FEC FUSIONE-HS-2 User Manual

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FUSIONE-HS-2

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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 (586) 781-2100, faxed to (586) 781-0044 or emailed to:

support@fec-usa.com.

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

With out 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.

Revision History

Revision

date

Manual No. Content of Revision

2005/July First Edition

2007/August FUSIONE-HS-2 Revision 2 - Updated format & added relevant information

2008 / June FUSIONE-HS-2

2008 / July FUSIONE-HS-2

DSP1500 = Servo Press

AFC1500 = Nutrunner

FUSION = DC Hand Tool

E = English Version S = Spanish Version

*Japanese Version furnished by DDK uses

DDK numbering convention.

Original Operation Manual

MINOR Revision – Chapter 2 – Page 2-4 (Chapter Rev. 2.1 now) Updated Power Consumption (Running & Idle) MINOR Revision – Chapter 4 – Page 4-48 – 4-53 (Chapter Rev.2.1 now) Added DeviceNet Interface

Manual Numbering Convention

FUSIONE-HS-2

Version Number (Major Revision Level)

HS = Controller unit Hardware Operation Manual HM = Multi / Main Unit Hardware Operation Manual HM-ENET = Ethernet Manual for Multi / Main Unit SW = Software Manual

Thank you for purchasing our Electric Servo Nutrunner – FUSION System.

Introduction

This instruction manual describes the procedures for installation, wiring, and 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 equip-

ment.



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.



tained herein for other than its intended purpose, is strictly prohibited.

For the safety of operator and equipment



It is important for you to read all “Safety Precautions” before using the equipment, and under-

stand 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 equipment.



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.



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

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

Points to check when unpacking

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.

Warranty

Introduction

Warranty Period

The standard warranty period is one year from the date of purchase or one year from delivery to the designated End User (not to exceed 18 Months). Actual terms are order specific.

Provision of warranty

If your product proves to be defective, although it has been used properly in accordance with this instruction manual, during the period of warranty, this product will be repaired free of charge. However, in the following cases, the customer will be required to pay for repair charges, even for defects occurring within the warranty period.

1. Any defect due to improper conditions, improper circumstances, and improper handling.

2. Any defect due to modifications or repairs performed by the customer.

3. Any defect caused by other equipment.

4. Any defect caused by customer failing to meet the equipment’s specification.

5. Any defect due to natural disasters and accidents.

This warranty shall be limited to repairing or replacing this product. Any liability for indirect or consequential loss or damage of any kind incurred or suffered by the customer due to a defect of the product is excluded.

R

ead all instructions before operating the

instruction

ments functions, safety precautions and

[Warning] and [Caution].

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

observed are marked with the symbols below.

This instruction manual uses the

that may be caused when the instruction is not observed.

nstructions that are marked with

are not observed according to conditions.

marked with the above symbols are very

and especially those

the following additional

Safety Precautions

This symbol indicates that failure to observe instruction mar

with this symbol

This symbol indicates that failure to observe instruction marked

with this symbol

damage.

Warning:

Electric shock

Caution:

equipment safely and

the equi

. Safety precautions in this manual are

nstruction

two symbols according to the degree of damage

may result in severe damage if they

instructions. For your safety, f

s that shall be

may result in severe personal injury or death.

personal injury or

Caution

Warning:

F

ire

Caution:

Electric shock

Caution:

High

Temperature

correctly. Prior to use, read this

marked with two symbols

equipment in order to use this

manual carefully and fully understand

instructions

p-

must be fully



Warning

Caution

Even i

Contents low all instructions

, i

following

marked with these symbols.

may result in minor

important

s that

ked

material

ol-



This instruction manual uses observed.

Fire

Prohibited

Required

symbols for instruction

Do not disassemble

Ground

Do not remove the motor

tool output spindle may rotate and cause injury.

Do not repair, disassemble, or modify the equipment

Never operate the eq

flammable gases

Keep fingers away from the

ter the equipment is turn

operation and maintenance work shall be conducted by a

Turn OFF the power when conducting wiring operation

damage the cables, apply excess

Never use damaged cables.

Properly GROUND all Field Ground (

pin on the POWER CORD.

power cord grounded!

abnormal odor, noise, or operation error

power

Install a Power shutdown

When equipment is automatically operated, i

der to stop

Keep away from the equipment

measures are conducted

while power is applied.

individual components of the system.

injury, electric shock, fire, and malfunction.

corrosive

fire.

connectors while the equipment is turned ON

this instruction may cause

qualified

maintenance

the cables.

including the ground

operate this equipment without the ground pin on the

stop operation

this instruction may cause

in order to ensure the safety of equipment.

rgency stop circuit

may cause

recovery from a temporary blackout

he equipment may

Safety Precautions

Warning

s and gear cases of tools

The

.

Failure to observe

or

shock.

Wiring,

Failure to observe

Never

Failure to observe

In case of an and turn OFF the

Failure to observe

equipment in or

Failure to observe

this instruction may cause

uipment where it is exposed to water, near a

. Failure to observe this instruction may cause

ed OFF. Failure to observe

this instruction may cause electric shock and injury.

and

this instruction may cause electric shock and injury.

stress to cables, or squeeze

this instruction may cause electric shock and fire.

FG) Connections and terminals

NEVER

this instruction may cause electric shock.

occurrence,

source. Failure to observe

device

this instruction may cause injury.

nstall an eme

operation promptly. Failure to observe this,

during

after restarting the equipment. T

this instruction may cause injury.

.

atmosphere

and for a while af-

electric

professional.

.

immediately

injury and fire.

on the outside of

injury.

, and ensure safety

suddenly restart.

Transport the equipment properly according to its weight.

this instruction may cause

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

-

0% RH or lower

Rust prevention measure: Apply

this instruction may cause

transport tools by grasping cables

this instruction may cause

The equipment shall be stored under the following conditions.

-

Ambient humidity: 90% RH or lower

Indoors (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

Transportation / Storage

Safety Precautions

Caution

Failure to observe



Ambient temperature:



Ambient humidity: 5



Package: Tight seal



Failure to observe

Do not Failure to observe

.



Ambient temperature:



Atmosphere:



Failure to observe

injury and malfunction.

5°C+55°C (Avoid freezing)

(Avoid moisture)

light oil on steel portion of tools.

earth leakage and malfunction.

.

injury and malfunction.

5°C+55°C (Avoid freezing)

(Avoid moisture)

No

a ground fault and malfunction.

or provide torque reaction for

Failure to observe

Make sure controller is firmly mounted and will not come lose or fall during operation

Failure to observe

The power source shall be provided with safety measures

use tools or

Failure to observe

Do not subject the

Failure to observe

)

ailure to observe

Operate the equipment within the specified power supply voltage

Failure to observe

When operating the equipment in the following conditions,

the equipment.

where

where the equipment is subjected to

near a

Failure to observe

Installation / Wiring

where they can bear the maximum torque

injury and malfunction.

such as breakers

fire and malfunction.

or missing parts.

fire, injury, and malfunction.

, and malfunction.

injury, electric shock, fire, and malfunction.

sufficient

strong electric field

injury, false operation, and malfunction.

Caution

Safety Precautions

Install operation.

circuit protectors.

Do not

Route all wiring(s F

to shield



Location



Location



Location

all tools

this instruction may cause

this instruction may cause malfunction.

Failure to observe this instruction may cause

controller units that are damaged

this instruction may cause

equipment to excess shock and impact.

this instruction may cause malfunction.

) properly and firmly.

this instruction may cause injury, false operation

this instruction may cause

take

electrical noise is generated

a

high power wire.

this instruction may cause

during

.

and

.

measures

or magnetic field

equipment with wet hands

this instruction may cause electric shock.

Properly GROUND all Field Ground (

on the POWER CORD.

this instruction may cause

Use the equipment under the following conditions.

Ambient temperature: 0°C

Ambient humidity: 90% RH or lower

Indoors (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

movement of the equipment.

this instructi

experience sudden torque reaction when operated by hand while

engaged to a part. Grasp tool firmly with firm footing when operating. Additionally, be sure

work piece is securely clamped from any movement during torqueing operations.

instruction

Do not turn ON and OFF the equipment repeatedly.

instruction

equipment at torque higher than

Failure to observe this instruction may shorten

due to the high temperature caused by overload.

In case any abnormality occurs,

and restarting the equipment.

Failure to observe this instruction may cause injury.

Operation

/ Adjustment

Safety Precautions

or while standing in a wet location

including the ground

operate this equipment without the ground pin on the

in order to prevent unexpected

and malfunction.

or cause malfunction

remove the cause and ensure safety before resetting

Caution

Never operate the Failure to observe

pin power cord grounded! Failure to observe



Atmosphere:



No



Failure to observe

Confirm and adjust a

Failure to observe

The equipment may

the

Failure to observe this

FG) Connections and terminals

NEVER

electric shock.



+45°C (Avoid freezing)

(Avoid moisture)

a ground fault and malfunction.

on may cause injury, false operation

may cause injury.

.

Failure to observe this

Do not use the

may cause malfunction.

the maximum torque.

equipment life

Table of contents

Table of Contents

Chapter 1: Outline

1.1 About This operations manual 1-2

1.2 Features 1-3

1.3 Functions. 1-5

1.4 System requirements 1-6

Chapter 2: Specifications

2.1 Main Specifications 2-2

2.2 Duty Cycle Calculation 2-3

2.3 Controller Unit Specifications 2-4

2.4 Capability. 2-5

2.4.1 Nutrunner Tool Specification Table. 2-6

2.4.2 Nutrunner Decimal Point Display Table. 2-7

Chapter 3: System Description

3.1 Controller 3-2

3.1.1 Controller Part Number Breakdown 3-2

3.1.2 Controller Front Panel 3-4

3.1.3 Controller Back Panel 3-5

3.2 Fusion Tool 3-7

3.2.1 Fusion Tool Part Number Breakdown 3-7

3.2.2 Fusion Tool Control, Displays and Connectors 3-8

Page

1-1

2-1

3-1

Chapter 4: System Setup and Wiring 4-1

4.1 Design and Build Procedure 4-2

4.2 Component Dimensions 4-3

4.2.1 Controller Unit Dimensions 4-3

4.3 Unit Arrangement 4-4

4.4 Nutrunner (Tool) Dimensions 4-5

4.4.1 Straight Tool 4-5

4.4.2 Right Angle Tool 4-6

4.4.3 Pistol Tool 4-7

4.5 Connection Diagrams 4-9

4.6 Power Requirements and Connections 4-10

4.6.1 Controller Unit 4-10

4.7 Wiring PLC I/O 4-11

4.7.1 Explanation of Controller Unit I/O 4-12

4.7.2 Work / Parameter Select Table 4-13

4.7.3 Bank Select Table 4-14

4.7.4 Bank Output Servo Error Table 4-16

4.7.5 PLC Wiring Sample 4-17

4.8 RS-232 Data Communication Ports. 4-18

4.8.1 Front Panel DB9 PC Connection for AFC User Console Software 4-18

4.8.2 Rear Panel DB9 PC Connection (RS232) 4-19

4.8.3 Rear Panel RS232 Communication Protocol 4.20

4.8.4 Rear Panel RS232 Alternate Communication Protocol 4-24

4.8.5 Rear Panel RS232 Alternate Communication Protocol 4-25

4.9 Torque/Angle MON. DB9 (external monitoring connector). 4-26

i

Table of contents

4.10 Controller Unit DIP Switch setting. 4-27

4.10.1 Controller Unit DIP switch positions 1 ~ 3 4-27

4.10.2 Controller Unit DIP switch positions 4 ~ 8 4-28

4.11 Tool Connection (cabling) 4-29

4.11.1 Cable Installation Guidelines 4-30

4.11.2 Considerations for Cable Trolleys 4-31

4.11.3 Considerations for Flexible Cable Tracks 4-31

4.11.4 Considerations for Cable Trays and Ladders 4-31

4.11.5 Tool Cable - Preamplifier Connector. 4-32

4.11.6 Tool Cable - Motor Connector 4-32

4.11.7 Tool Cable - Resolver Connector 4-32

4.12 Firmware Flash Connector (CN8). 4-33

4.13 SYNC Connector 4-34

4.14 Options – Ethernet Card 4-35

4.14.1 Ethernet Set-up of PC to Communicate to Ethernet Module 4-36

4.14.2 Ethernet Module Connection 4-37

4.15 Options – Fieldbus Interfaces 4-38

4.15.1 Fieldbus Interfaces – Profibus-DP 4-39

4.15.2 Fieldbus Interfaces – Allen Bradley Remote I/O

4.15.3 Fieldbus Interfaces – DeviceNet

4-44 4-48

Chapter 5: Power Up and Initial Checks 5-1

5.1 Before Powering On 5-2

5.2 Initial Data Setting 5-3

Chapter 6: Fastening Instructions 6-1

6.1 Fastening Control 6-2

6.1.1 Torque Control Method 6-2

6.1.2 Angle Control Method 6-6

6.2 Monitoring Functions 6-12

6.2.1 Peak Torque Monitoring 6-12

6.2.3 Final Torque Monitoring 6-14

6.2.3 Angle Monitoring 6-16

6.2.4 Point-to-Point Torque Rate Monitoring 6-18

6.2.5 Time 6-20

6.3 Speed Functions 6-21

6.4 Reverse Functions 6-23

6.5 Torque Recovery 6-24

6.6 Added Functions 6-25

6.6.1 Current Monitor / Control 6-25

6.6.2 Angle Correction 6-26

6.6.3 Reduced Fastening Reaction 6-26

6.6.4 VariSpeed 6-26

6.6.5 Work (Batch Counting) 6-26

6.6.6 Torque Inhibit 6-27

Chapter 7: System Operations 7-1

7.1 Fusion Display and Programming Unit Operation 7-2

7.1.1 Manual Fastening controls 7-2

7.1.2 Fastening Indicators 7-3

7.1.3 Fastening Preset / Result displays 7-3

ii

Table of contents

7.2 Run State Modes. 7-5

7.2.1 Display indication modes. 7-5

7.2.2 Real-time display indication mode. 7-6

7.2.3 Fastening results display mode. 7-7

7.2.4 Parameter display mode 7-8

7.2.5 Parameter Data List & Data Explanation 7-9

7.2.6 Status Display 7-24

7.3 Download / Setup Mode Operation. 7-25

7.3.1 Download Mode selection 7-25

7.3.2 Setup Mode selection 7-26

7.3.3 Parameter Number Selection. 7-27

7.3.4 Data # selection 7-28

7.3.5 Data Edit Mode Operation 7-29

7.3.6 Parameter Copy 7-30

7.4 Calibration adjustment. 7-31

7.5 Optional Real Time Clock Module 7-32

7.6 Tubenut Head Setup 7-33

7.6.1 Recommended Parameter Setup for Tubenut Head 7-34

7.6.2 Tubenut Head Operation 7-35

Chapter 8: Maintenance and Inspection 8-1

8.1 Inspection Items 8-2

8.1.1 Nutrunner (Tool) 8-2

8.1.2 Tool Cable 8-2

8.1.3 Controller Unit 8-3

8.1.4 Auxiliary Tool Heads 8-3

8.2 Basic operational tests 8-4

8.2.1 Torque transducer. 8-4

8.2.2 Resolver. 8-4

8.2.3 Motor. 8-4

8.2.4 Transmission Disassembly and Inspection 8-6

8.3 Replacements 8-7

8.3.1 Controller Unit Replacement 8-7

8.3.2 Replace Nutrunner (tool) 8-8

8.3.3 Replace Homerun cables 8-8

Chapter 9: Troubleshooting 9-1

9.1 Abnormal Conditions. 9-2

9.2 Torque Transducer Abnormals. 9-3 Calibration Error 9-3

9.2.1 Code 1-0 Torque transducer / Zero Voltage error. 9-3

9.2.2 Code 1-1 Torque transducer / Cal Voltage error. 9-3

9.2.3 Code 1-2 Torque transducer / Zero check error. 9-4

9.2.4 Code 1-3 Torque transducer / Cal self-check error. 9-4

9.2.5 Code 1-4 Torque transducer / started on Zero condition error. 9-4

9.2.6 Code 1-5 Torque transducer / started on Cal condition error 9-4

9.2.7 Code 1-6 Torque transducer / Zero Level Self Check Error 9-5

9.3 Torque Over 9-6

9.3.1 Code 2-0 Torque Over Abnormal / Torque Inhibit High Limit 9-6

iii

Table of contents

9.4 Tool EEPROM Errors 9-7

9.4.1 Code 3-0 Preamplifier / Tool ID Checksum error 9-7

9.4.2 Code 3-1 Preamplifier / Tool type error 9-7

9.4.3 Code 3-2 Preamplifier / Started without tool connected 9-7

9.4.4 Code 3-3 Preamplifier / Tool is not connected 9-7

9.5 System Memory Errors 9-8

9.5.1 Code 4-0 system memory error / Flash ROM write error 9-8

9.5.2 Code 4-1 system memory error / Flash ROM read error 9-8

9.5.3 Code 4-2 system memory error / Servo Amp Flash ROM error 9-8

9.6 Servo Amplifier Response / Resolver 9-9

9.6.1 Code 5-0 Servo Amplifier reply error / No reply from Resolver 9-9

9.7 Servo Type Error 9-10

9.7.1 Code 6-0 Servo Type error / Servo Type mismatch 9-10

9.9 Servo Amplifier Error 9-11

9.9.1 Code 8-1 Servo Amplifier error / Servo is over heated 9-11

9.9.2 Code 8-4 Servo Amplifier error / Over current 9-11

9.9.3 Code 8-5 Servo Amplifier error /Internal power supply. 9-11

9.9.4 Code 8-6 Servo Amplifier error / Input Voltage abnormal 9-12

9.9.5 Code 8-9 Servo Amplifier error / Over speed. 9-12

9.9.6 Code 8-10 Servo Amplifier error / over load ( I square T) 9-12

9.9.7 Code 8-11 Servo Amplifier error / Resolver Signal Error . 9-12

9.10 Parameter Error 9-13

9.10.1 Code 9-0 Parameter Error / Missing speed preset. 9-13

9.10.2 Code 9-1 Parameter Error/ Missing Speed or Time 9-13

9.10.3 Code 9-2 Parameter Error/ Parameter Select Error 9-13

9.10.4 Code 9-3 Parameter Error/ Missing Reverse Speed 9-13

9.10.5 Code 9-4 Parameter Error/ Torque Speed not set 9-13

9.10.6 Code 9-5 Parameter Error/ Torque Setup Error 9-14

9.10.7 Code 9-6 Parameter Error/ Angle Setup Error 9-14

9.10.8 Code 9-7 Parameter Error/ Reverse Torque over. 9-14

9.11 AFC1500 SAN Unit Fastening Faults and Causes 9-15

9.11.1 Accept Conditions 9-15

9.11.2 Torque Reject Conditions 9-15

iv

FEC FUSION Operations Manual Chapter 1: Outline (Rev 2)

Chapter 1: Outline

Page 1-1

Chapter 1: Outline

Chapter

Item

Contents

1.1 About This operations manual

This manual details the configuration, components, specifications, and the operation of the FUSION Fastening System.

