FEC AFC1500 User Manual

ELECTRIC SERVO NUTRUNNER

AFC1500 MULTI SYSTEM

MULTI-2 UNIT HARDWARE MANUAL

SECOND Edition March 2009

Automation Systems

	51327 Quadrate Drive	Phone: [phone]
	Macomb, MI. 48042	Fax: [phone]
	Web: www.fec-usa.com	E-mail: [e-mail]
		AFC1500E-HM2-2

WARNING

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

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

Any questions regarding the contents of this document or any related matter should be directed to FEC INC. at [phone], faxed to [phone] or emailed to [e-mail].

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

This document shall not be released to or copied for any person and/or organization without the expressed prior consent of FEC INC.

Unauthorized reproduction or distribution of this manual is strictly prohibited.

Please contact FEC INC. if you require additional copies.

ii

Revision

Revision Revision History

Date

104/2008 Initial Release

	2	3/2009	Revision affecting most chapters including minor fixes, revised
			information and new items – Added Ethernet, Profinet & Toolsnet info.

2.12/2010 Chapter 5 onlyrevised toolsnet version output format pg: 5-74 to 5-83

Manual Numbering Convention

AFC1500 E -HM2-2

DSP1500 = Servo Press

Version Number

DSP1500 = Servo Press

AFC1500 = Nutrunner

AFC1500 = Nutrunner

(Major Revision Level)

FUSION = DC Hand Tool

FUSION = DC Hand Tool

HS = SAN Unit Hardware

E = English Version

Operation Manual

S = Spanish Version

HM2 = Multi2 / Main Unit

*Japanese Version furnished by DDK

Hardware Operation Manual

(uses DDK numbering convention)

HM-ENET = Ethernet Manual for

Multi / Main Unit

SW = Software Manual

iii

Points to check when unpacking

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.

For the safety of operator and equipment

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.

iv

Introduction

Warranty

Warranty Period

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.

Provisions of Warranty

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.

Non - Warranty Items

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.

v

Saffety Precautions

Read all instructions before operating the equipment in order to use this equipment safely and correctly. Prior to use, read this instruction manual carefully and fully understand the equipments functions, safety precautions and instructions. Safety precautions in this manual are marked with two symbols [Warning] and [Caution].

To prevent danger to the user and other persons as well as property damage, instructions that must be fully observed are marked with the symbols below.

This instruction manual uses the following two symbols according to the degree of damage that may be caused when the instruction is not observed.

		Warning	Thiis symbol indicates that failure to observe innstruction marked
			with this symbol may result in severe personal injury or death.
		Caution	Thiis symbol indicates that failure to observe instruction marked
			with this symbol may result in minor personal injury or material
			damage.

Even instructions that are marked with	Caution	may result in severe dammage if they are not
observed according to conditions.

Contents marked with the above symbols are very important instructions. For your safety, follow all instructions and especially those marked with these symbols.

This instruction manual uses the following additional symbols for instructions that shall be observed.

	Warning:		Warning:					Warrning:
	Electric shock		Fire					Pinch Point
	Caution:		Caution:					Ca ution:
	Fire		Electric shock					High Temperature
	Prohibited		Do not disassemble
	Required		Ground

vi

Safety Precautions

Warning

Never touch rotating devic es or any part of the nutrunner tool while it is rotating. Make sure that no part of your body gets near any moving part of the tool.

The spindle may rotate un expectedly, resulting in injury.

Do not remove the motors and gear cases of tools while power is applied. The tool output spindle may rotate and cause injury.

Do not repair, disassemble, or modify the equipment individual components of the system. Failure to observe this instruction may cause injury, electric shock, fire and malfunction.

Never operate the equipment where it is exposed to water, near a corrosive atmosphere or flammable gases. Failure to observe this instruction may cause fire.

Keep fingers away from th e connectors while the equipment is turned ON and for a while after the equipment is turned OFFF. Failure to observe this instruction may cause electric shock.

Wiring operation and mainttenance work shall be conducted by a qualified profeessional. Failure to observe this instruction may cause electric shock and injury.

Turn OFF the power when conducting wiring operation and maintenance. Failure to observe this instruction may cause electric shock and injury.

Never damage the cables, apply excess stress to cables, or squeeze the cables. Never use damaged cables.

Failure to observe this instruction may cause electric shock and fire.

Use type-3 grounding of F G terminals.

Failure to observe this instruction may cause electric shock.

In case of an abnormal od or, noise, or operation error occurrence, stop operation immediately and turn OFF the power soource. Failure to observe this instruction may cause injury and fire.

Install a Power shutdown d evice in order to ensure the safety of equipment. Failure to observe this instruction may cause injury.

Install an emergency stopp circuit on the outside of equipment in order to stop operation promptly. Failure to observe this instruction may cause injury.

Keep away from the equipment during recovery from a temporary blackout and ensure safety measures are conducted after restarting the equipment. The equipment may s uddenly restart. Failure to observe this instruction may cause injury.

vii

Safety Precautions

	/ Storage	Caution

Transport the equipment properly according to its weight.

