FEC FUSIONE-HS-2 User Manual
FUSIONE-HS-2
WARNING
All applicable national and local codes must be followed when installing and operating the
equipment detailed in this manual.
FAILURE TO ABIDE BY THESE CODES AND THE SPECIFICATIONS DESCRIBED IN
THIS MANUAL CAN RESULT IN SERIOUS INJURY TO PERSONNEL AND/OR DAMAGE
TO THE EQUIPMENT!
Any questions regarding the contents of this document or any related matter should be
directed to FEC INC. at (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
DSP1500 = Servo Press
AFC1500 = Nutrunner
AFC1500 = Nutrunner
FUSION = DC Hand Tool
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.
All rights reserved. Any disclosure, copying, distribution, or use of the information con-
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
Failure to observe
Never
Failure to observe
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
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Page 2-8
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