The following table outlines the contents of each chapter:

Chapter 1 Outline Basic characteristics and requirements of the

Chapter 2 Specifications General specifications of the FUSION System. Chapter 3 System Description Description of standard and optional system

Chapter 4 System Setup and Wiring Equipment installation procedure, dimensions,

Chapter 5 Power Up and Initial Checks Preliminary power on and operational tests. Chapter 6 Fastening Instructions Basic fastening operations and presetting

Chapter 7 System Operations Instructions for the input of preset data and

Chapter 8 Maintenance and Inspection Guide for preventive maintenance. Chapter 9 Troubleshooting Descriptions of fastening rejects, abnormal

FUSION System.

components.

Input and Output signal descriptions and requirements for PLC programming.

procedures.

monitoring explanations.

operation faults, and corrective actions.

Page 1-2

FEC FUSION Operations Manual Chapter 1: Outline (Rev 2)

1.2 Features

The FUSION Fastening System is a culmination of over twenty years of electric fastening expertise integrated with the latest electronic technology. The system is designed with modular construction in mind. The basic elements of this system are:

1) A brushless DC permanent magnet high speed motor, with resolver feedback

2) A combination Fastening Controller / Servo Amplifier

3) 32-bit RISC (Reduced Instruction Set Computing) CPU for spindle control

4) Fully digital controlled drive amplifier

5) Configurable communications interfaces

• Compact Design As the result of miniaturization circuit technology, the controller maintains a maximum

width of 160mm in spite of the built-in power source, controller interface and servo amplifier. Controllers operate on single-phase 100 ~ 230 VAC (Auto switching) for simplified connection to standard plant floor receptacles. System components can be back panel mounted with quick replacement capabilities.

• Front Keypad-Display.

A front keypad display is an integral component for programming single units and/or monitoring the fastening results and status conditions in the system. Large alphanumeric LED displays and status lights provide excellent visibility in plant operations.

• Fastening Functions. Fastening can be performed in either the Torque Control or the Angle Control method.

Angle (rotational) and torque rate monitoring provide additional error proofing functions.

• Parameter Selection

• Totally digitized system eliminates analog potentiometers.

• Up to 16 sets of parameters can be stored into Flash ROM.

• No battery-backup of memory is required.

• “No Cost” AFC User Console Programming Software

Nutrunner programming and data collection can be performed via the user-friendly AFC software provided at no cost with every system. Functions such as Preset Parameter programming, fastening data monitoring and fastening data analysis can be performed. The software is primarily utilized on single spindle application in a detachable mode via a laptop computer with RS232 communications.

• Communication and I/O Interface (1) Programming and Display – Front Panel -Input/Output – Manual interface.

(1) RS232 – Front Panel - Input/output – Programming and Data collection (2) RS232 – Rear Panel – Output – Printer or data collection device. (1) T/A MON – Front Panel – Output – Analog Torque and Angle analysis. (1) Discrete I/O Terminal – Rear panel - Control and PLC interface (1) Optional Ethernet – Output - Data collection (1) Optional Fieldbus I/O interfaces – Input/Output – Control and PLC interface

Page 1-3

Chapter 1: Outline

• Motor A permanent magnet High Speed DC motor provides for improved fastening control.

The sealed design of the motor provides greater protection from contamination without generating excess heat. The resolver is uniquely designed to withstand harsh environments and provide high resolution control / angular feedback signals.

• Preamplifier Quality control of the tool torque transducer is accomplished electronically (digitally) through the EEPROM (Electrically Erasable Programmable Read Only Memory) in the preamplifier. During factory setup of the torque transducer, the unit is Dead Weight and Dynamically tested against Standards that are certified and traceable to the National Institute of Standards and Technology. The resultant data is then programmed into the preamplifier where it is stored on non-volatile EEPROM. The preamplifier also contains the “Smart Tool ID” system which allows automatic tool recognition and protects against misapplication of tools onto the wrong controller or set-up.

• Servo Amplifier (Servo Drive) Reduced equipment size with improved drive circuit strength is the result of

incorporating Isolated Gate Bipolar Transistor (IGBT) technology into the drive System.

• Plug-In Firmware Update System The CONTROLLER Firmware is stored in Flash ROM and can be rewritten with future

Firmware updates via a plug-in connector located on each unit. There is no need to remove the unit or disassemble the unit for any Firmware upgrades.

• Motor, Resolver and Transducer Combined Cable A single high flex cable incorporates durable metal connectors to provide for extended

life in harsh environments. Twist lock connectors provide easy separation of connection points for maintenance, while maintaining superior contact under operating conditions. Separate tool and extension cables (Straight and 90 Degree) are available for improved cable management.

• ToolsNet / Network Connectivity

Optional Ethernet connectivity (10/100BaseT) available for export of fastening data or connection to existing Atlas Copco ToolsNet network via the Open Protocol for ToolsNet.

Page 1-4

FEC FUSION Operations Manual Chapter 1: Outline (Rev 2)

1.3 Functions.

• Fastening function. The following fastening control methods can be selected for either clockwise (CW) or

counterclockwise (CCW) operation:

 Torque Control / Angle Monitoring  Angle Control / Torque Monitoring

The Controller unit has capability for one, two & three step fastening.

Torque rate monitoring in up to 3 areas is available in any configuration.

• Multi-Speed Rundown The Initial, Freerun, Slowdown, Torque and Reverse speed set-ups provide capability of

multi-speed fastenings for any application.

• Reject / Abnormal Condition Display When a fastening Reject has occurred the system stops, outputs the appropriate signal

and displays the resultant data in the Keypad-Display. Upon a fastening reject, the unit will not require resetting prior to the next cycle.

The System will output an abnormal signal when it detects there is a problem (Zero Check out of limits, incorrect component connection, etc.) within the system itself. The output will be displayed as a code on the Front Panel Display. Refer to Chapter 9 Troubleshooting for more details. Reset of the system is required on an abnormal before normal operation can resume.

• Axis Bypass Function When a PLC Bypass input signal is activated, the Bypass output signal is activated. In

this condition, the spindle will not START, REVERSE, CAL OR RESET.

• Auto Tool Recognition (Smart Tool ID) The FUSION tools have an EEPROM in the preamplifier that contains tool data specific

for each tool. The Tool type check function reads the information of the tool EEPROM and compares it to the information of the CONTROLLER unit; any mismatch is reported as a Tool Type Error Abnormal.

The tool type check is performed during the following times:

1) When the equipment is powered on.

2) When preset data is downloaded from a user console to the Axis unit.

• Torque Recovery The ability to “hold” torque after fastening allows the system to overcome problems

associated with joint relaxation or “slip stick” friction. After peak torque has been reach, this function allows the tool to “hold” torque for a pre-programmed number of pulses.

• Batch Counting The Batch Count function allows multiple fastening accepts to be counted for an overall

“Work Accept” of the work piece.

Page 1-5

Chapter 1: Outline

1.4 System requirements

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

• Tool Installation Tools can generate a large amount of torque during operation, and the reaction force is

applied to the Operator or mounting area of the tool. Therefore, tools must be installed in the proper positions and with adequate reaction devices. Tools MUST be mounted either using there supplied mounting plate or clamped only in designated areas of the tool or tool damage may result.

Keep in mind that the fastening tool is a strain gage based instrument and, although it has been designed to withstand sudden shock, repeated shock (over time) could damage some components. Therefore, support devices must be used whenever practical to ease in handling and operation of the Fastening Tool.

• Fastening Operation Avoid fastening beyond the full scale torque. Do not use a duty cycle (the ratio of the

tool “On” time to Tool “Off” time) higher than 50%, even when the torque is below the full scale value.

• Cable Wiring

• Use the specified cables for all System connections.

• Completely lock the tool cable twist lock connectors.

• PLC I/O cables must be run separate from any high voltage power sources or cabling, and

must not exceed 50 feet in length.

• Control Equipment Installation Environment

• Controller units must be located a minimum of 600 mm from high transient voltage sources

such as transformers, motor starters, AC inverters and AC contactors. If it cannot be avoided, the units must be properly shielded.

Do not use at the following locations.

• Areas under direct sunlight.

• Areas where the environmental temperature is out of the 32 °~122°F range.

• Areas where the relative humidity is below the 20% range.

• Areas where the relative humidity is above the 90% range.

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

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

• Areas that have corrosive or combustible gases.

• Areas that have strong electric or magnetic fields.

• Areas where a strong vibration or shock could be transmitted directly to a Controller unit or

tool.

• Static Electricity FUSION System construction incorporates 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 when handling the units.

Page 1-6

FEC FUSION Operations Manual Chapter 1: Outline (Rev 2)

• Cleaning Do not use any organic solvents, such as thinner, to clean a Controller unit or a tool.

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.

• Handling and Shipping It is critical that FUSION 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 FUSION System components must be individually packaged in an approved anti- static container or wrap to prevent damage from electrostatic discharge.

• Adhere to Chapter 2 Specifications for environmental requirements.

Page 1-7

Chapter 1: Outline

(Blank Page)

Page 1-8

FEC FUSION Operations Manual Chapter 2: Specifications (Rev. 2

)

Chapter 2: Specifications

Page 2-1

Chapter 2: Specifications

2.1 Main Specifications

Power Supply Voltage

• Single Phase 100 ~ 230 VAC +/- 10% , 50/60 Hz Auto-Switching

Installation Requirement

• No Vibration should be applied directly to the Controller. Securely mount controllers to a fixed point.

Range of Operation

• Duty cycle below 50% (reference Section 2.2 Duty Cycle Calculation)

Operating Conditions (may be met by incorporating an Air Handling Unit into System)

• Temperature: 0° ~ 50°C (32° ~ 122°F)

• Humidity: 20% ~ 90%, no moisture

Storage Conditions

• Temperature: -5° ~ 55°C (23° ~ 131°F)

• Humidity: Below 90%, no moisture

Shipping Conditions

• Temperature: -5° ~ 55°C (23° ~ 131°F)

• Humidity: Below 90%, no moisture

Page 2-2

FEC FUSION Operations Manual Chapter 2: Specifications (Rev. 2.1)

2.2 Duty Cycle Calculation

Duty Cycle is rated as a percentage of the time the motor is running to the time the motor is idle. This is an important factor in determining overload protection for Servo Amplifiers and motors as it directly relates to the amount of power or heat dissipation of the motor / servo package. The rated duty cycle for the FUSION System is calculated as follows:

Tool Rotation Time

X 100 = Duty Cycle Percentage (%)

Total Cycle Time (Tool Rotation + Tool Waiting)

Example: Tool Rotation Time = 3 Seconds x 100 = 25% Duty Cycle Percentage Total Cycle Time = 12 Seconds

Duty cycle ratings vary between tools. As a general rule, however, it should not exceed 50%. IF duty cycles remain above 60% for extended periods, a Servo Amplifier Error / Overload will result (See abnormal CODE 8 -10). Protection for high duty cycle is a standard feature of the Servo Amplifier to prevent servo or motor damage.

Page 2-3

Chapter 2: Specifications

Caution

2.3 Controller Unit Specifications

Controller Model

HFC-EC-16

Motor Model

Controller Supply Voltage

Power Consumption (Running)

Power Consumption (Idle)

Inrush current @ Power on

If the equipment is powered on and off repeatedly, internal circuit protection devices may trip due to high in-rush current overload, and the Controller will not function until it is cleared (powered off). (It may take up to five minutes of “off” time to clear the selfprotection circuit.)

Single Phase 100~ 230 VAC 50/60/Hz +/- 10%

95 watt/hour @ 99% Capacity / 50% Duty

RM80, RM50

37 watt/Hour

11A

• Controller Processor: 32-bit RISC (Reduced Instruction Set CPU)

• Parameter / Firmware Storage: Flash ROM

• Fastening Data Storage: More than 10,000 cycles (stored in flash)

• Fastening Method: Torque and Angle, 1 ~ 3 step fastening

• Torque Rate Calculation: 3 ranges

• Data communications:

(1) RS232 – Front Panel - Input/output – Programming and Data collection (1) RS232 – Rear Panel – Output – Printer or data collection device. (1) T/A MON – Front Panel – Output – analog Torque and Angle analysis. (1) Discrete I/O – Rear panel - Control and PLC interface (1) Real Time Clock Connection (1) Optional Ethernet – Output - Data collection (1) Optional Fieldbus – Input/Output – Control and PLC interface

Page 2-4

FEC FUSION Operations Manual Chapter 2: Specifications (Rev. 2

)

2.4 Capability.

• Fastening Accuracy (Torque): From 1/4 to full scale torque: 3 sigma scatter less than 6% of target torque. Accuracy improvements available with application specific set-up.

• Torque resolution: Full Scale Torque x 1/1000.

• Torque Display Resolution: 4-digit display with floating decimal point.

• Angle Resolution: .1 Degree (1024 pulses / motor rev.)

• Angle Display Resolution: .1 degree.

Forward Max. count 9999 degree Reverse Max. count 1999 degree

• Torque transducer accuracy: (0 - Full Scale) ±1%

• Linearity of torque transducer: ± 0.5% of Full Scale value (Maximum).

Page 2-5

Chapter 2: Specifications

2.4.1 Nutrunner Tool Specification Table.

TOOL TYPE

HFT-015M50-A1 HFC-EC-16 14.7 1.5 150 10.8 130.2 1215 1 1.3 3/8 381 HFT-025M80-A1 HFC-EC-16 24.5 2.5 250 18.1 217.0 1070 1 1.7 3/8 400

ANGLE

HFT-040M80-A1 HFC-EC-16 39.2 4.0 400 28.9 347.2 648 1 1.9 3/8 425 HFT-060M80-A HFC-EC-16 58.8 6.0 600 43.4 520.8 446 1 1.9 1/2 425 HFT-080M80-A HFC-EC-16 78.4 8.0 800 57.9 694.4 330 1 3.8 1/2 507 HFT-130M80-A HFC-EC-16 127.5 13.0 1300 94.0 1128.4 203 1 3.8 1/2 516

HFT-010M50-S1 HFC-EC-16 9.8 1.0 100 7.2 86.8 1665 1 1.3 3/8 342

STRAIGHT

HFT-015M80-S1 HFC-EC-16 14.7 1.5 150 10.8 130.2 1665 1 1.4 3/8 363 HFT-025M80-S1 HFC-EC-16 24.5 2.5 250 18.1 217.0 900 1 1.4 3/8 363 HFT-040M80-S HFC-EC-16 39.2 4.0 400 28.9 347.2 694 1 1.4 3/8 363 HFT-080M80-S HFC-EC-16 TBA

PISTOL

HFT-015M50-P HFC-EC-16 14.7 1.5 150 10.8 130.2 1000 1 1.4 3/8 230 HFT-040M80-P HFC-EC-16 39.2 4.0 400 28.9 346.9 694 1 1.8 3/8 230 HFT-040M80-T HFC-EC-16 39.2 4.0 400 28.9 346.9 694 1 1.8 3/8 250

CONVERSION GUIDE: 1 KGM = 100 KGCM = 9.8 NM = 7.2 FTLB = 86.8 INLB

FULL SCALE TORQUE VALUES (WORK 1~16 D-NO 10) IN CONTROLLER ARE BASED UPON LIMIT SET BY Kgm VALUE.