Failure to observe this instruction may cause injury and malfunction.

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

Ambient temperaturre: -5°C +55°C (Avoid freezing)

Ambient humidity: 50% RH or lower (Avoid moisture)

Package: Tight seal

Rust prevention measure: Apply grease or oil on tools.

Failure to observe this instruction may cause earth leakage and malfunction.

Do not hold cables and outtput spindles when transporting the tools.

Failure to observe this instruction may cause injury and malfunction.

Do not hold the indictor on the front panel when transporting the AXIS Unit.

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

Failure to observe this instruction may cause injury and malfunction.

The equipment shall be stoored under the following conditions.

Ambient temperaturre: -5°C +55°C (Avoid freezing) Ambient humidity: 90% RH or lower (Avoid moisture)

Atmosphere: Indoorrs (Avoid direct sunlight)

No corrosive gases or flammable gases

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

Avoid direct vibration or shocks

Failure to observe this instruction may cause earth leakage and malfunction.

viii

Saffety Precautions

	Wiring	Caution

Install all tools firmly wheree they can bear the maximum torque during operation. Failure to observe this instruction may cause injury and malfunction.

Install the AXIS Unit firmly inside the control panel using the specified screws.

Failure to observe this instruction may cause malfunction.

Use the specified tool for the AXIS (SAN) Unit.

Failure to observe this instruction may cause fire and malfunction.

The AXIS (SAN) Unit shall maintain the specified distance from other devices.

Failure to observe this instruction may cause fire and malfunction.

Do not block the ventilationn hole of the AXIS (SAN) Unit.

Avoid any foreign body from entering inside the equipment.

Failure to observe this instruction may cause fire and malfunction.

The power source shall be provided with safety measures such as breakers and circuit protectors. Failure to observe this instruction may cause fire and malfunction.

Do not use tools or AXIS (SAN) Units that are damaged or missing parts.

Failure to observe this instruction may cause fire, injury and malfunction.

Do not get on the top of eqquipment or do not place heavy objects on the top of equipment. Failure to observe this instruction may cause injury and malfunction.

Do not subject the equipment to excess shock and impact.

Failure to observe this instruction may cause malfunction.

Apply proper wiring size annd firmly tighten all termination points.

Failure to observe this instruction may cause injury, false operation and malfunction.

Operate the equipment within the specified power supply voltage.

Failure to observe this instruction may cause injury, electric shock, fire and malfunction.

Take sufficient measures to shield the equipment when operating the in the following conditions:

Location where electrical noise is generated

Location where the equipment is subjected to a strong electric field or magnetic field

Location near a high power wire.

Failure to observe this instruction may cause injury, false operation, and malfunnction.

ix

Saffety Precautions

	stment	Cautioon

Never operate the equipment with wet hands or while standing in a wet locationn.

Failure to observe this instruction may cause electric shock.

Keep fingers away from the AXIS (SAN) Unit radiating fin and tool motors while the equipment is turned ON or for a while after the equipment is turned OFF. These parts may become very hot. Failure to observe this instruction may cause burns.

Use the equipment under the following conditions.

Ambient temperature: 0°C +45°C (Avoid freezing) Ambient humidity: 90% RH or lower (Avoid moisture)

Atmosphere: Indoors (Avoid direct sunlight)

No corrosive gases or flammable gases

No oil mist, dust, water, salt, iron powder Avoid direct vibratioon or shocks

Failure to observe this instruction may cause earth leakage and malfunction.

Confirm and adjust all paraameters before operation in order to prevent unexpected movement of the equipment.

Failure to observe this instruction may cause injury, false operation and malfunction.

Never conduct extreme adjustments or setting changes that may cause instability of operation. Failure to observe this instruction may cause injury, false operation and malfunction.

The equipment may restart suddenly when the equipment is reset with the start signal ON. Always ensure that the staart signal is OFF before resetting the equipment.

Failure to observe this instruction may cause injury.

Do not turn the equipment ON and OFF repeatedly.

Failure to observe this instruction may cause malfunction.

Do not use the equipment at torque higher than the maximum torque capacity.

Failure to observe this instruction may shorten equipment life or cause malfuncction due to the high temperature caused by overload.

In case any abnormality occurs, remove the cause and ensure safety before resetting and restarting the equipment.

