: Control Interfaces

FEC Multi

-2

Bank Bit

Sp

indle No.1 Accept

Spindle No.1 Reject

Spindle No.1 ABN.

Spindle No.1 BYP

Sp

indle No.2 Accept

Spindle No.2 Reject

Spindle No.2 ABN

Spindle No.2 BYP

Spindle No.3 Accep

t

Spindle No.3 Reject

Spindle No.3 ABN

Spindle No.3 BYP

Sp

indle No.4 Accept

Spindle No.4 Reject

Spindle No.4 ABN.

Spindle No.4 BYP

Sp

indle No.5 Accept

Spindle No.

5 Reject

Spindle No.

5 ABN.

Spindle No.

5 BYP

Sp

indle No.6 Accept

Spindle No.

6 Reject

Spindle No.

6 ABN

Spindle No.

6 BYP

Spindle No.

7 Accep

t

Spindle No.

7 Reject

Spindle No.

7 ABN

Spindle No.

7 BYP

Sp

indle No.8 Accept

Spindle No.

8 Reject

Spindle No.

8 ABN.

Spindle No.

8 BYP

Sp

indle No.9 Accept

Spindle No.

9 Reject

Spindle No.

9 ABN.

Spindle No.

9 BYP

shown is only an EXAMPLE.

AFC1500 Multi-2 Unit Hardware Manual (Rev2.1)

5.10.4 Ouput Signals (CH1 ~ CH16)

The Multi-2 Unit is capable of providing over 570 Output signals to indicate the status of the Multi-2
Unit and of all the AFC1500 SAN Controllers connected to it (up to 31 controllers).
See Section 4.7.3 for available output signals.

CH. No. Bit Signal

0bit Total Reject 1 1
1bit Total Accept 1 2
2bit Abnormal 1 3
3bit Ready 1 4
4bit Busy 1 5
5bit End 1 6

Output CH.

No.01

Output CH.

No.02

Output CH.

No.03

：

CH. No. Bit Signal

Output CH.

No.16

6bit Sequence Output 0 1 7
7bit Sequence Output 1 1 8
8bit Sequence Output 2 1 9

9bit Sequence Output 3 1 10
10bit Spindle in Bypass 1 11
11bit Current Warning 1 12
12bit

13bit
14bit
15bit

0bit

1bit

2bit

3bit

4bit

5bit

6bit

7bit

8bit

9bit
10bit
11bit
12bit
13bit
14bit
15bit

0bit

1bit

2bit

3bit

4bit

5bit

6bit

7bit

8bit

9bit
10bit
11bit
12bit
13bit
14bit
15bit

0bit 8 1

…

15bit 8 32

1 13
1 14
1 15
1 16
1 17
1 18
1 19
1 20
1 21
1 22
1 23
1 24
1 25
1 26
1 27
1 28
1 29
1 30
1 31
1 32
2 1
2 2
2 3
2 4
2 5
2 6
2 7
2 8
2 9
2 10
2 11
2 12
2 13
2 14
2 15
2 16

These Output signals are user

configurable using the AFC User

Console Software and may be

programmed on any designated

bit.

The Output signal mapping

The signals may be programmed

for placement in ANY bit

position.

The CH. No. at the Master input side differs according to rack address settings.
Please check before operating the unit.

PAGE 5 - 54

Item

Description

2

1

3

4

5

AFC1500 Multi-2 Unit Hardware Manual (Rev2.1)

Chapter 5: Control Interfaces

5.11 Ethernet-I/P Interface

The Ethernet-I/P communication interface allows slave connection to PLC networks that support
Ethernet communication via TCP/IP.
Maximum I/O data is 256 input bits & 256 output bits. FEC Inputs match the discrete input layout. FEC
Output location is programmed using the AFC User Console Software. Communication speeds of
10/100M baud (auto-selectable) are supported.

FEC integrates the Ethernet-I/P board manufactured by HMS Fieldbus Systems AB into the Multi-2
Unit’s modular I/O board. For further technical information on the Ethernet-I/P interface go to the HMS
website. (www.hms.se)

- Represents switch position

1 Application Connector
2 Ethernet Connector
3 Configuration Switches
4 Status LEDs (4)

Red - (flashing @ 2Hz) - ASIC and FLASH ROM check fault.
Green (flashing @ 2Hz) - module not initialized.

5 Watchdog LED

Green (flashing @ 1Hz) - module initialized and running OK.
Red (flashing @ 1Hz) - RAM check fault.
Red (flashing @ 4Hz) - DPRAM check fault.

PAGE 5 - 55

Chapter 5: Control Interfaces

5.11.1 Component Descriptions

Connections

Signal

DIP Switch

This switch is not used for FEC IP configuratio

OFF

below) “Fieldbus Configuration” feature.

LED

Modul

Network Status

Activity

1

2 3

4

Hardware

Normally left unused; to ensure signal integrity, these pins are tied

t in the module.

Normally left unused; to ensure signal integrity, these pins are tied

together and terminated to PE via a filter circuit in the module.

n and should be set to all

up using the AFC Software (see 5.11.2

Description

ed / Not Online

Controlled by scanner in run state

Not configured or scanner in idle state

A major unrecoverable fault has been

A minor recoverable fault has been

No power to device or no IP address

Online. One or more connections

Data size bigger than configured.

Duplicate IP address. Fatal error.

One or more connections timed out.

Flashes each time a packet is

transmitted or received.

Fieldbus Interface

Pin

Configuration

Status LEDs

1 TD+
2 TD­3 RD+
4 ­5 ­6 RD­7 ­8 -

1 - Link

2 -

AFC1500 Multi-2 Unit

Note

together and terminated to PE via a filter circui

. The IP address is set-

State

Off No Link Established
On Link Established
Off Not Power
Green solid
Green flashing

e Status

Red solid

Red flashing

detected.

detected.

Manual (Rev2.1)

Off

Green solid

3 -

4 -

Green

Green flashing
Red solid
Red flashing
Green / Red Self test in progress

PAGE 5 - 56

has been set.

established.