The tool lists located throughout this manual identify the specifications for the standard tools used with the FUSION System. Additional tools are available. If additional capacity, information or special needs are required, please contact FEC INC.

SERVO

TYPE

CALIBRATION TORQUE

NM KGM KGCM FTLB INLB MAX MIN (Kg) (inch) (mm)

SPEED

RPM

Weight

Sq.

Drive

Length

Page 2-6

FEC FUSION Operations Manual Chapter 2: Specifications (Rev. 2

)

2.4.2Nutrunner Decimal Point Display Table.

POSITIONS FOR DECIMAL POINT DISPLAY

TORQUE

TOOL TYPE

HFT-010M50-x 2 2 0 2 1 3 3 2 3 2 HFT-015M50-x 2 2 0 2 1 3 3 2 3 2 HFT-015M80-x 2 2 0 2 1 3 3 2 3 2 HFT-025M80-x 2 2 0 2 1 3 3 2 3 2 HFT-040M80-x 2 2 0 2 1 3 3 2 3 2 HFT-060M80-x 1 2 0 2 0 3 3 2 3 2 HFT-080M80-x 1 2 0 2 0 3 3 2 3 2 HFT-130M80-x 1 2 0 2 0 2 3 1 2 1

Example: HFT-025M80-A Torque Display = 25.00 NM (2 positions) Torque Rate Display = 1.999 NM/degree (3 positions)

DECIMAL POINT DISPLAY

NM KGM KGCM FTLB INLB NM KGM KGCM FTLB INLB

TORQUE RATE

DECIMAL POINT DISPLAY

Page 2-7

Chapter 2: Specifications

[Blank Page}

Page 2-8

FEC FUSION Operations Manual Chapter 3: System Description (Rev 2)

Chapter 3: System Description

Page 3-1

Chapter 3: System Description

3.1 Controller

3.1.1 Controller Part Number Breakdown

HFC-EC-16-[14]-[E] A B

(A) I/O INTERFACE Blank = 24VDC Discrete I/O 3 = Modbus Plus® Interface 6 = Allen Bradley Remote I/O Interface 9 = DeviceNet® Interface 13 = Profibus® Interface 14 = CC-Link® Interface

(B) OPTIONS Blank = Standard (with Real Time Clock) E = Ethernet (Data Output / Toolsnet Connection)

Page 3-2

FEC FUSION Operations Manual Chapter 3: System Description (Rev 2)

3.1.2 Controller Front Panel

2 3 4 5

1

6

8 7

18

9

13

10

11

14 12

16 15

19

Note: Numbers correspond to

item # in following table

17



Fig. 3.1.2 Front Panel description

Page 3-3

Chapter 3: System Description

FRONT PANEL DISPLAY FEATURES

ITEM ITEM AS MARKED ON UNIT

1 ACCEPT

2 WORK ACCEPT

3 REJECT

4 TORQUE

5 ANGLE

6 LED Display

7 WORK

8 COUNT/D-NO.

(Green) Lights to indicate that the spindle has completed an acceptable fastening cycle. Flashes for an individual accept during a Batch Count. (Green) Lights to indicate that the spindle has completed an acceptable group of fastenings. (Reached Batch Count No.) (Red). Indicates the spindle performed a rejected fastening, out of the operation limits. Flashes indicating a rate reject. (Yellow). Indicates the “Data Display LED” is displaying Torque fastening Data. (Yellow). Indicates the “Data Display LED” is displaying Angle fastening Data. Four digit display which function is dependent upon the D-NO selected.

“



” is displayed here during an “Abnormal” condition. Displays two-digit parameter number and, as required, will override parameter output to display an Abnormal code. Display number that indicates which data in the "DATA" display field is being displayed and as required, will display an Abnormal Sub-code. Displays Fastening Count during Batch Count function.

DESCRIPTION

FRONT PANEL CONTROL FEATURES

9 CAL Manual calibration (CAL) check pushbutton 10 RESET Manual zero check and system reset pushbutton. 11 UP - Arrow Data change increase pushbutton. 12 DOWN - Arrow Data change decrease pushbutton. 13 MODE Display mode selection pushbutton. 14 SET Data change confirmation set pushbutton. 15 WORK RIGHT - Arrow Parameter selection increase pushbutton. 16 WORK LEFT - Arrow Parameter selection decrease pushbutton. 17 POWER 0 / 1 0-Off / 1-On controller power switch

FRONT PANEL CONNECTOR FEATURES

18 T/A MON.

19 PC

Optional DB9 connector for Torque / Angle monitor. Analog outputs for use with external analysis equipment. RS232 communications port for interfacing with the AFC user console software.

Page 3-4

FEC FUSION Operations Manual Chapter 3: System Description (Rev 2)

3.1.3 Controller Back Panel

1

9

3

5

2

Fig. 3.1.3 Back Panel Description

8

6

7

4

Note: Numbers correspond to

item # in following table

Page 3-5

Chapter 3: System Description

DB9 connector for fastening result data Output only. Utilized for

BACK PANEL CONNECTOR FEATURES

ITEM ITEM AS MARKED ON UNIT DESCRIPTION

Twist Lock single connector for tool cable connection. Twist lock type connector can be connected and disconnected by

1 CN1

2 RS232C

3

AC100 ~ 230 VAC

4 TB1

5 Ground Lug

6 RTC Connection 8 pin plastic connector – Real Time Clock Connection 7 SYNC Connection 4 pin plastic connector – Sync. Connector 8 Interface option Mtg. Interface adapter port – Optional Fieldbus or Ethernet board

9 Breaker

twisting the outside ring 90 degrees Clockwise and Counter Clockwise respectively

connection to a PLC, printer, personal computer, etc.

Primary power-supply input connection. Input for 100 ~ 230 VAC single-phase 50/60Hz. +/- 10% AUTO SWITCHING

*DO NOT RUN WITHOUT GROUND CONNECTED!

Connection point for discrete inputs and outputs (I/O). When wired in, the entire connector can be removed by loosening the upper and lower retaining screws. Refer to chapter 4 for detailed descriptions of I/O signal. . Ground terminal for connection to the Back Panel Cover’s ground wire

Electrical Leakage Breaker / Ground Fault detector. I=on, 0=off

WARNING!: DO NOT RUN THIS SYSTEM WITHOUT A PROPER GROUND CONNECTED TO THE CONTROLLER. THE CONTROLLER IS SUPPLIED WITH A 3-PRONG AC CABLE INCLUDING A GROUND CONDUCTOR. DO NOT BYPASS THE GROUND CONNECTION OR SEVERE INJURY OR SHOCK MAY RESULT!

Page 3-6

FEC FUSION Operations Manual Chapter 3: System Description (Rev 2)

3.2 FUSION Tool

3.2.1 FUSION Tool Part Number Breakdown

HFT-[051][M80]-[A][1][ ]-[01][A] A B C D E F G

(A) MAXIMUM TORQUE 010 = 1.0Kgfm (9.8Nm / 7.2ft lb) 015 = 1.5Kgfm (14.7Nm / 10.8ft lb) 025 = 2.0Kgfm (24.5Nm / 18.0ft lb) 040 = 4.0Kgfm (39.2Nm / 28.9ft lb) 060 = 6.0Kgfm (58.8Nm / 43.3ft lb) 080 = 8.0Kgfm (78.4Nm / 57.8ft lb) 130 = 13.0Kgfm (127.5Nm / 94.0ft lb)

(B) MOTOR M50 = Only used on 015 Angle & Pistol Tools M80 = Used on all other tools

(C) TOOL TYPE A = Angle S = Straight P = Pistol T = “T” Type Pistol

(D) MODEL REVISION BLANK = Original Release 1 = 1st Generation

(E) SPECIAL BLANK = Normal Function

(F) MINOR REVISION Two Digit Minor Rev. Level (Factory Use Only) (G) HANDLE OPTION A = Includes handle with trigger start & reverse

pushbutton switch

B = Includes handle with NO trigger start or

reverse switch (switch holes plugged)

C = Includes handle with twist reverse, trigger

start

D = Hole for pin & O-ring

E = 3/8” drive on 60Nm tool (1/2” is STD)

F = 1/2” drive on 40Nm tool (3/8” is STD)

Page 3-7

Chapter 3: System Description

3.2.2 FUSION Tool Control, Displays and Connectors

Fig. 3.2.2 Tool Description

TOOL MAJOR COMPONENT IDENTIFICATION

ITEM ITEM AS MARKED ON UNIT

1 MOTOR / RESOLVER

Provides feedback for speed regulation to the Servo Amplifier. Provides angular rotation monitoring for fastening operation. Totally enclosed DC permanent magnet motor.

DESCRIPTION

2 TRANSMISSION

3 ANGLE HEAD

4 TRANSDUCER / PREAMP

5 CABLE CONNECTOR

6 START SWITCH

7 REVERSE SWITCH

Durable planetary gear transmission. Refer to Chapter 2 for standard tools and gear ratios.

Durable right angle head. Refer to Chapter 2 for standard tools and gear ratios.

Highly accurate strain gage transducer. Highly durable, compact design minimizes space requirements. Intelligent transducer design uses an “ID Chip” to verify integrity of fastening operations.

Twist lock single connector for tool cable connection. Twist lock type connector can be connected and disconnected by twisting the outside ring 90 degrees clockwise and counter clockwise respectively.

Variable speed start switch. Depressing the Start switch partially initiates a manually controlled slow speed start. Depressing the Start switch fully initiate a fastening cycle as programmed into the controller. Releasing the Start switch at any time terminates the fastening operation.

Used to initiate a reverse tool operation when in Reverse/Backout mode.

Momentary Reverse selector switch. Depressing the Reverse selector switch places the tool in the Reverse/Backout mode. The Accept/Reject LED display on the tool flashes to indicate Reverse operation selection. Depressing the Reverse selector switch again, places the tool back in the fastening mode.

360 degree LED display ring. Green indicates an accept condition.

8 LED DISPLAY RING

Red indicates a Reject condition. Flashing Red and Green indicate Reverse/Backout mode. Solid Red and Green during power on for verification.

Page 3-8

FEC FUSION Operations Manual

Chapter 4: System Setup and Wiring (Rev. 2.1)

Chapter 4: System Setup and Wiring

Page 4-1

Chapter 4: System Setup and Wiring

Reference

Section

Set Controller Unit dip

4.2

4.3

Connect Tool / extension

5.2

4.1 Design and Build Procedure

Review Chapters 1 and 2 prior to designing a System. If the requirements and specifica-

tions in these two (2) Chapters are not addressed, there is a chance of degraded System performance.

WARNING:

No. Items Comments

Follow Lockout/Tagout and other safety precautions when connecting and/or disconnecting cabling, wiring, and equipment.

Keep torque range between 50% and 75 % of tool capability for best performance and to

1

Select correct tool size.

Determine tool suspension

2

/reaction requirements.

Select correct Control Unit

3

for the tool selected. Select the circuit

4

protectors.

5

Select an adequate PLC.

Design (or review) PLC

6

logic.

Determine Controller

7

mounting requirements.

8

switches.

9

Mount the Controller Units. Refer to recommended installation layout.

compensate for fastening specification revisions. Verify fastener location and tool clearance concerns.

Determination of suspension and reaction requirements is dependent upon end user standard ergonomic design guidelines and preferred supplier lists.

Different tool motors may require different Servo Amplifiers. Ensure the correct one is selected.

Circuit protection for Controller Units should be separate from other units.

Select a PLC which will facilitate direct connection to the FUSION System I/O (24 VDC true low).

A PLC logic program can be written using signal descriptions and timing charts provided.

Keep clearances among units according to the recommended installation layout. End user specific input should be used to determine mounting requirements.

Check the setting before connecting the Unit.

2.4.1

4.4.1

4.4.2

4.4

4.4.3

2.4.1

4.5

4.6

4.7

4.2

4.3

4.10

10

Wire power connections.

11

Wire I/O connections.

12

cables.

13

Turn on the equipment.

14

Input preset data.

15

Verify normal function. Confirm normal operation.

Connect the power cables. VERIFY VOLTAGE PRIOR TO APPLYING POWER.

Connect all I/O wiring. VERIFY VOLTAGE

SOURCE PRIOR TO CONNECTION.

VERIFY POWER IS OFF, then connect cables for

every motor, encoder and preamplifier.

VERIFY WIRING AND THE VOLTAGE OF ALL POWER SUPPLIES PRIOR TO POWERING UP.

Set the preset data for torque, angle, speed, time, etc.

Page 4-2

4.6

4.7

Appendix A

5.1

Chapter 6 Chapter 7

FEC FUSION Operations Manual

4.2 Component Dimensions

The specifications for all of the FUSION standard system equipment are outlined in this Chapter to aid in determining space, mounting & wiring requirements.

4.2.1 CONTROLLER Unit Dimensions

FIG. 4-2-1 Controller Unit Dimensions

Controller weight is 8.6 Kg (18.9lbs.)

The Unit(s) must be mounted with a minimum clearance of 25mm on the left side and 126mm on the right side to allow for proper heat dissipation. If mounting multiple controllers side by side you must leave a minimum clearance of 260mm between the units for clearance when opening the back cover. Programming Cable connections on the front of the Unit require 100mm of clearance. Cable connections on the rear of the Units require 150mm of clearance below the unit for exiting the Rear cover other than straight down. Controller Units must be located at a minimum 300mm from any high transient voltage power source. High transient sources such as relays, AC contactors, AC motor drives, etc. may cause malfunction of the FUSION Controller unit. All motor cables and I/O cables must be run separate from all high transient voltage sources. When locating inside an enclosure, avoid mounting at or near the top where internal enclosure heat is most extreme. The controller of the FUSION System is designed with 4 mounting holes for easy mounting to a back panel using standard 6mm screws.

Chapter 4: System Setup and Wiring (Rev. 2.1)

Page 4-3

Chapter 4: System Setup and Wiring

4.3 Unit Arrangement

** See preceding page for actual unit width

FIG. 4-3 Unit Arrangement

Figure 4-3 provides a reference for the layout of the FUSION System components. The Units may be mounted in any desired configuration as long as the minimum spacing requirements are not neglected. Clearance for opening the controller (260mm) and accessing the back connectors should be maintained as shown.

Page 4-4

FEC FUSION Operations Manual

4.4 Nutrunner (Tool) Dimensions

Tool dimensions and mounting specifications are critical in determining the design of the suspension / reaction equipment required for the tool assemblies. Provide adequate clearance to ensure that the tool assemblies do not come in contact with any object. Failure to provide adequate clearance may result in torque inaccuracies in the monitoring capability of the system, possible damage to the tool assembly, or operator injury.

Customer specific ergonomic guidelines and preferred supplier lists should be used in determining suspension / reaction equipment requirements

WARNING: Torque tools generate large amounts of torque that can cause injury when held in the hand of an operator. Be sure all precautions are taken to ensure torque reaction devices are installed to absorb or suppress reaction torque from operators!

4.4.1 Straight Tool

FIG. 4-4-1 Straight Tool (dimensions in mm)

Chapter 4: System Setup and Wiring (Rev. 2.1)

HFT-TYPE TORQUE SPEED A

010M50-S1 1.0KgM 1800 015M80-S1 1.5KgM 1665 025M80-S1 2.5KgM 900 rpm 363 326 21 1.5 10.6 12.1 6 10 18 50 80

040M80-S 4.0KgM 694 080M80-S 8.0KgM T B A

HFT-TYPE

010M50-S1 015M80-S1 025M80-S1 60 41 9 (2) 46 9.5 (.375) 40 46 50 55 43 230

040M80-S 080M80-S T B A

N

60 41 9 (2) 46 9.5 (.375) 40 46 50 55 43 230 60 41 9 (2) 46 9.5 (.375) 40 46 50 55 43 230

60 41 9 (2) 46 9.5 (.375) 40 46 50 55 43 230

rpm rpm

rpm

O P

B

C

D

E

G

H

J

K

343 306 21 1.5 10.6 12.1 6 10 18 50 80 363 326 21 1.5 10.6 12.1 6 10 18 50 80

363 326 21 1.5 10.6 12.1 6 10 18 50 80

Q

R

S T

V X

Y Z WEIGHT

1.3Kg(2.8lb)

1.4 Kg(3.2lb)

L

Mounting: Tool may be mounted by using a clamp collar located in the area shown in the drawing above. Tolerance for diameter of inside of clamp must be +0.1 to +0.2 of dimension shown as the “clamping area”.

Note: Dimensions shown are subject to change without warning due to design improvements.

Page 4-5

M

Chapter 4: System Setup and Wiring

4

may be mounted by using a clamp collar located in the area shown in the

rawing above. Tolerance for diameter of inside of clamp

of dimension shown in dimension “S”.

Diameter of clamping device

diameter of clamp area or tool damage may result.

Note: Dimensions shown are subject to change without warning due to design improvements.