Failure to observe this instruction may cause injury.

x

Table of Contents

Chapter 1: Outline

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

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

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

Chapter 2: Specifications

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

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

Chapter 3: System Description

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

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

Chapter 4: Installation & Wiring

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

xi

Table of Contents

Chapter 5: Control Interfaces

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

xii

Table of Contents

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

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

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

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

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

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

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

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

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

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

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

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

Chapter 6: Troubleshooting

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

xiii

Blank Page

xiv

Chapter 1: Outline

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	Title	Contents
1	Outline	Basic characteristics and	requirements of the	AFC1500
		Multi-2 Unit.
2	Specifications	General specifications of the AFC1500 Multi-2 Unit.
3	System Description	Description of standard and optional system components.
4	Installation and Wiring	Mounting requirements,	wiring connection	references
		including communication port specifications.
5	Control Interfaces	Description of standard Discrete I/O and optional Fieldbus I/O
		PLC 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

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

PAGE 1 - 2

Chapter 1: Outline

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

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 32~1220~50 ) 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

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®			(Includes data messaging capability)
	Profibus®
	Profinet IO
	Ethernet I/P			(Includes data messaging capability)
	Mitsubishi CC Link® 1
	Allen Bradley Remote I/O 1
	Modbus Plus®
	CC Link® Version 2 (Includes data messaging capability)
	Interbus-S®
	M-Net
	Additional Interfaces also available:
	Contact FEC for special fieldbus requirements
Fastening Sequence	100
Programming Steps	(99 plus “End” Step)
Fastening	Torque Control / Angle Control
Control Methods	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	3
monitoring areas	(1st , 2nd and 3rd Rate areas)
	# of	Stored		# of	Stored		# of		Stored		# of	Stored
	Spdls.	Cycles		Spdls.	Cycles		Spdls.		Cycles		Spdls.	Cycles
Data Storage	1	7878		9	2288		17		1326		25	936
	2	6032		10	2080		18		1248		26	910
(Non-volatile RAM)
	3	4888		11	1924		19		1196		27	858
Based on the number of	4	4108		12	1794		20		1144		28	832
	5	3536		13	1690		21		1092		29	806
spindles connected.2
	6	3120		14	1586		22		1040		30	780
	7	2782		15	1482		23		1014		31	754
	8	2496		16	1404		24		962
Installation requirement	NEMA12 Enclosure
Operation Temperature	0ëto 50 ëC (32 ëto 122 ëF)
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

Chapter 2: Specifications

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

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)

Blank Page

PAGE 2 - 4

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

Chapter 3: System Description

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

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

Interface Board

Power Connector

Ethernet U/C

Status LED

Power ON LED

Busy LED

Accept LED

Reject LED

Abnormal LED

Reset Button

Start Button

Reverse Button

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

PAGE 3 - 3

(RS422) Display Port

Ethernet U/C

Status LED

Chapter 3: System Description			AFC1500 Multi-2 Unit Hardware Manual (Rev.2)
Multi-2 Unit Panel Description
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	Yellow		10/100 Link
	Green		(RX) Receiving Data
Reset Button	Resets all signal and communication buffers to “clear” conditions.
	Clears the Abnormal signal and performs the Torque Transducer Zero
	Level Check.
Start Button	Starts the fastening cycle. Requires a pulse of 0.1 to 0.5 sec. for
	“Normal” start selection or must be maintained during complete cycle
	for “Deadman” start selection.
Reverse Button	Turns the spindles in the opposite direction of the preset fastening
	direction while the button is held active.
Cal Button	Performs the Torque Transducer shunt calibration test. When pressed,
	the Servo (SAN) Units will display either a green accept LED or red
	reject LED indicating status of the individual Calibration test.
Power Connector	Connects to incoming power: 100 to 220VAC (auto-sensing), Single
	phase, 50/60 Hz.
Interface Board (I/O)	Allocation socket for input/output signal Interface boards. Options
	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
RS232C – PC Port	Communication port for the User Console PC.
RS232C – Data Out Port #1	Communication port for fastening result data output to any external
(RS232C – Data Out Port)	device, i.e.: host computer, serial printer, etc. Data output format is
	configured using the User Console (AFC) Software package.
RS232C – Data In Port	Communication port for ASCII data input from peripheral devices. (Ex:
	bar code readers, RF tag, etc.) Allows external ASCII data to be merged
	with fastening result data.
RS232C – Data Out Port #2	Not Used
RS422 – Display Port	Not Used
Ethernet Network Port*	for network connectivity (Toolsnet®, QDAS®, SQL, Custom Protocol,
	etc.)
Ethernet Reset Button*	For resetting the Network Ethernet Port IP address to default setting.
	(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.
*On Ethernet Version only.

PAGE 3 - 4

Chapter 4: Installation & Wiring

Chapter 4: Installation & Wiring

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.

	4
	3
	2
	1
4.4	RS485 Connection

	Wiring Chart
Pin	Description
4	100 ~ 220VAC +/-15%
3	100 ~ 220VAC +/-15%
2	No Connection **
1	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.

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.

1

8

RS485 port specifications (RJ45)

Speed				9600, 19200, 38400 baud
Cable				Std Cat 5 Ethernet
Maximum number of				31
connected devices
Protocol				Proprietary
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

Chapter 4: Installation & Wiring

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

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 , ToolsNet , FECNet , SQL Servers or other 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 Part #FEB-1331-6). If connected through an may be used (FEC Part Number FEB-1258-6).

Crossover cable if connected directly to a PC (FEC Ethernet switch, a standard ethernet CAT5 or CAT5e

1

8

Ethernet port specifications (RJ45)

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

1Tx+

2Tx-

3Rx+

4-

5-

6Rx-

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