+0.1 to +0.2

”

WEIGHT

4.4.2 Right Angle Tool

FIG. 4-

HFT-TYPE TORQUE SPEED A

-2 Right Angle Tool (dimensions in mm)

B

C

D

E

F

H

J

K

L

015M50-A1 1.5KgM 1215

025M80-A 2.5KgM 1218

040M80-A1 4.0KgM 648 rpm 426

060M80-A 6.0KgM 446 rpm 426 080M80-A 8.0KgM 330rpm 507 130M80-A 13.0KgM 203 rpm 516

rpm rpm

381 401

HFT-TYPE M

015M50-A1 11 25 38 11

025M80-A 11 25 38 11 040M80-A1 11 25 40 13

060M80-A 18 25 45 13

080M80-A 18 37 73.5 14.5

130M80-A 18 37 73.5 14.5

N

P Q

Mounting: Tool d

Warning:

72 62 247 14 20 16 14 28 72 62 267 14 20 16 14 28 90 69 267 14 20 16 18 36

90 69 267 14 20 16 18 36 125 119 263 18 27 16 22.5 45 125 128 263 18 27 16 22.5 45

R T V W

38 46 50 36 55 43 76 38 46 50 36 55 43 76 40 46 50 36 55 43 76 40 46 50 36 55 43 76 54 58.5 50 36 55 43 76 54 58.5 50 36 55 43 76

X

Y

must not be smaller than the specified “R

Z

must be

9.5 (.374)

12.7 (.50)

1.3 Kg

1.7 Kg

1.9 Kg

3.8 Kg

or “T”

Page 4-6

FEC FUSION Operations Manual

4.4.3 Pistol Tools

The FEC Pistol tool is available in two configurati

tol style. The “T” style is for applications where the tool will be hung using some type of

overhead hanging device and where the tool will be exposed to torques larger than 12 Nm

without a torque reaction device

erator and used for torques smaller than 1

: It is recommended when

other torque reaction devices

duce operator fatigue or injury.

The FEC Pistol tool incorporates the latest “active

duce operator torque reaction to very low levels.

function to apply torque to the fastener. This is extremely effective in applications where the

tool is supported from some type of cable of other balancer.

Smo

may be used in horizontal or vertical applications

Pistol

over 15Nm, weight increases 0.5kg

Chapter 4: System Setup and Wiring (Rev. 2.1)

ons. The “T” style and the standard “P” pi

The “P” type is for applications that will be held by the o

Smoothing” function

ons with target torques over 12Nm to r

Ergonomic smoothing” technology to r

This works by using an electric “pulsing”

(See Parameter data list (7.2.5)

using supplied hanging bracket

s-

Note

for set-up of Ergo-

Tools

“T” Type

HFT-TYPE TORQUE SPEED A

040M80-T 4.0KgM 694 250

* Up to 15Nm –

.

5Nm.

using pistol type tools, that the “Ergo-

are used on applicati

othing function – Data No. 80 - 89)

Tool

Fig. 4.4.3a “T” Type Pistol Tool

B

C

D

E

F G

418 182 60 182 23 20 111 44

Page 4-7

H K

p-

or

e-

.

L

M N WEIGHT

9.5 (.375) 310 12 1.6* Kg

Chapter 4: System Setup and Wiring

The “P” type pistol tool is mainly used for hand

an optional mounting bracket. If held in the hand of an operator

“Ergo

Smoothing function

: It is recommended when using pistol type tools, that the “Ergo

torque reaction devices are used on applications with target torques over 12Nm to reduce

Optional hanging bracket available

applications, but may be hung or supported using

or the tool is not supported by other

Smoothing” function be disabled. (See Parameter data list

Smoothing” function or other

operator

“P” Type Pistol Tool

means, it is recommended that the (7.2.5) for set-up of Ergo-

Note

fatigue or injury.

-held

– Data No. 80 - 89)

-

Fig. 4.4.3b “P” Type Pistol Tool

HFT-TYPE TORQUE SPEED A

015M50-P 1.5KgM 1000 230

B

C

D

E

F G

182 159 55 46 43 3.2 5 12

Page 4-8

H J

K

21 44 1.4 Kg

L WEIGHT

FEC FUSION Operations Manual

Diagram

A basic layout of System

ence drawings can

Follow Lockout/Tagout and other safety precautions when connecting and/or

disconnecting cabling, wiring, and equipment.

The Fusion controller can be connected to various external devices for control and monitoring

the fastening process.

control I/O is required, d

external controllers (PLC or PC Control). Serial RS232 or optional Ethernet is available

for resultant fastening data output.

RS232 connection with a computer runnin

Chapter 4: System Setup and Wiring (Rev. 2.1)

nection is shown in Figure 4

be found throughout this Chapter, and also in Appendix A.

The system will operate with no connection to any external devices. If

ldbus connection is

Additionally, the front panel provides easy access for

g the AFC User Console software.

4.5 Connection

WARNING:

component intercon

-5. Detailed refer-

FIG. 4-5 Connection Diagram

iscrete Inputs / Outputs or optional fie

for

Page 4-9

available

Chapter 4: System Setup and Wiring

Power Requirements and Connections

The Controller uses a standard “computer” power cord which connects to the AC power co

nector located at the back of the unit and to a standard wall outlet.

240VAC 50/60Hz). Power consumption is 80watts

. Inrush current

Do not disconnect power cable while system is in cycle.

DESCRIPTION

FRAME GROUND

240 VAC 50/60Hz

Fig. 4

unit is powered down, the power must not be applied again for at

least five (5) seconds. Repeated power up and power down may temporarily disable a

as a self protection feature

ff for five (5) minutes before making another attempt to power up.

The unit operates on si

idle &

unit does become disabled,

4.6

4.6.1 Controller Unit

gle phase power (1001200watts @ max. Torque

WARNING:

PIN NUMBER

1 2 100 – 3 100 –

NOTE:

After a Controller

(at power on) is 11amps.

-6-1 Controller Unit Power Connector

n-

while

Controller unit turn the power o

Page 4-10

. If a Controller

FEC FUSION Operations Manual

4.7 Wiring PLC I/O

All interface devices must accommodate active true low logic for correct operation with

CONTROLLER

provided for isolated connection to an external controller.

Outputs are rated at 12~24 VDC, 200mA. When activated, open collector sink

outputs (normally high) pull the input device signal low (0 VD

and activated when pulled low (0 VDC).

TB1

aptive screws located at the top and bottom of the

over to a new controller without disconnecting the terminal wires.

The PLC I/O wiring must be routed a minimum of 300 mm away from any transient high vo

tage sources. Cable length must not exceed 50 feet.

DO NOT connect a positive DC

Output signals shown on terminals A11

SELECT inputs are used, these outputs WILL CHANGE DEFINITION

Chapter 4: System Setup and Wiring (Rev. 2.1)

Four output relay

ieldbus interface

C). Inputs are (normally high)

erminal block can be quick disconnected from the Controller by

terminal strip, for quick

B14 are for BANK 1 signals only. If BANK

according to the Bank

FUSION

available.

Once wired, the ing the c

CAUTION:

Unit DC inputs and outputs (I/O).

t

voltage source to the output common.

Optional F

the

contacts are

s are

loosen-

change-

l-

FIG. 4-7-1 Controller Unit PLC Connector

*

Select output table

and the selection of BANK SELECT INPUTS.

–

Page 4-11

Chapter 4: System Setup and Wiring

Reset Input (Normally Open)

between cycles, due

Emergency Stop Input (Normally Open)

Start Cycle Input (Normally Open)

Reverse Spindle Rotation Input (Normally Open)

Input signal used to disable the performance

of the automatic Self

Spindle Bypass Input (Normal Open)

Bank Select Input Signals (Normally Open)

Reset Batch count to the initial condition/Count. D

-

NO

display will be

4.7.1 Explanation of CONTROLLER Unit I/O

INPUT SIGNALS

Pin # SIGNAL NAME DESCRIPTION

When active (on), this signal will clear all fastening data, discrete outputs, and communication buffers. A Zero Check of the torque transducer will be completed. During the Zero Check, the Tool

A1 RESET

ACCEPT and REJECT lamp will light to indicate the performance of the Zero Check. If the System has been disabled by an Abnormal output, the System will not return to normal operation until the Abnormal condition has been corrected, and this signal has been input for 200~500 milliseconds. Do not input this signal to the potential for data loss.

B1 STOP

A2 START

B2 REVERSE

SELF CHECK

A3

DISABLE

B3 BYPASS

A4

BANK SELECT 0

B4

BANK SELECT 1

A5

WORK SELECT 1

B5

WORK SELECT 0

A6

WORK SELECT 3

B6

WORK SELECT 2

A7 NOT USED

This signal must be inactive (off) for controller operation. When this signal is active (on), controller operation will stop, and input/outputs will be disabled.

The Start input automatically resets the previous cycle, clears all data to zero, and initiates the next fastening cycle. The Start input must be maintained "on" for the entire cycle.

The spindle will rotate in an opposite direction for as long as this signal is activated (on) and maintained. (input disabled during RESET)

Check function at the beginning of the fastening cycle.

When active, all functions of this spindle are bypassed, and the Bypass output is active. Programming of the Controller is enabled

These two (2) inputs form a binary code that is used to define the function/definition of outputs for Bank Data 0~7 (A11-B14). This allows up to 32 different output definitions with only 8 discrete outputs (4 Banks, 8 available outputs per Bank). See 4.7.3 Bank Select Table.

Work / Parameter Select Input (Normally Open) These 4 inputs form a binary code which is capable of selecting up to 16 different sets of Fastening Parameters. Refer to Section 4.7.2 Work Sequence Select Table.

B7 WORK OK RESET

A8 NOT USED A9 INPUT COMMON

B9 OUTPUT COMMON A10 DC POWER (+24v) B10 DC POWER (0v)

cleared. (If controller is setup for the work select from TB1, this input MUST be used to reset the batch count)

Input signal common. Connection to +12 ~ 24 VDC required. Output signal common. Connection to 0 VDC required Auxiliary 24VDC power – 0.5amp max. Zero volt common for Auxiliary power

Page 4-12

FEC FUSION Operations Manual

B15

Future Programmable D

ry Contact Relay output

Cycle End

Dry Contact Relay output

Batch Accept Dry Contact Relay output

A17

Relay Contact

Accept Pulse (300

– 500 msec) Dry Contact Relay output

– used to

PARAMETER

WORK SELECT 3

WORK SELECT 2

WORK SELECT 1

WORK SELECT 0

OFF = Disabled

ON =Enabled

A14

BANK DATA 7

B14

BANK DATA 6

A13

BANK DATA 5

B13

BANK DATA 4

A12

BANK DATA 3

B12

BANK DATA 2

A11

BANK DATA 1

B11

BANK DATA 0

Bank Data Output Signals (Normally Open) These output signals designate various fastening conditions and results as determined by Bank Select 0 & 1 (Pins A4 & B4) inputs. Refer to 4.7.3 Bank Select Table for output data descriptions.

Relay Contact “A”

B16 A15

Relay Contact

A16

“CYCLE END”

B17

Relay Contact

B18

“WORK OK”

Rating : 0.3A @125VAC or 1A @ 30VDC

Output when Reverse Mode is active and Operator activates start trigger (used as operator “Auxiliary Output”)

Output after the number of accepts programmed in the Work Count parameter is met. (D-No 74) (Rating as above) Output can be programmed as either “Pulse” or “State” type using the AFC software.

A18

“Pulsed Accept”

replace a QL click style torque wrench. (Rating as above)

Chapter 4: System Setup and Wiring (Rev. 2.1)

OUTPUT SIGNALS

4.7.2 Work / Parameter Select Table

NO.

1 OFF OFF OFF OFF 2 OFF OFF OFF ON 3 OFF OFF ON OFF 4 OFF OFF ON ON 5 OFF ON OFF OFF 6 OFF ON OFF ON 7 OFF ON ON OFF 8 OFF ON ON ON

9 ON OFF OFF OFF 10 ON OFF OFF ON 11 ON OFF ON OFF 12 ON OFF ON ON 13 ON ON OFF OFF 14 ON ON OFF ON 15 ON ON ON OFF 16 ON ON ON ON

Note: TB1 terminal must be enabled. (See Section 7.2.4)

PIN A6

Page 4-13

PIN B6

PIN A5

PIN B5

Chapter 4: System Setup and Wiring

BANK

SEL.

TORQUE





1ST TIME

FINAL TIME

resulted in a Final Time

 











4.7.3 Bank Select Table

Bank Select inputs are used to “multiplex” the output signals allowing up to 32 signals from only 8 physical outputs. By changing the input conditions of the two Bank Select inputs, up to four “Banks” may be selected, changing the definition of each output point.

INPUT

PLC / CONTROLLER UNIT BANK DATA

BANK

NO.

SEL 1

B4

1 OFF OFF

SEL 0

A4

Output

A11~B14



  

 

   



   

 

   

 

  

 

   

NAME OF

SIGNAL

REJECT

ACCEPT

ABNORMAL

READY

BUSY

HIGH REJECT

DESCRIPTION

Output when the fastening result is a REJECT. Indicates that the spindle has failed 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 that the spindle is within the fastening limits. This output remains active until the START signal or RESET signal is input. Output when an Abnormal condition occurs, indicates that the System has detected an internal fault, and can no longer proceed. An Abnormal condition must be corrected before the System will resume normal operation. Output when the system is in READY condition 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 Fastening resulted in a Torque High Reject.

2 OFF ON

 

  



   

  

 

   



   

  

   

LOW REJECT

BYPASS

OVER REJECT

WORK 0

WORK 1

WORK 2

Page 4-14

Output when Fastening resulted in a Torque Low Reject.

Output when the spindle is bypass either via PLC input or the Controller Unit front panel switch.

NOT USED

Output when Fastening resulted in a 1st Time Reject.

Output when Fastening Reject.

Output confirmation of WORK SELECT 0~3 (Pins 9 and 14~16) input selections.

FEC FUSION Operations Manual

BANK

SEL.

ANGLE HIGH

1ST RATE

2ND RATE











ZERO CAL









 

















Chapter 4: System Setup and Wiring (Rev. 2.1)

INPUT

BANK

NO.

SEL 1

B4

SEL 0

3 ON OFF

A4

Output

A11~B14

 

  



   



  

 

   



   

 

   

PLC / CONTROLLER UNIT BANK DATA

NAME OF

SIGNAL

DESCRIPTION

WORK 3

NOT USED

Output when Fastening resulted in an Angle

REJECT

ANGLE LOW REJECT

1ST RATE HIGH REJECT

LOW REJECT

High Reject.

Output when Fastening resulted in an Angle Low Reject.

Output when Fastening resulted in a 1st Torque Rate High Reject.

Output when Fastening resulted in a 1st Torque Rate Low Reject.

4 ON ON



 

  

 

   

  

   

  

   

   

  

   

  

   

HIGH REJECT

LOW REJECT

Output when Fastening resulted in a 2nd Torque Rate High Reject.

Output when Fastening resulted in a 2nd Torque Rate Low Reject.

NOT USED

Outputs when an abnormal condition occurs

ERR

PSET ERR.

RES ERR

TOOL ERR

SV AMP ERR

during the SELF CHECK (CAL and Zero). Outputs when an abnormal condition occurs in the parameter setting. Outputs when an abnormal condition occurs in the resolver. Outputs when a tool related abnormality occurs. Outputs when a servo abnormality occurs, see SV ERR 0~2 codes below.

SV ERROR 0

Outputs a detailed code when a SV AMP ERR

SV ERROR 1

is output. Error code is output in three bits. (See Section 4.7.4 ).

SV ERROR 2

Page 4-15

Chapter 4: System Setup and Wiring

SV ERR

4.7.4 Bank Output Servo Error Table

The Bank Servo Error Table defines the type of servo error (fault) output from Bank 4 Data bits 4-7(see above)

SV AMP ERR

(Data 4)

ON OFF OFF OFF

ON OFF OFF ON

ON OFF ON OFF ON OFF ON ON ON ON OFF OFF ON ON OFF ON ON ON ON OFF ON ON ON ON

OFF - - -

2

(Data 7)

1

(Data 6)

(Data 5)

0

DESCRIPTION

Over current or Controller type mis-

match.

Resolver abnormal.

Controller unit overheated.

Internal voltage level abnormal.

Input voltage abnormal.

Overload.

No error

Page 4-16

FEC FUSION Operations Manual

4.7.5 PLC Wiring Sample

This diagram represents standard I/O connections to a PLC. The 24VDC power can be supplied from the FUSION controller (terminals A10,B10) if total consumption is less than 0.5A.

All inputs and outputs (I/O) are active true low. All interface devices must accommodate active true low logic for correct operation. Outputs are rated at +12~24 VDC, 40mA. When activated, open collector sink outputs (normally high) pull the input device signal low (0 VDC). Inputs are sourced (normally high) and activated when pulled low (0 VDC).

Chapter 4: System Setup and Wiring (Rev. 2.1)

FIG. 4-7-5 PLC Wiring Sample

Page 4-17

Chapter 4: System Setup and Wiring

Data communication ports.

rogramming and

ommunication is performed via an RS

communication to the AFC User Console

An additional port is available on the rear panel of the

put data to a variety of collection devices.

PC Connection

Cabling length should be kept to a minimum

near high signal noise areas such as AC Motor invertors, speed controllers or strong

DB9 Null Modem cables

. No special cabling is required. (These are standard

cables which can be purchased at most computer stores)

See the AFC User Console Manual for more information. (Available for downl

onitoring can be performed utilizing a PC, Laptop or

located on the front

(No cost

that can provide RS232 ou

for AFC User Console Software

and avoid routing

(to a PC running the AFC

Null Modem

oad on the FEC

4.8 RS-232

The FUSION system p Industrial based system. C of the unit. This port provides with a system purchase)

4.8.1 Front Panel DB9 RS232

PIN SIGNAL

1 2 RXD 3 TXD 4 DTR 5 GND 6 DSR 7 RTS 8 CTS 9

Note:

m

232 port

controller

DESCRIPTION

NOT USED

RECEIVE DATA

TRANSMIT DATA

DATA TERMINAL READY (ALWAYS ON)

SIGNAL GROUND

NOT USED

REQUEST TO SEND (ALWAYS ON)

CLEAR TO SEND

NOT USED

(Max 50 Feet)

Software.

t-

RF signals.

Standard User Console Software)

website – www.fec-usa.com)

can be used for this connection

Page 4-18

FEC FUSION Operations Manual

DB9

9P (Male)

Mating Connector: DB

The CTS signal needs to be activated in order for the fastening data to be output. If it

the data will be overwritten in a First In, First Out (FIFO) process. The CTS signal may be

connected to the RTS signal if data is to be “dumped” at every fastening.

Connection with hardware handshake (

Connection without handshake

  

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 !"#

$&%'()

Chapter 4: System Setup and Wiring (Rev. 2.1)

Fastening Data Output)

TERMINAL READY (ALWAYS ON)

4.8.2 Rear Panel

Connector: DB-

1 2 3 4 5 6 7 8 9

Note:

RS232 PC Connection (

-9S (Female)

SIGNAL DESCRIPTION

NOT USED

RXD NOT USED

TXD TRANSMIT DATA

DTR DATA GND SIGNAL GROUND DSR NOT USED

RTS REQUEST TO SEND (ALWAYS ON)

CTS CLEAR TO SEND

NOT USED

with DTR signal)

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B

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C BED

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



3= 



F G 



– data “dumped” (without DTR signal)

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Page 4-19

Chapter 4: System Setup and Wiring

Byte

5

Byte

2

3

Byte

4

4.8.3 Rear Panel RS232 Standard Communication Protocol

Communication protocol from the rear panel RS232 port is as follows;

Speed: 9600bps Parity: None Data Bits: 8 Bit Start Bit: 1 Bit Stop Bit: 2 Bit Error Control: None

The data format from the Fusion system is a formatted ASCII output. This can be connected to a serial printer, computer or other peripheral device. 214 bytes of data is output per fastening using the Standard Format. The data format is described below.

Description

Example

ASCII Data

1 Start Of Text 02H 2 Parameter No. 20H 3 Parameter No. 31H 1 4 Clock – Year* 30H 0 5 Clock – Year* 37H 7 6 / 2FH / 7 Clock – Month* 30H 0 8 Clock – Month* 38H 8

9 / 2FH / 10 Clock – Day* 31H 1 11 Clock – Day* 35H 5 12 Time – Hour* 31H 1 13 Time – Hour* 32H 2 14 : 3AH : 15 Time – Minute* 34H 4 16 Time – Minute* 35H 5 17 : 3AH : 18 Time – Second* 33H 3 19 Time – Second* 30H 0 20 Spindle Number 30H 0 21 Spindle Number 31H 1 22 Judgment Flag1 4FH O 23 Judgment Flag1 30H 0 24 Judgment Flag1 30H 0 25 Judgment Flag1 30H 0 26 Judgment Flag1 30H 0 27 Judgment Flag1 30H 0 28 Batch Count 30H 0 29 Batch Count 34H 4 30 Torque Unit 31 Torque Decimal 32 Rate Decimal

30H 0 32H 2

33H 3 33 Cycle Count 31H 1 34 Cycle Count 33H 3

Description

35 Cycle Count 35H 5 36 Cycle Count 37H 7 37 Peak Torque 31H 1 38 Peak Torque 39H 9 39 Peak Torque 39H 9 40 Peak Torque 39H 9 41 Final Torque 31H 1 42 Final Torque 39H 9 43 Final Torque 39H 9 44 Final Torque 39H 9 45 Final Angle 31H 1 46 Final Angle 39H 9 47 Final Angle 39H 9 48 Final Angle 39H 9 49 1st Rate 31H 1 50 1st Rate 39H 9 51 1st Rate 39H 9 52 1st Rate 39H 9 53 2nd Rate 31H 1 54 2nd Rate 39H 9 55 2nd Rate 39H 9 56 2nd Rate 39H 9 57 3rd Rate 31H 1 58 3rd Rate 39H 9 59 3rd Rate 39H 9 60 3rd Rate 39H 9 61 Rate Sign Flag 62 1st Rate Incr. TQ. 30H 0 63 1st Rate Incr. TQ. 30H 0 64 1st Rate Incr. TQ. 32H 2 65 1st Rate Incr. TQ. 30H 0 66 1st Rate Incr. Ang. 30H 0 67 1st Rate Incr. Ang. 31H 1 68 1st Rate Incr. Ang. 32H 2

Example

ASCII Data

30H 0

Description

Example

ASCII Data

69 1st Rate Incr. Ang. 32H 2 70 2nd Rate Incr. TQ. 30H 0 71 2nd Rate Incr. TQ. 30H 0 72 2nd Rate Incr. TQ. 32H 2 73 2nd Rate Incr. TQ. 35H 5 74 2nd Rate Incr. Ang. 30H 0 75 2nd Rate Incr. Ang. 31H 1 76 2nd Rate Incr. Ang. 30H 0 77 2nd Rate Incr. Ang. 30H 0 78 3rd Rate Incr. TQ. 30H 0 79 3rd Rate Incr. TQ. 30H 0 80 3rd Rate Incr. TQ. 31H 1 81 3rd Rate Incr. TQ. 30H 0 82 3rd Rate Incr. Ang. 30H 0 83 3rd Rate Incr. Ang. 30H 0 84 3rd Rate Incr. Ang. 32H 2 85 3rd Rate Incr. Ang. 31H 1 86 1st Time 30H 0 87 1st Time 30H 0 88 1st Time 36H 6 89 1st Time 35H 5 90 2nd Time 30H 0 91 2nd Time 30H 0 92 2nd Time 32H 2 93 2nd Time 37H 7 94 Rundown Revs 30H 0 95 Rundown Revs 31H 1 96 Rundown Revs 31H 1 97 Rundown Revs 35H 5 98 Offset Torque 30H 0

99 Offset Torque 30H 0 100 Offset Torque 30H 0 101 Offset Torque 30H 0 102 Fastening Mode

30H 0

Page 4-20

FEC FUSION Operations Manual

Byte

4

Byte

Chapter 4: System Setup and Wiring (Rev. 2.1)

Description

103 104 105 106 107 Peak TQ. Lo Limit 31H 1 108 Peak TQ. Lo Limit 31H 1 109 Peak TQ. Lo Limit 30H 0 110 Peak TQ. Lo Limit 30H 0 111 Peak TQ. Hi Limit 31H 1 112 Peak TQ. Hi Limit 34H 4 113 Peak TQ. Hi Limit 30H 0 114 Peak TQ. Hi Limit 30H 0 115 Final TQ. Lo Limit 30H 0 116 Final TQ. Lo Limit 30H 0 117 Final TQ. Lo Limit 30H 0 118 Final TQ. Lo Limit 30H 0 119 Final TQ. Hi Limit 32H 2 120 Final TQ. Hi Limit 34H 4 121 Final TQ. Hi Limit 39H 9 122 Final TQ. Hi Limit 38H 8 123 Standard Torque 31H 1 124 Standard Torque 32H 2 125 Standard Torque 30H 0 126 Standard Torque 30H 0 127 128 129 130 131 Snug Torque 30H 0 132 Snug Torque 133 Snug Torque 134 Snug Torque 135 Threshold Torque 30H 0 136 Threshold Torque 32H 2 137 Threshold Torque 30H 0 138 Threshold Torque 30H 0 139 Crossover Torque 30H 0 140 Crossover Torque 36H 6

Cal Value 32H 2 Cal Value 34H 4 Cal Value 35H 5 Cal Value 32H 2

1st Torque 30H 0 1st Torque 36H 6 1st Torque 30H 0 1st Torque 30H 0

Example

ASCII Data

35H 5 30H 0 30H 0

Byte Numbers 2 – 106 = actual fastening data Byte Numbers 107 – 213 = PRESET (limit) data

*Date & Time only with clock (RTC) module installed in Fusion Controller

1-5

See next page(s) for explanation

Description

141 Crossover Torque 30H 0 142 Crossover Torque 30H 0 143 2nd Rate Start TQ 30H 0 144 2nd Rate Start TQ 36H 6 145 2nd Rate Start TQ 30H 0 146 2nd Rate Start TQ 30H 0 147 Angle Low Limit 30H 0 148 Angle Low Limit 30H 0 149 Angle Low Limit 30H 0 150 Angle Low Limit 35H 5 151 Angle High Limit 30H 0 152 Angle High Limit 31H 1 153 Angle High Limit 30H 0 154 Angle High Limit 30H 0 155 Standard Angle 30H 0 156 Standard Angle 30H 0 157 Standard Angle 30H 0 158 Standard Angle 30H 0 159 160 161 162 163 Crossover Angle 30H 0 164 Crossover Angle 30H 0 165 Crossover Angle 30H 0 166 Crossover Angle 30H 0 167 Correction Angle 30H 0 168 Correction Angle 30H 0 169 Correction Angle 30H 0 170 Correction Angle 30H 0 171 2nd Rate Start Ang. 30H 0 172 2nd Rate Start Ang. 30H 0 173 2nd Rate Start Ang. 30H 0 174 2nd Rate Start Ang. 30H 0 175 3rd Rate Start Ang. 30H 0 176 3rd Rate Start Ang. 30H 0 177 3rd Rate Start Ang. 30H 0 178 3rd Rate Start Ang. 30H 0

1st Angle 30H 0 1st Angle 30H 0 1st Angle 30H 0 1st Angle 30H 0

Example

ASCII Data

Page 4-21

Description

ASCII Data

179 1st Rate Lo Limit 180 1st Rate Lo Limit 181 1st Rate Lo Limit 182 1st Rate Lo Limit 183 1st Rate Hi Limit 184 1st Rate Hi Limit 185 1st Rate Hi Limit 186 1st Rate Hi Limit 187 1st Rt. Sign Flag 188 2nd Rate Lo Limit 189 2nd Rate Lo Limit 190 2nd Rate Lo Limit 191 2nd Rate Lo Limit 192 2nd Rate Hi Limit 193 2nd Rate Hi Limit 194 2nd Rate Hi Limit 195 2nd Rate Hi Limit 196 2nd Rt. Sign Flag 197 3rd Rate Lo Limit 198 3rd Rate Lo Limit 199 3rd Rate Lo Limit 200 3rd Rate Lo Limit 201 3rd Rate Hi Limit 202 3rd Rate Hi Limit 203 3rd Rate Hi Limit 204 3rd Rate Hi Limit 205 3rd Rt. Sign Flag 206 R/D Rev Lo Limit 207 R/D Rev Lo Limit 208 R/D Rev Lo Limit 209 R/D Rev Lo Limit 210 R/D Rev Hi Limit 211 R/D Rev Hi Limit 212 R/D Rev Hi Limit 213 R/D Rev Hi Limit 214 End Of Text 03H

Example

30H 0 30H 0 31H 1 30H 0 30H 0 35H 5 30H 0 30H 0

30H 0

30H 0 30H 0 31H 1 30H 0 30H 0 35H 5 30H 0 30H 0

30H 0

30H 0 30H 0 30H 0 30H 0 31H 1 39H 9 39H 9 39H 9

30H 0

30H 0 30H 0 30H 0 30H 0 30H 0 30H 0 30H 0 30H 0

Chapter 4: System Setup and Wiring

Output

ASCII

Rear Panel RS232 Standard Communication Protocol (Continued)

1

Judgment Flag

The Judgment Flag uses (6) ASCII bytes for detailed information to identify specific REJECT causes. Below is the definition of byte 1-6 of the Judgment Flag.

Byte 1

Status

Data

(Hex)

Accept O 4F

Reject N 4E

Stop S 53

Bypass B 42

Abnormal A 41

Bytes 2-6 use flags to identify reject causes. It uses an ASCII coded hexadecimal format where the upper bits (of the byte) automatically consider an ASCII “3” or “4” for conversion purposes. (hex numbers 0-9 will automatically generate an ASCII “3x”, and hex letters A-F will automatically generate an ASCII “4x”)

Byte 2

Torque Reject Byte

MSB LSB

LSB

1 : Peak Torque Low Reject 1 : Peak Torque High Reject 1 : Final Torque Low Reject

MSB

1 : Final Torque High Reject

Byte 3

Angle / Rev Reject Byte

LSB

1 : Angle Low Reject 1 : Angle High Reject 1 : Rundown Revolution Low Reject

MSB

1 : Rundown Revolution High Reject

Byte 4

Time Reject Byte

LSB

1 : 1st Time Reject 1 : 1st Time Low Reject 1 : Final Time Reject

MSB

1 : Final Time Low Reject

Byte 5

Torque Rate Reject Byte

LSB

1 : 1st Rate Low Reject 1 : 1st Rate High Reject 1 : 2nd Rate Low Reject

MSB

1 : 2nd Rate High Reject

Byte 6

Torque Rate Reject Byte

LSB

1 : 3rd Rate Low Reject 1 : 3rd Rate High 1 : Not Used

MSB

1 : Not Used

Page 4-22

FEC FUSION Operations Manual

Output

ASCII

Decimal

Output

ASCII

Fastening

Output

ASCII

Chapter 4: System Setup and Wiring (Rev. 2.1)

Rear Panel RS232 Standard Communication Protocol (Continued)

2

Torque Unit

Unit

Data

(Hex)

Nm 0 30

Kgm 1 31

Kgcm 2 32 Ft. Lb. 3 33 In. Lb. 4 34

3

Torque / Rate Decimal

Place

Data

(Hex)

0000. 0 30

000.0 1 31

00.00 2 32

0.000 3 33

4

Rate Sign Flag

MSB LSB

LSB

1 : 1st Rate Negative 1 : 2nd Rate Negative 1 : 3rd Rate Negative

MSB

1 : Not Used

5

Fastening Mode

Method

Torque

Control

Angle

Control

Data

0 30

1 31

(Hex)

Page 4-23

Chapter 4: System Setup and Wiring

4.8.4 Rear Panel RS232 Abbreviated Communication Protocol

The RS232C output format can be switched between the standard format (preceding page) and the abbreviated format shown below. This function is available in firmware versions 2.22 or later. The table below describes the data set-up for enabling and configuring the abbreviated output format.

Work # Data # Item Setting

00 40 Format selection 0: Standard (214 bytes) Data # 41 ~ 49 Disabled

1:Abbreviated (32bytes) Data # 41 ~ 49 Enabled 00 41 End data selection 0: 0Dh (CR) 1: 0Ah (LF) 3: 0Dh+0Ah (CR & LF) 00 42 Comm. Speed 1: 9600 BPS 2: 19200BPS 3: 38400BPS 00 43 Data bit 0: 7Bit 1: 8 Bit 00 44 Stop bit 0: 1 Bit 1: 2 Bit 00 45 Parity 0: None 1: Even 2: Odd 00 46 Torque data 0: No data 1:Enable data 00 47 Angle data 0: No data 1:Enable data 00 48 Cycle Time data 0: No data 1:Enable data 00 49 Judgment 0: No data 1:Enable data

Example of abbreviated format:

Byte

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Desc. ASCII

Data

Spindle # Work Cycle Count Peak Torque Final Angle

23H 31H 31H 30H 31H 32H 31H 32H 2EH 33H 34H 31H 31H 32H 2EH 33H

Hex

# 1 1 0 1 2 1 2 . 3 4 1 1 2 . 3

Byte

Desc. ASCII

Data

17 18 19 20 21 22 23 24 25 26 27 28 29 30

Not Used Cycle Time Judge

30H 30H 30H 30H 30H 30H 30H 30H 30H 31H 32H 2EH 33H 40H

Hex

0 0 0 0 0 0 0 0 0 1 2 . 3 @

Byte

Desc. ASCII

Data

31 31 31 32

0DH OR 0AH OR 0DH 0AH

Hex

CR LF CR LF

Definition of “Judge” (Byte 30):

@ = Accept G = Stop E = Low Time Reject F = Time Reject P = Bypass K = Angle High Reject J = Angle Low Reject I = Torque High Reject H = Torque Low Reject A = Abnormal X = Other Reject

Page 4-24

FEC FUSION Operations Manual

ASCII

Chapter 4: System Setup and Wiring (Rev. 2.1)

4.8.5 Rear Panel RS232 Alternate Communication Protocol

An alternate communication protocol is available upon set-up in a different “Fastening Function Mode” (See 7.2.5 Fastening Function Version [Work]-00, [D-No]-03) If the system is setup in a “DDK” mode, this protocol becomes the Standard Communication Protocol. This alternate protocol has 79 bytes of data per fastening.

Byte

Desc.

Hex

Data

Byte

1 2 3 4 5 6 7 8 9 10 11 12 13 14

Cycle Count

30H 30H 30H 31H 20H 20H 30H 31H 20H 20H 20H 31H 20H 20H

0 0 0 1 0 1 1

15 16 17 18 19 20 21 22 23 24 25 26 27 28

Spindle Number

Work

Number

Desc. ASCII

31H 32H 2EH 33H 34H 4CH 20H 20H 20H 20H 35H 30H 48H 20H

Hex

Data

Byte

Desc. ASCII

Data

Byte

Desc. ASCII

Data

Byte

Desc. ASCII

Data

29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44

31H 32H 2EH 33H 34H 20H 20H 20H 30H 2EH 31H 32H 33H 20H 20H 20H

Hex

45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60

30H 2EH 31H 32H 33H 20H 20H 20H 30H 2EH 31H 32H 33H 20H 20H 20H

Hex

61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79

20H 31H 30H 2EH 30H 20H 20H 20H 20H 20H 32H 2EH 30H 20H 20H 20H 58H 0DH 0AH

Hex

Final Judgment: “X” Reject = 58H, “O” Accept = 4FH, “A” Abnormal = 41H, “S” Stop=53H, “B” Bypass=42H Judge: “H” High Reject= 48H, “L” Low Reject= 4CH (H = Hex)

Peak Torque Judge

1 2 . 3 4 L 5 0 H

Final Torque Judge

1 2 . 3 4 0 . 1 2 3

2nd Rate Judge

0 . 1 2 3 0 . 1 2 3

1st Time Judge

1 0 . 0 2 . 0 X

Final Angle Judge

1st Rate Judge

3rd Rate Judge

2nd Time Judge

Final

Judge

CR LF

Page 4-25

Chapter 4: System Setup and Wiring

4.9 T/A MON. DB9 Connector - External Torque/Angle/Current/Speed Output

This auxiliary connector is used to output Torque, Angle, Current & Speed signals to external equipment for monitoring purposes (X-Y Plotter, etc). The signals output from this connector are the same signals that the system receives during the fastening process. This connector is not required for the system to operate.

No

1 None 2 None 3 Angle Pulse Out Angle Pulse Monitor TTL 4 Angle CW/CCW Out CW/CCW Monitor TTL 5 GND Out Ground 6 None 7 Current Monitor Out -10V]+10V 10V=(HFC-EC-16 16A )

8

9 Torque Monitor Out Max Torque=2.5V

Signal In/Out Description

Speed Voltage Monitor

Out

-10V

]

+10V 10V=Max Speed

Torque voltage (Analog voltage) Monitor voltage represents zero torque to full-scale torque by an electric potential difference of 2.5V. Zero Level voltage is voltage measured with the nutrunner stopped with no load. Angle pulse (TTL signal 0V or 5V) Angle pulse is output at 1 pulse per degree. It differs slightly from the actual angle of rotation displayed from the controller. Normal/reverse revolution pulse (TTL signal 0V or 5V) A 5v (High) signal is output during CW revolution, and 0V (Low) signal is output during CCW revolution.

Angle and direction are output as shown below;

TOOL STOPCW

CCW

ANGLE PULSES

CW/CCW

Page 4-26

FEC FUSION Operations Manual

Unit DIP Switch

controller u

purposes. The number is set using the DIP switch located

of the unit.

DIP switch located on printed

ircuit board through access

anel at the back of unit.

Unit DIP Switch positions 1 ~ 3

DIP switch positions 1 ~ 3 are used for setting the special configuration features as defined in the

. The DEFAULT setting is switch 1

Check

Zero

NOT USED

Disable Motor Ramp Down

Enables dynamic brake for motor speed changes.

Used for applications which overshoot standard torque

Will reduce Motor/Tool life

Disables Dynamic brake during speed changes (Default)

unit must be powered off and on

Chapter 4: System Setup and Wiring (Rev. 2.1)

controllers

behind the access panel

again for the DIP switch changes to be

4.10 Controller

In a multiple zational on the back panel

c p

Setting.

nit system, it may be beneficial to address the

FIG. 4-10 Dip Switch settings

for organi-

4.10.1 Controller

• following explanation

• DIP Switch 1 - Zero

o ON – Expanded o OFF – Normal

• DIP Switch 2 -

o ON – Not Used o OFF – Not Used

• DIP Switch 3 -

o ON -

-

o OFF -

Note: The Controller initialized.

acceptance window selection.

Check acceptance window

.

– 3 OFF.

Page 4-27

Chapter 4: System Setup and Wiring

4.10.2 Controller Unit DIP Switch positions 4 ~ 8

DIP switch positions 4 ~ 8 are used for setting the

described in the following table.

from multiple spindles whereas the data needs to be identified differently between each spi

Do not set two spindles with the same address.

unit must be powered off a

Unit

DIP SWITCH NUMBER

OFF

ON

OFF

ON

OFF

ON

OFF

ON

unit spindle address number as

This can be beneficial if fastening data is being collected

nd on again for the DIP switch changes

Unit

8

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

dle.

Note: The Controller to be initialized

No.

4 5 6 7

1 OFF OFF OFF 2 OFF OFF OFF 3 OFF OFF OFF 4 OFF OFF ON 5 OFF OFF ON 6 OFF OFF ON 7 OFF OFF ON 8 OFF ON OFF

9 OFF ON OFF 10 OFF ON OFF 11 OFF ON OFF 12 OFF ON ON 13 OFF ON ON 14 OFF ON ON 15 OFF ON ON

Controller

8 4 5 6 7

ON 16 ON OFF OFF OFF OFF 17 ON OFF OFF OFF ON 18 ON OFF OFF ON

OFF 19 ON OFF OFF ON

ON 20 ON OFF ON OFF OFF 21 ON OFF ON OFF ON 22 ON OFF ON ON

OFF 23 ON OFF ON ON

ON 24 ON ON OFF OFF OFF 25 ON ON OFF OFF ON 26 ON ON OFF ON

OFF 27 ON ON OFF ON

ON 28 ON ON ON OFF OFF 29 ON ON ON OFF ON 30 ON ON ON ON

No.

31 ON ON ON ON

DIP SWITCH NUMBER

n-

Page 4-28

FEC FUSION Operations Manual

Connection

Tools are connected to the

and

number and should be connected to the corresponding

supported to reduce fatigue points

allow the cable to move, but yet hold it in place. Cable tie

point leading to premature cable failure.

Do not make motor connections with the power on. Turn off all controller power

before attempting to connect or disconnect any motor cables

able length:

Main Cable Straight Female Plug

Main Cable Straight Female

Main Cable Straight Female Plug

Main Cable 90 Degree Female Plug

Extension Cable Straight Female Plug

Extension

Extension Cable 90

Wave Washer (Part # WAV

sired. The washer must be split and inserted by threading the washer

Chapter 4: System Setup and Wiring (Rev. 2.1)

cable. One cable connects to the

specific

and

should be loose enough to

too tight cause a stress

or tool damage may occur.

25036) can be used to tighten the tool side twist lock connector is d

underneath the twist lock rol

4.11 Tool Cable

• ducer preamp, motor fication

• Cables should be

WARNING:

Recommended c Maximum cable length:

Fusion Cable List

FEC Part #

FEB-1309-M5 FEB-1309-M10 FEB-1309-M15

FEB-1311-M5 FEB-1311-M10 FEB-1311-M15

FEB-1310-M1 FEB-1310-M2 FEB-1310-M3 FEB-1310-M5 FEB-1310-M10

FEB-1312-M1 FEB-1312-M2 FEB-1312-M3 FEB-1312-M5 FEB-1312-M10

ers.

controller using one

resolver. Each cable should be labeled with a

controller

. Cable tie points

points that are

75’ or less.

100’ (must be free from Electrical Noise)

Cable Description Length

Plug

Cable Straight Female Plug

Degree Female Plug Degree Female Plug Degree Female Plug Degree Female Plug Degree Female Plug

-

Page 4-29

5 meter 10 meter 15 meter

1 meter

2 meter

3 meter

5 meter 10 meter

1 meter

2 meter

3 meter

5 meter 10 meter

torque trans-

spindle or identi-

tool.

e-

l-

Chapter 4: System Setup and Wiring

4.11.1 Cable Installation Guidelines

Improper installation of cables can reduce cable life expectancy drastically. The following guidelines should be used when installing cables.

• The cables must be prepared for installation without twists, bends or kinks. Upon unpacking the cables, any tie wraps used in shipping should be removed.

• Before inserting the cables in the cable tray, cable track or other overhead suspension, it is important that the cables be laid out or hung prior to installation long enough to relax any stresses and remove any “memory” resulting from packaging, transit or storage. If the cables cannot be relaxed, they should be shook out by grasping the cable length at its mid point and shaking the cables as you move to each end. Then, wrap the end of each cable with masking tape and make alignment marks on the top of each end. Maintain this alignment throughout the installation to assure cable is not being twisted.

• The minimum recommended bending radius of the cable should not be exceeded. The minimum bend radius is calculated by multiplying the cable’s outer diameter by ten (Rmin = O.D. x 10). When multiple cables are run together, the largest diameter cable in the bundle should be used for calculating bend radius. Minimum bend radius must be increased when repeated flexing occurs at a given point on the cables.

• Use the most direct path when routing cables.

• Do not weave cables between or wrap around one another.

• Route cables and connectors away from liquid of any type.

• Protect cable connectors from any impact or abrasion that may cause damage (IE: pulling

cables through cable tray and dropping cables to the floor).

• Check cable route for possible chafing or abrasion points. Re-route or protect cable at these points with a nylon cable wrap or similar means to avoid future cable damage.

• The use of plastic cable ties (ty-wraps) should be avoided if possible. The use of Velcro straps is preferable. If the use of plastic cable ties cannot be avoided, the following practices should be followed:

o Cables should not be tied so tight as to cause indentations in the cable jack-

et. Flexible cables are designed to move inside their cable jacket. If this movement is restricted, wires in the cable may become stressed and break.

o Plastic cable ties around grouped cables should be used minimally so that

cables have the ability to move individually rather than all as one.

o An acceptable method is to include the use of a flexible tubing or sleeve be-

tween the plastic cable tie and the cable(s).

• Do not tie or hang anything, whatsoever, from tool cables.

• Avoid running cables directly next to high voltage or high frequency lines.

• Cables must be supported near connectors in panel and at tool to avoid strain on connec-

tion points.

• Certain tool operations may have foreseeable cable damaging aspects which are unavoidable. In these situations a shorter “extension” cable can be provided with the expectation of replacing this intermediate, less expensive cable as required. The use and proper placement of an “extension” cable will also make cable replacement less time consuming.

Page 4-30

FEC FUSION Operations Manual

Chapter 4: System Setup and Wiring (Rev. 2.1)

4.11.2 Considerations for Cable Trolleys

• Cables hung by festooning type systems must be secured to the individual cable trolley and positioned to avoid sharp bends and eliminate or minimize any torsion twisting.

• Restraint cords should be used in between cable trolleys to limit movement and reduce the stress on cables as they are extended. Restraint cord lengths must always be shorter than the length of cable hung between trolleys.

• Cable loops should be consistent in length,typically not exceeding 5 feet in depth between trolleys. Sufficient number of trolleys should be used in a system to support the entire length of moving cable and to allow relaxed stacking/festooning of cable loops when tool is in the retracted position.

• One trolley should be fixed to the runway rail to eliminate tugging on or stretching of cables.

4.11.3 Considerations for Flexible Cable Tracks

• Cables must under no circumstances have the opportunity to tangle. Therefore the clearance height of a track compartment with several similar cables next to one another must not amount to more that one and a half times the cable diameter.

• There should be an “all around” minimum clearance between cables of 10% of the cable’s diameter.

• Cables and hoses with very different diameters should be laid separately. Separation is achieved by using Flexible Track separators. The following rules should be followed for cable separation:

o If (Cable 1 Diameter) + (Cable 2 Diameter) > 1.2 x Track Inner Height, then

no separation is necessary.

o If (Cable 1 Diameter) + (Cable 2 Diameter)  1.2 x Track Inner Height, then a

horizontal or vertical separator must be used to reduce the inner height, thereby preventing the entanglement of the cables.

• The cable weight should be symmetrically distributed along the width of the track.

• Cables must be able to move freely along the radius.

• The cables must be secured with strain relief at both ends. In exceptional cases, the

cables may be fixed with strain relief at the moving end only. Unless using a Flexible Cable Track with integrated strain relief, a gap of 10~30 x cable diameter between the end of the bending segment and the fixed point is recommended for most cables.

•

Under no circumstances should excess cable be put into a Flexible Cable Track.

4.11.4 Considerations for Cable Trays & Ladders

• Cable drop out panels should be used where cables enter and exit a tray or ladder system. Sharp bends need to be avoided whenever possible.

• Cables should be secured at both entry and exit points of a tray or ladder.

• Avoid running high voltage or high frequency cables in the same tray or ladder as signal or

control cables unless cables are designed for such environments.

• If excess cable is to be stored in a tray or ladder, do not tightly coil cable. Cable should be laid in as large of a loop as possible.

Page 4-31

Chapter 4: System Setup and Wiring

4.11.5 Tool Cable - Preamplifier Pins.

The preamplifier connection links the controller to the tool torque transducer to: a) Read the torque voltage values from the preamplifier. b) Test the preamplifier full scale torque via the calibration function. c) Test the preamplifier zero level by the zero level check function. d) Read and Write the EEPROM memory located in the preamplifier.

PIN DESCRIPTION

T TRx +

J TRx -

G GND

F +12VDC H TORQUE OUT E -12VDC

4.11.6 Tool Cable - Motor Pins

The Motor connection provides control power to the motor.

PIN DESCRIPTION

N FRAME GROUND

L W PHASE

M V PHASE

A U PHASE

4.11.7 Tool Cable - Resolver Pins

The resolver connection handles the signals which define the rotation of the motor. The controller provides a signal to the winding of the rotor. As the rotor spins, two sets of stators electrically shifted 90 degrees generate a sine wave and a cosine wave signal. Both signals are processed by the controller to define position and speed of the motor.

PIN DESCRIPTION

C ROTOR (R1) P STATOR (S2) V STATOR (S1) D ROTOR R2 R STATOR S4 S STATOR S3 N SHIELD

Page 4-32

FEC FUSION Operations Manual

4.12 Firmware Flash Connector (CN8)

Upgrades or revisions to Firmware are handled easily with the on board Flash connector located behind the access panel on the bottom of each controller 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.

FIG 4-12: CN8 location (CONTROLLER) unit bottom view).

Page 4-33

Chapter 4: System Setup and Wiring (Rev. 2.1)

Chapter 4: System Setup and Wiring

4.13 SYNC Connector

The Sync connector is provided for a means to synchronize more than one spindle during the fastening process. Synchronized fastening allows spindles to synchronize at a preset torque before attempting to reach the next target or final torque. For synchronized fastening operation using individual Fusion controllers, the SYNC terminals must be wired between all affected spindles.

The SYNC signals are Bi-directional signals for synchronized fastening (5V, TTL signal).

1. At the start of the cycle until reaching the synchronization point (1st torque), the SYNC signal is ON (LOW condition) to stop other Fusion Units from continuing to the second step (wired OR).

2. When the 1st torque is reached, the signal works as an input signal. If it reads LOW meaning that other Fusion units have not reached 1st torque yet - the Fusion unit stays in the standby state waiting for all connected spindles to reach first torque.

When the SYNC signal is HIGH (all Fusion units have completed the first step), all units simultaneously start the second step.

CN6 (Sync Connector)

PIN DESCRIPTION

1 Sync Signal (5V TTL) 2 Not Used 3 Sync Common (0v) 4 Frame Ground (FG)

Spindle SYNC signals are connected in series from one spindle to the next.

Fig. 4.13 Sync Connector

Page 4-34

FEC FUSION Operations Manual

4.14 Options – Ethernet card

An optional Ethernet card is available for fastening data communication over an Ethernet network (TCP/IP – 10 / 100BaseT). Current developed communication protocols include ToolsNet Open Protocol (Atlas Copco), Q-DAS (Qs-Stat), FECNet (proprietary protocol), Part ID / Model select via Ethernet as well as custom protocols as required by customer specifications.

The Ethernet module is installed in the back of the controller located in the top right auxiliary opening. (The Real Time Clock module (RTC) should be removed when using an Ethernet card module.) Connections are made to the RS232 port as well as the TB1 terminal strip.

The Ethernet module is set-up using an onboard browser - based configuration firmware that allows a laptop to connect to the module by an Ethernet connection and set-up the module without installing additional software. This configuration allows you to set-up the Ethernet module to communicate over various networks (described above).

For configuration, an Ethernet CROSSOVER cable (FEC Part # A3X126-07-YLW-M) must be used between the configuration computer and the Ethernet module.

Chapter 4: System Setup and Wiring (Rev. 2.1)

Fig. 4.14 Ethernet Configuration

Page 4-35

Chapter 4: System Setup and Wiring

4.14.1 Ethernet Set-up of PC to Communicate to Ethernet Module

The PC used to configure the Ethernet module must have the Ethernet TCP/IP settings configured for the following to communicate to the Fusion Ethernet module. (See you network administrator or Windows® support for detailed information to set-up your Ethernet port if you are unfamiliar with Ethernet port set-up. You may also request the “Fusion Ethernet Module Set-Up Procedure” from FEC for more detail)

PC Ethernet Set-up

IP address: 10.1.1.1 Subnet mask: 255.255.255.0 Default Gateway: 10.1.1.1

Once the PC is configured and connected to the Ethernet Module using an Ethernet crossover cable, you can use your web browser (Ex. Internet Explorer) to configure the Ethernet module including the network IP address , Station Name, etc.

Open the web browser and put this address in the address bar ;

This screen should appear:

If this screen does not appear, re-check your cables and connection. (See the “Fusion Ethernet Module Set-Up Procedure” from FEC for more detail)

Note: If this screen does not show up, the IP address setup of the Fusion Ethernet module may have already been changed. The IP configuration setup of the Fusion Ethernet Module can be reset to default by putting a jumper wire between pin 3 and 5 of the Fusion Ethernet I/O “Power & I/O” connector at power up.

Once the Ethernet module is configured for the network you are connecting to, you can disconnect the PC and cycle power. Upon the next power-up, the Ethernet module can be connected to the configured network using the IP address that was configured.

Page 4-36

FEC FUSION Operations Manual

4.14.2 Ethernet Module Connection

The Ethernet Module connections are shown below. Note that the power for the module is supplied from the Fusion controller TB1 terminal. Optional Work Select terminations only need to be made if the desired Ethernet protocol requires selection of work selects by Ethernet.

Chapter 4: System Setup and Wiring (Rev. 2.1)

Fig. 4.14.2 Ethernet Module Connection

Connection to an Ethernet network is done by using the RJ-45 Ethernet port on the Ethernet module. (Set-up of the TCP/IP configuration must be completed in the module set-up before communication can take place) After Connection to an Ethernet network, the Ethernet status is displayed on the Ethernet Status display LED’s located just above the RJ-45 Ethernet connection port (shown to the left of the Ethernet port on the drawing above)

Ethernet Status LED

Link

Active

Link: LED is “ON” (solid) when link is established Active: LED flashes during data transmission

Page 4-37

Chapter 4: System Setup and Wiring

4.15 Options – Fieldbus Interfaces

The Fusion controller is able to operate under different Input/Output control structures through use of a modular I/O interface board installed in the rear of the unit. With the introduction of “Open” communication networks known as “Fieldbus”, the direct interfacing to these networks became necessary. FEC integrated many of these Fieldbus directly into our system through use of a modular I/O board interfacing these networks directly to our I/O. The available I/O interfaces are: Profibus, & Allen Bradley Remote I/O. (others available Contact FEC for additional Fieldbus requirements) 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 PLC/CPU. Some of the Fieldbus interfaces are also capable of sending limited fastening data as well as I/O control. The Fieldbus interface module is factory installed in the rear auxiliary opening (where the real time clock (RTC) module normally resides). With a fieldbus interface installed, the real time clock is installed internally with the RTC cable extending through the fieldbus cover plate for connection to the rear real time clock connector.

Fieldbus interface module is factory-installed in this auxiliary slot.

Note: With the fieldbus module installed for I/O control, the I/O on Terminal TB1 is still enabled

Fieldbus Link Status

The Fusion controller display has a special function for displaying the Fieldbus link status whether the controller is connected and active on the fieldbus network or not.

Count / D-NO.

The COUNT/D-NO LED on the front of the controller indicates the fieldbus link status. The two decimal points will illuminate when the Fieldbus link is DISABLED. Check all connections and configurations for proper set-up.

Page 4-38

FEC FUSION Operations Manual

4.15.1 Fieldbus Interfaces – Profibus-DP

The Profibus-DP communication interface allows slave connection to an industrial ProfibusDP 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 switch. Baud rate is auto detected from the master and no user setup is required. Module & Network status LED’s provide network diagnostics. Maximum I/O data is pre-configured for the FUSION system. FEC uses 16 Bytes (128bits) for Fusion OUTPUTS (Fusion to PLC) which includes Binary Integer output of both Fastening Torque & Angle. Fusion INPUTS (PLC to Fusion) uses 4 Bytes (32 bits). The I/O signal map defines what signals/data for each address. (See below)

Note: The Profibus-DP interface is implemented according to the Profibus-DP EN 50 170 (DIN 19245 Part 1) specification.

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

PROFIBUS CONNECTOR

TERMINATION SWITCH

ADDRESS SETTING

LED INDICATORS

Profibus Interface Board

Page 4-39

Chapter 4: System Setup and Wiring (Rev. 2.1)

Chapter 4: System Setup and Wiring

Profibus Specifications

Profibus connector

- D-Sub

Termination

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

GSD File

Each device on a Profibus network is associated with 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.fec-usa.com (See Support/Download area) (File : hms_1003.gsd)

(the file can also be downloaded directly from HMS - www.hms.se)

Speed 9.6K - 12M baud – auto-selected Nodes 126 Note: Node 126 is reserved for

Distance 200m max. at 1.5Mbit/s extendable with

Cable Shielded Copper Twisted Pair or fiber

Communications Type Master/Slave - EIA RS485 Protocol Version Ver. 1.10 Maximum Cyclic I/O Size 244bytes In, 244 bytes out max.

Data transmission The module only supports cyclic I/O da-

Pin 1 Not Connected Pin 2 Not Connected Pin 3 B- Line Positive RxD/TxD accord-

Pin 4 RTS Request to send Pin 5 GND Bus Isolated GND from RS

Pin 6 +5V Bus Isolated +5V from RS 485

Pin 7 Not connected Pin 8 A- Line Negative RxD/TxD ac-

Pin 9 Not Connected Housing Shield Connected to PE

commissioning purposes only

repeaters.

optic

416 total bytes max.

ta transmission. Note: Limited Coded Binary Integer data is sent in the cyclic I/O data

ing to RS485 Spec.

485 side

side

cording to RS485 Spec.

Page 4-40

FEC FUSION Operations Manual

Status LEDs

Profibus Status LED

Fieldbus Diagnostics Red Indicates faults on fieldbus side LED #4 Flashing Red -

Flashing Red -

On-Line LED #2

Off- Line LED #3

Note: LED #1- Not Used

1sec

2sec

4sec Off Module not online Green Module online and communica-

Off Module is not offline Red Module is offline on the fieldbus

Chapter 4: System Setup and Wiring (Rev. 2.1)

Config. Error - in/out length set at module initialization does not match length in network config. Error in user parameter data parameter length/content does not match network length/content Error in initialization of Profibus communication ASIC

tion OK

Node Address

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

Configuration

FEC Profibus I/O is pre-configured according to the I/O Signal Map (See below). Configuration of the Profibus Master MUST match the configuration of the FEC Profibus slave. In the Profibus Master set-up, input size and output size is set as “byte” 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.

Page 4-41

Chapter 4: System Setup and Wiring

Word

Byte Bit No. Signal Description

Comment

Profibus Signal I/O Map

From Fusion to PLC : 8 Words (16 Bytes – 128 Bits)

0 1 End 1 2 Accept 2 3 Reject 3 4

0

4 5 5 6 Job Cycle Accepted Future 6 7 Job Done Status Aborted Future

0

1

2

3

7 8 0 9 1 10 2 11 Time 1 Reject 3 12 Time 2 Reject

1

4 13 Work Select Bit 0 / Job Bit 0 (echo) Job Function is Future 5 14 Work Select Bit 1 / Job Bit 1 (echo) Job Function is Future 6 15 Work Select Bit 2 / Job Bit 2 (echo) Job Function is Future 7 16 Work Select Bit 3 / Job Bit 3 (echo) Job Function is Future 0 17 Reject 1 18 Accept 2 19 Abnormal 3 20 Ready

2

4 21 Busy 5 22 Torque High Reject 6 23 Torque Low Reject 7 24 Bypass 0 25 Angle High Reject 1 26 Angle Low Reject 2 27 Rate1 High Reject 3 28 Rate1 Low Reject

3

4 29 Rate2 High Reject 5 30 Rate2 Low Reject 6 31 Rate3 High Reject 7 32 Rate3 Low Reject 0 33 Torque Integer bit 0 1 34 Torque Integer bit 1 2 35 Torque Integer bit 2 3 36 Torque Integer bit 3

4

4 37 Torque Integer bit 4 5 38 Torque Integer bit 5 6 39 Torque Integer bit 6 7 40 Torque Integer bit 7 0 41 Torque Integer bit 8 1 42 Torque Integer bit 9 2 43 3 44

5

4 45 5 46 6 47 7 48 0 49 Torque Decimal bit 0 1 50 Torque Decimal bit 1 2 51 Torque Decimal bit 2 3 52 Torque Decimal bit 3

6

4 53 Torque Decimal bit 4 5 54 Torque Decimal bit 5 6 55 Torque Decimal bit 6 7 56 0 57 1 58 2 59 3 60

7

4 61 5 62 6 63 7 64

Outputs Fastening Torque using bi-

nary integer

0 - 999 max.

(number LEFT of decimal only)

Example:

bit 2, 4, 7 Logical "1" = 148

Total Torque including Torque de-

cimal (word3) = 148.38

Outputs Fastening Torque Decimal

value using binary integer

0 - 99 max.

(number RIGHT of decimal only)

Example:

bit 1, 2, 5 Logical "1" = 38

Page 4-42

FEC FUSION Operations Manual

Word

Byte Bit No. Signal Description

Comment

Word

Byte Bit No. Description

Comment

Profibus Signal I/O Map

(Continued)

0 65 Angle Integer bit 0 1 66 Angle Integer bit 1 2 67 Angle Integer bit 2 3 68 Angle Integer bit 3

8

4 69 Angle Integer bit 4 5 70 Angle Integer bit 5 6 71 Angle Integer bit 6

4

Byte

5-7

10-15

From PLC to Fusion: 2 Words (4 Bytes – 32bits)

7 72 Angle Integer bit 7 0 73 Angle Integer bit 8 1 74 Angle Integer bit 9 2 75 Angle Integer bit 10 3 76 Angle Integer bit 11

9

4 77 Angle Integer bit 12 5 78 Angle Integer bit 13 6 79 7 80 81 128

Chapter 4: System Setup and Wiring (Rev. 2.1)

Outputs Fastening Angle value using

binary integer 0 - 9999 max.

Example:

bit 1, 2, 5, 7 Logical "1" = 166

Not Used

0 1 1 2 2 3 3 4

0

4 5 5 6 6 7 Abort Job Reserved for Future Use

0

1

7 8 Reset 0 9 1 10 2 11 3 12

1

4 13 Work Select/Job 0 Job Function is Future 5 14 Work Select/Job 1 Job Function is Future 6 15 Work Select/Job 2 Job Function is Future 7 16 Work Select/Job 3 Job Function is Future 0 17 Stop 1 18 Reset 2 19 Reverse 3 20 Start

2

4 21 Bypass 5 22 Disable Self-check 6 23 7 24 0 25 1 26 2 27 3 28

3

4 29 In 12 Terminal Input 12 not assigned 5 30 In 13 Terminal Input 13 not assigned 6 31 In 14 Terminal Input 14 not assigned 7 32 In 15 Terminal Input 15 not assigned

`

Page 4-43

Chapter 4: System Setup and Wiring

4.15.2 Fieldbus Interfaces – Allen Bradley Remote I/O

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. The network can have up to 240 nodes with valid rack addresses of 0-59. Its maximum communication baud rate is 230K baud with two other settings of 115K & 57.6K baud. Rack addressing & baud rate is selectable using the baud/address selection DIP switch. Module status LED’s provide network diagnostics. Maximum FEC I/O data is 32 inputs & 32 outputs (1/4 Rack). 1/2, 3/4 & Full rack configuration are not supported by the Fusion system.

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)

Allen Bradley Remote I/O interface Board

BAUD/ADDRESS SETTING

LED INDICATION

TERMINATION SWITCH

REMOTE I/O CONNECTOR

Page 4-44

FEC FUSION Operations Manual

AB Remote I/O Specifications

AB Remote I/O connector

Status LEDs

Termination

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

Specifications

Speed 57.6, 115, 230K baud - Selectable Rack Addresses 0-59 Nodes up to 240 1/4 racks Rack Configuration supported 1/4 Distance 57.6k - 3048 meter

Cable 78 ohm Twinax

Communications Type Master/Slave

Pin 1 COM line Blue Pin 2 GND Shield Pin 3 COM line Clear

Chapter 4: System Setup and Wiring (Rev. 2.1)

115K - 1524 meter 230K - 762 meter

Belden #9463 or equivalent

Status LED

Error OFF Normal Operation ON - Red Bus off / Error Active OFF No Communication

Power OFF Power Off

ON - Green Communication Active

ON - Green Power On

Page 4-45

Chapter 4: System Setup and Wiring

Address setting (DIP switch)

SW-3

SW-4 SW-5 SW-6 SW-7 SW-8 MAC ID

. . . . . . .

Baud rate setting (DIP switch)

SW-1 SW-2 Baud rate

Octal Bit Signal Description

Comment

Dip Switch Setting

(LSB)

OFF OFF OFF OFF OFF OFF Address 0* ON OFF OFF OFF OFF OFF Address 1 OFF ON OFF OFF OFF OFF Address 2 ON ON OFF OFF OFF OFF Address 3

ON OFF OFF ON ON ON Address 57 OFF ON OFF ON ON ON Address 58 ON ON OFF ON ON ON Address 59

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

OFF OFF 57.6K ON OFF 115K OFF ON 230K ON ON Reserved

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

I/O Signal Map

From Fusion to PLC – (4 Bytes – 32 Bits)

0 0 End 1 1 Accept 2 2 Reject

I:00

I:01

3 3 4 4 5 5 Job Cycle Accepted Future 6 6 Job Done Status Aborted Future

7 7 10 8 11 9 12 10 Time 1 Reject 13 11 Time 2 Reject 14 12 Work Select Bit 0 / Job Bit 0 (echo) Job Function is Future 15 13 Work Select Bit 1 / Job Bit 1 (echo) Job Function is Future 16 14 Work Select Bit 2 / Job Bit 2 (echo) Job Function is Future 17 15 Work Select Bit 3 / Job Bit 3 (echo) Job Function is Future

0 0 Reject

1 1 Accept

2 2 Abnormal

3 3 Ready

4 4 Busy

5 5 Torque High Reject

6 6 Torque Low Reject

7 7 Bypass 10 8 Angle High Reject 11 9 Angle Low Reject 12 10 Rate1 High Reject 13 11 Rate1 Low Reject 14 12 Rate2 High Reject 15 13 Rate2 Low Reject 16 14 Rate3 High Reject 17 15 Rate3 Low Reject

Page 4-46

FEC FUSION Operations Manual

Octal Bit Description

Comment

I/O Signal Map

(Continued)

From PLC to Fusion – (4 Bytes – 32 Bits)

0 0 1 1 2 2

O:00

O:01

3 3 4 4 5 5 6 6 Abort Job Reserved for Future Use

7 7 Reset 10 8 11 9 12 10 13 11 14 12 Work Select/Job 0 Job Function is Future 15 13 Work Select/Job 1 Job Function is Future 16 14 Work Select/Job 2 Job Function is Future 17 15 Work Select/Job 3 Job Function is Future

0 0 Stop

1 1 Reset

2 2 Reverse

3 3 Start

4 4 Bypass

5 5 Disable Self-check

6 6

7 7 10 8 11 9 12 10 13 11 14 12 In 12 Terminal Input 12 not assigned 15 13 In 13 Terminal Input 13 not assigned 16 14 In 14 Terminal Input 14 not assigned 17 15 In 15 Terminal Input 15 not assigned

Chapter 4: System Setup and Wiring (Rev. 2.1)

Firmware Set-up

Two items are configurable in the set-up of the Fusion controller for the Allen Bradley Remote I/O interface. Both the I/O Rack Starting Quarter and the Last Rack setting is set-up in the system parameter settings.

I/O Starting Quarter

Sets the Starting Quarter for the rack address WORK [00] Data No. [28] “0”: 1st Quarter “1”: 2nd Quarter “2”: 3rd Quarter “3”: 4th Quarter

Last Rack

Sets the Fusion system as the last rack or not on the Remote I/O link WORK [00] Data No. [29] “0”: Not Last Rack “1”: Last Rack

Page 4-47

Chapter 4: System Setup and Wiring

Item

Description

2

1

3

4

5

4.15.3 Fieldbus Interfaces – DeviceNet®

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/Outputs are shown in the following I/O signal map layout.

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 MultiUnit 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)

Interface Board with DeviceNet Daughter Board

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 4-48

FEC FUSION Operations Manual

Twisted

DeviceNet Specifications

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

Maximum Distance

Cable

Communications Type Master/Slave

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

* Actual FUSION Configuration is 16 Bytes of OUTPUTS (128 points) and 4 Bytes of INPUTS (32 points). (See DeviceNet Signal Reference at the end of this chapter for I/O Signal map)

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 support & downloads pages. www.fec-usa.com (file: abs.eds) (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.

500 meters at 125K baud 250 meters at 250K baud 100 meters at 500K baud

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

Chapter 4: System Setup and Wiring (Rev. 2.1)

pair for signal and power

Page 4-49

Chapter 4: System Setup and Wiring

Pin No.

Signal

Wire Color

1 V-

Black

2 CAN_L

Blue

3 Drain/Shield

4 CAN_H

White

5 V+ Red

See “Termination”

Configuration

FEC DeviceNet I/O is pre-configured according to the I/O Signal Map (See below). Configuration of the DeviceNet Master MUST match the size configuration of the FEC DeviceNet slave or the network will not connect/operate properly. In the DeviceNet Master set-up using RSNetworx, set the Input/Output length using the “Polled” option. When setting the DeviceNet Master I/O configuration, Input size refers to FEC output size (ie. Accept, Reject, Busy, etc.) and Output size refers to FEC inputs (ie. Start, Stop, Reset, etc.). See the below screen shots of this configuration using RSNetworx.

DeviceNet Interface Connections

Termination

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

Page 4-50

FEC FUSION Operations Manual

Baud

R

ate SW-1 SW-2

125K

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

Address 1

OFF

ON

Address 2

OFF

ON

OFF

Address 3

OFF

ON ON

… … … … … … …

Addres

s 61 ON ON ON ON OFF

ON

Address 62

ON ON ON ON ON

OFF

Address 63

ON ON ON ON ON ON

Off No power to device

ON

8

5

4

2

3

7

6

1

2 3

4

Chapter 4: System Setup and Wiring (Rev. 2.1)

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

Mac ID Settings

Status LEDs

LED State Description

1 - Reserved - Reserved for future use.

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

2 - Network Status

3 - Module Status

4 - Reserved - Reserved for future use.

Green flashing Online, Not connected Red solid Critical Link Failure Red flashing Connection Timeout

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

Page 4-51

Chapter 4: System Setup and Wiring

Data Bit No. Signal Description

Comment

DeviceNet Signal I/O Map

From Fusion to PLC : 8 Words (16 Bytes – 128 Bits)

0 1 End 1 2 Accept 2 3 Reject 3 4

0

4 5 5 6 Job Cycle Accepted Future 6 7 Job Done Status Aborted Future 7 8 8 9

9 10 10 11 Time 1 Reject 11 12 Time 2 Reject

0

12 13 Work Select Bit 0 / Job Bit 0 (echo) Job Function is Future 13 14 Work Select Bit 1 / Job Bit 1 (echo) Job Function is Future 14 15 Work Select Bit 2 / Job Bit 2 (echo) Job Function is Future 15 16 Work Select Bit 3 / Job Bit 3 (echo) Job Function is Future 16 17 Reject 17 18 Accept 18 19 Abnormal 19 20 Ready

0

20 21 Busy 21 22 Torque High Reject 22 23 Torque Low Reject 23 24 Bypass 24 25 Angle High Reject 25 26 Angle Low Reject 26 27 Rate1 High Reject 27 28 Rate1 Low Reject

0

28 29 Rate2 High Reject 29 30 Rate2 Low Reject 30 31 Rate3 High Reject 31 32 Rate3 Low Reject

0 33 Torque Integer bit 0

1 34 Torque Integer bit 1

2 35 Torque Integer bit 2

3 36 Torque Integer bit 3

1

4 37 Torque Integer bit 4

5 38 Torque Integer bit 5

6 39 Torque Integer bit 6

7 40 Torque Integer bit 7

8 41 Torque Integer bit 8

9 42 Torque Integer bit 9 10 43 11 44

1

12 45 13 46 14 47 15 48 16 49 Torque Decimal bit 0 17 50 Torque Decimal bit 1 18 51 Torque Decimal bit 2 19 52 Torque Decimal bit 3

1

20 53 Torque Decimal bit 4 21 54 Torque Decimal bit 5 22 55 Torque Decimal bit 6 23 56 24 57 25 58 26 59 27 60

1

28 61 29 62 30 63 31 64

Outputs Fastening Torque using bi-

nary integer

0 - 999 max.

(number LEFT of decimal only)

Example:

bit 2, 4, 7 Logical "1" = 148

Total Torque including Torque de-

cimal (word3) = 148.38

Outputs Fastening Torque Decimal

value using binary integer

0 - 99 max.

(number RIGHT of decimal only)

Example:

bit 1, 2, 5 Logical "1" = 38

Page 4-52

FEC FUSION Operations Manual

Data Bit No. Signal Description

Comment

Data Bit No. Description

Comment

DeviceNet Signal I/O Map

(Continued)

0 65 Angle Integer bit 0 1 66 Angle Integer bit 1 2 67 Angle Integer bit 2 3 68 Angle Integer bit 3

2

4 69 Angle Integer bit 4 5 70 Angle Integer bit 5 6 71 Angle Integer bit 6 7 72 Angle Integer bit 7 8 73 Angle Integer bit 8

9 74 Angle Integer bit 9 10 75 Angle Integer bit 10 11 76 Angle Integer bit 11

2

12 77 Angle Integer bit 12 13 78 Angle Integer bit 13 14 79 15 80

2-3

16 81 31 128

Data

From PLC to Fusion: 2 Words (4 Bytes – 32bits)

Chapter 4: System Setup and Wiring (Rev. 2.1)

Outputs Fastening Angle value using

binary integer

0 - 9999 max.

Example:

bit 1, 2, 5, 7 Logical "1" = 166

Not Used

0 1 1 2 2 3 3 4

0

4 5 5 6 6 7 Abort Job Reserved for Future Use 7 8 Reset 8 9

9 10 10 11 11 12

0

12 13 Work Select/Job 0 Job Function is Future 13 14 Work Select/Job 1 Job Function is Future 14 15 Work Select/Job 2 Job Function is Future 15 16 Work Select/Job 3 Job Function is Future 16 17 Stop 17 18 Reset 18 19 Reverse 19 20 Start

0

20 21 Bypass 21 22 Disable Self-check 22 23 23 24 24 25 25 26 26 27 27 28

0

28 29 In 12 Terminal Input 12 not assigned 29 30 In 13 Terminal Input 13 not assigned 30 31 In 14 Terminal Input 14 not assigned 31 32 In 15 Terminal Input 15 not assigned

Page 4-53

Chapter 4: System Setup and Wiring

(Blank Page)

Page 4-54

FEC FUSION Operations Manual Chapter 5: Power Up and Initial Checks (Rev. 2)

Chapter 5: Power Up and Initial Checks

Page 5-1

Chapter 5: Power Up and Initial Checks

cabling, wiring, and equipment.

Each item below lists the manual Section(s) that will provide a reference for that specific item.

Connection

Damage may occur if the 24 VDC and 0 VDC Commons are improperly co

it DIP switch settings (4.10)

Verify that the eight (8) DIP switches visible

each unit are set to indicate the appropriate spindle number and options.

CONTROLLER DIP Switch setting.

Interface (PLC) connection (4.7)

CONTROLLER

3. Check connections between the tool and the

cable (resolver/ motor and transducer) connecting the tool and

secure.

appropriate TOOL

If the layout contains moveable parts, visually in

there is proper clearance and that cables have sufficient length. If movement would

create any excessive stress on a cable, or create any potential for damage to the system

or other components in the layout, then make a

Do not make motor connections with the power on. Turn off all controller

power before attempting to connect or disconnect any motor cables or tool damage may

4. Check the input voltage (3.

t power is properly connected (4.

Ensure input power voltage to the

unit is powered down, the power must not be applied again

for at least five (5) seconds. Repeated power up and power down

as a safety precaution

disabled, keep the power off for five (5) minutes, then power on again to reset the fault.

and other safety precautions when connecting or

through the rear panel removable plate

Section 4.10

unit I/O Interface wiring is connected to the corresponding

3.

the correct

spect all components to ensure that

may temporarily dis

unit does become

5.1 Before Powering On

WARNING:

disconnecting

Also refer to Section 4.5 Caution:

nected.

1. Verify CONTROLLER Un

•

Follow Lockout /

Tag out

Diagram.

n-

of

2. Confirm

• Verify that the PLC terminals.

CONTROLLER unit (section

1.2)

• Verify that the Single CONTROLLER unit is connected to the

If using multiple systems, ensure that

and CONTROLLER unit.

cable is

•

ppropriate adjustments.

WARNING:

occur.

1.2, 4.6)

• Verify inpu

•

CONTROLLER Units is 100~230 VAC.

6.1).

NOTE:After a CONTROLLER

ble the CONTROLLER unit

,

. If a CONTROLLER

a-

Page 5-2

FEC FUSION Operations Manual Chapter 5: Power Up and Initial Checks (Rev. 2)

5.2 Initial Data Setting

After completion of the System verification/power on procedure in Section 5.1, the system is ready for the input of data required for the fastening operation. Chapters 6 and 7 give details on the types of information required, and the procedure for entering data into the System. The system will not run until this data is correctly set-up.

NOTE: Most FUSION systems are delivered with application-specific fastening data already setup (if provided by customer). This set-up data is considered preliminary and should be adjusted according to actual process / part runs for optimal performance.

After the system is setup with the appropriate data, perform the following procedure.

1. Check the transducer ZERO output.

• Press the RESET button on front of the Keyboard-display Unit. The CONTROLLER unit will output a number (voltage) to the DATA display WITHOUT the “ABN” LED displayed (See NOTE 1 below.)

2. Check the transducer CAL output.

• Press the CAL button on front of the Keyboard-display Unit. The CONTROLLER Unit will output a number (voltage) to the DATA display WITHOUT the “ABN” LED

NOTE 1: If the Zero and/or Cal check results in an "ABNORMAL" LED output from the

WARNING:

3. Check manual reverse operation.

A. Set the Tool assembly to Reverse Mode.

1. Momentarily depress the Reverse pushbutton switch on the Tool Assembly.

2. The Tool Assembly light ring should be flashing to indicate Reverse Mode

B. Press the manual Start switch on the Tool Assembly while the tool is in Reverse

1. Verify that the spindle is turning in the appropriate direction (opposite the

4. Verify operation of manual start.

1. Momentarily depress the Reverse pushbutton switch on the Tool Assembly.

2. The Tool Assembly light ring should not be flashing (flashing indicates Re-

B. Press the manual Start switch on the Tool Assembly while the tool is in Fastening

1. Verify that the spindle is turning in the appropriate direction for fastening.

5. Verify System operation by external commands (not required for normal operation).

displayed (See NOTE 1 below.)

CONTROLLER unit refer to Section 9 for guidance.

VERIFY THERE ARE NO PERSONNEL OR OBSTRUCTIONS IN THE TOOL AREA

PRIOR TO ACTIVATING A SPINDLE OR OTHER MOVEABLE COMPONENT.

has been selected.

Mode.

preset (parameter) direction),

A. Set the Tool assembly to Fastening Mode.

verse Mode has been selected)

Mode.

• Confirm that the equipment operates correctly when PLC inputs are activated (as required). Use the PLC to perform all of the functions (Start, Work Sel, etc.) that will be utilized in system operation.

• Confirm all PLC Output signals (Accept, Reject, Ready,etc.) that will be used in system operation.

Page 5-3

Chapter 5: Power Up and Initial Checks

(Blank Page)

Page 5-4

FEC Fusion Operations Manual Chapter 6: Fastening Instructions (Rev. 2)

Chapter 6: Fastening Instructions

Page 6-1

Chapter 6: Fastening Instructions

is user programmable to select from two different fastening methods, r

ferred to as Torque Control and Angle Control methods.

ntal step

NOTE: All setting recommendations are based upon common fasten

Applications that experience high Prevailing torque, excessive joint compre

other unique characteristics must be set

In Torque Control method, fastening is performed based upon attaining a desired torque va

ncremental steps, whil

and time. Additional monitor items (limits) can be set to enhance the systems

ability to determine if the fastener was properly secured

be used primarily for joints which have no requirement to synchronize

with another spindle during the final stage of the rundown.

Plugs, single spindle applications.

Once SPEED CHANGE TORQUE is reached

tem will switch from FREERUN

The system will fasten to the 1ST TORQUE value during the specified 1ST TIME. 1ST

TORQUE must be reached within the 1ST TIME limits or a reject wi

Upon reaching 1ST TORQUE, 1ST TIME ends and FINAL TIME begins. 1ST TORQUE is

the shift point to TORQUE SPEED

The system will fasten to STANDARD TORQUE

STANDARD TORQUE must be reached within the FINAL T

RECOMMENDATION

10% of STANDARD TORQUE

Start point of 1

30% of STANDARD TORQUE

Used for RATE/TIME settings

Angle Monitoring Start Point

Start point of 3

Engineered product fastening specification

Acceptance

Acceptance range to go from 1ST TORQUE to STANDARD

TORQUE

ach control method can be pe

which will successively secure the fastener to the spec

applications.

ssion or

e monitoring the degrees of rotation (Angle) of

Examples: Pipe Plugs, Spark

xpires

and continue to fasten to

using TORQUE SPEED during FINAL TIME.

IME limits or a reject will occur.

st

and TORQUE SPEED initiation.

RD

6.1 Fastening Control.

The Fusion system

formed in 1 to 3 increme fied torque or angle values.

6.1.1 Torque Control Method.

ue within one to three i the fastener



One-Step Fastening One-step fastening will

1.

1ST TORQUE.

2.

3.

4.

E

s,

with these characteristics in mind.

(Section 6.2).

or FREERUN REVOLUTIONS e

SPEED to SLOWDOWN SPEED

.

e-

r-

i-

ing

l-

, the sys-

ll occur.

FUNCTION SPEED CHANGE TORQUE

THRESHOLD TORQUE

1ST TORQUE

SNUG TORQUE CROSSOVER TORQUE STANDARD TORQUE 1ST TIME HIGH/LOW LIMIT

FINAL TIME HIGH/LOW LIMIT

/ COMMENT

torque rate monitoring (section 6.2)

(section 6.2)

torque rate monitoring (section 6.2)

range to reach 1ST TORQUE setting

Page 6-2

FEC Fusion Operations Manual Chapter 6: Fastening Instructions (Rev. 2)

Torque

Standard Torque

Crossover Torque

Snug Torque

1st Torque

Threshold Torque

Speed Change Torque

Angle/Time

1st Time

Final Time

FIG. 6-1-1a Torque Control Functions for One-Step Fastening

Page 6-3

Chapter 6: Fastening Instructions



Two-Step Fastening Two-step fastening will be used primarily for joints that have a requirement to synchronize

with another spindle during the final stage of the rundown or require joint conditioning. Examples: Connecting Rod, Main Bearing Cap, any multiple-spindle application.

1. Once SPEED CHANGE TORQUE is reached or FREERUN REVOLUTIONS expires, the system will switch from FREERUN SPEED to SLOWDOWN SPEED and continue to fasten to 1ST TORQUE.

2. The system will fasten to the 1ST TORQUE value during the specified 1ST TIME. 1ST TORQUE must be reached within the 1ST TIME limits or a reject will occur.

3. Upon reaching 1ST TORQUE, 1ST TIME ends and FINAL TIME begins. 1ST TORQUE is the shift point to TORQUE SPEED and the synchronization point prior to commencing the next step. (See 4.13 for Sync. info)

4. The system will fasten to STANDARD TORQUE using TORQUE SPEED during FINAL TIME. STANDARD TORQUE must be reached within the FINAL TIME limits or a reject will occur.

FUNCTION RECOMMENDATION / COMMENT SPEED CHANGE TORQUE 10% of STANDARD TORQUE

THRESHOLD TORQUE Start point of 1st torque rate monitoring (section 6.2)

30% of STANDARD TORQUE

1ST TORQUE

Used for RATE/TIME settings and TORQUE SPEED initiation. Synchronization point for 2ND STEP

SNUG TORQUE Angle Monitoring Start Point (section 6.2) CROSSOVER TORQUE Start point of 3RD torque rate monitoring (section 6.2) STANDARD TORQUE Engineered product fastening specification 1ST TIME HIGH/LOW LIMIT Acceptance range to reach 1ST TORQUE setting

FINAL TIME HIGH/LOW LIMIT

Acceptance range to go from 1ST TORQUE to STANDARD TORQUE

Torque

Standard Torque

Crossover Torque

Snug Torque

1st Torque

Threshold Torque

Speed Change Torque

FIG. 6-1-1b Torque Control Functions for Two-Step Fastening

1st Time

Angle/Time

Final Time

Page 6-4

FEC FUSIONE-HS-2 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual