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1. ITEM DATA SETTING WORK D No DATA 0 00 TORQUE UNIT 0 Nm 0 01 ROM VERSION 1 Kg m System 0 02 AMPLIFIER VERSION 2 0 03 FASTENING FUNCTION VERSION 1 03 for See Pg 7 12 3 Ftlb 0 04 External gear ratio 0 3 3 00 0 05 Gear Head Type 0 08 Fastening Curve Storage After ver 5 17 0 10 TOOL not adjustable 4 in Ib 0 11 TOOL CAL TORQUE Tool Data 0 12 CAL VOLTAGE 0 13 ZERO TORQUE VOLTAGE 0 14 PULSES PER DEGREE This section is 0 15 MOTOR factory set and 0 16 TRANSMISSION RATIO cannot be 0 17 ROTATE CW 0 CCW 1 changed 0 18 CCW TQ CAL VOLTAGE 0 19 TOOL SERIAL 1ST 4 DIGITS 0 1A TOOL SERIAL 2ND 4 DIGITS 0 1b Tool Cycle count Upper 4 digit 0 1c Tool Cycle count Lower 4 digit Tool type 0 20 TOOL See List on next pages 0 21 Start switch trigger level 10 Change to 100 to disable 0 22 Start switch High Speed level 40 Change to 100 to disable 0 23 CW CCW switch trigger level 20 Change to 100 to disable 0 24 Switch setup Factory setup 67 Tool Info 0 25 Switch setup Factory setup 30 0 26 Switch setup Factory setup 1 0 27 Switch setup Factory setup 200 0 28 Switch setup Factory setup 5 0 29 Switch setup Factory setup 80 0 30 Year yyyy example 2007 See 7 5 for detail Real Time Clock 0 31 Month amp Date mmdd example
2. 98 SET T SETUP oneness 2 Jw NEADON y ta 16 rf actin Soa MAS ue x fae fs Oera Gateway o CASIN Agree vett HA c DATA LESTE ROH gt 8 WRITES 2096 BIT INPUTS E HUMO 12 BYTES 256 BIT OUTPUTS 2 2 MESSAGE wessac mU 3 HPS DATA LENGTH MESSAGE 98 000 1 lt 512 1 In NETWORK SETUP input all of the IP settings required by the host PLC In I O SETUP select the Input Data Length and Output Data Length as required by you ap plication INPUT amp OUTPUT in this screen refer to PLC side I O INPUT FEC Output size OUTPUT FEC Input size Data lengths MUST MATCH the PLC s same I O length setup otherwise connection will not be possible The Ethernet l P interface also has the ability to transfer resultant fastening data using the message data Set the MESSAGE INPUT AFC1500 to PLC settings according to the PLC settings MESSAGE OUTPUT is currently not used Refer to Page 5 11 5 for message setup information Page 4 82 FEC FUSION Operations Manual Chapter 4 System Setup and Wiring Rev 3 I O Signal Specification Input number 32 bytes 256 bits Input map is permanently set Output number 32 bytes 256 bits Output map is permanently set Input Map Connection Co
3. INPUT SIGNAL Stop Bt RESET INPUT SIGNAL 32 A2 START A3 SELFCHECK DISABLE 4 A4 BANK SEL O A5 K SELI K SELS A7 WORK SEL 4 OT US 88 A8 NOT USED 4 OUTPUT OV B9 A9 INPUT COMMON O 110 424V 0 5A max OUTPUT SIGNAL IN BYPASS B11 LATE I TQ LOW REJECT OUTPUT SIGNAL TQ HI REJECT B12 A12 BUSY EADY B13 A13 ABNORMAL ACCEP REJECT B15 A15 Relay contact Cycle End 3161 A16 Relay contact Cycle End A171 Relay act OK PULSE M elay OK PULSE NOTE IF Optional PNP version A9 amp B9 polarity is REVERSED 9 is 0v common and B10 is common see 4 7 5 for wiring example FIG 4 7 1 Controller Unit PLC Connector Output signals shown on terminals A11 B14 are for BANK 1 signals only If BANK SELECT inputs are used these outputs WILL CHANGE DEFINITION according to the Bank Select output table and the selection of BANK SELECT INPUTS Page 4 10 FEC FUSION Operations Manual Chapter 4 System Setup and Wiring Rev 3 4 7 1 Explanation of CONTROLLER Unit I O INPUT SIGNALS Pin SIGNAL NAME DESCRIPTION A1 RESET Reset Input Normally Open 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 t
4. 104 Cal Value 34H 4 142 Crossover Torque 30H 0 180 1 Rate Lo Limit 30H 0 105 Cal Value 35H 5 143 2 Rate Start TQ 30H 0 181 1st Rate Lo Limit 31H 1 106 Cal Value 32H 2 144 2 Rate Start TQ 36H 6 182 1 Rate Lo Limit 30H 0 107 Peak TQ Lo Limit 31H 1 145 24 Rate Start TQ 30H 0 183 1 Rate Hi Limit 30H 0 108 Peak TQ Lo Limit 31H 1 146 2 Rate Start TQ 30H 0 184 1s Rate Hi Limit 35H 5 109 Peak TQ Lo Limit 30H 0 147 Angle Low Limit 30H 0 185 1st Rate Hi Limit 30H 0 110 Peak TQ Lo Limit 30H 0 148 Angle Low Limit 30H 0 186 1 Rate Hi Limit 30H 0 111 Peak TQ Hi Limit 31H 1 149 Angle Low Limit 30H 0 187 1s Rt Sign Flag 30H 0 112 Peak TQ Hi Limit 34H 4 150 Angle Low Limit 35H 5 188 2 Rate Lo Limit 30H 0 113 Peak TQ Hi Limit 30H 0 151 Angle High Limit 30H 0 189 27d Rate Lo Limit 30H 0 114 Peak TQ Hi Limit 30H 0 152 Angle High Limit 31H 1 190 2 Rate Lo Limit 31H 1 115 Final TQ Lo Limit 30H 0 153 Angle High Limit 30H 0 191 2 Rate Lo Limit 30H 0 116 Final TQ Lo Limit 30H 0 154 Angle High Limit 30H 0 192 2rd Rate Hi Limit 30H 0 117 Final TQ Lo Limit 30H 0 155 Standard Angle 30H 0 193 2rd Rate Hi Limit 35H 5 118 Final TQ Lo Limit 30H 0 156 Standard Angle 30H 0 194 2 9 Rate Hi Limit 30H 0 119 Final TQ Hi Limit 32H 2 157 Standard Angle 30H 0 195 2 9 Rate Hi Limit 30H 0 120 Final TQ H
5. 5 78 4 80 578 1 30 12 T CALIBRATION TORQUE Kg CONVERSION GUIDE 1 KGM 100 KGCM 9 8 NM 7 2 FTLB 86 8 INLB FULL SCALE TORQUE VALUES WORK 1 32 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 stand ard tools used with the FUSION System Additional tools are available If additional capacity information or special needs are required please contact FEC INC Page 2 6 FEC FUSION Operations Manual Chapter 2 Specifications Rev 3 2 4 2Nutrunner Decimal Point Display Table POSITIONS FOR DECIMAL POINT DISPLAY WAL POINT DIS TOOL TYPE DECIMAL POINT DISPLAY DECIMAL POINT DISPLAY HFT 200M80 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 Page 2 7 Chapter 2 Specifications Blank Page Page 2 8 FUSION Operations Manual Chapter 3 System Description Rev 3 Chapter 3 System Description Page 3 1 Chapter 3 System Description 3 1 Controller 3 1 1 Controller Part Number Breakdown Old Silver Controller HFC EC 16 14 E P A BC A VO INTERFACE B OPTIONS C OPTIONS New Gold Controller Blank 24VDC Discrete I O NPN 2 24VDC Discrete I O PNP
6. FIG 4 10 Dip Switch settings 4 10 1 Controller Unit DIP Switch positions 1 3 DIP switch positions 1 3 are used for setting the special configuration features as defined in the following explanation The DEFAULT setting is switch 1 3 OFF e DIP Switch 1 Zero Check acceptance window selection o ON Expanded Zero Check acceptance window o OFF Normal Zero Check acceptance window e DIP Switch2 NOT USED o ON Not Used o OFF Not Used e DIP Switch 3 Disable Motor Ramp Down o ON Enables dynamic brake for motor speed changes Used for applications which overshoot standard torque Will reduce Motor Tool life o OFF Disables Dynamic brake during speed changes Default Note The Controller unit must be powered off and on again for the DIP switch changes to be initialized Page 4 27 Chapter 4 System Setup and Wiring 4 10 2 Controller Unit DIP Switch positions 4 8 a DIP switch positions 4 8 are used for setting the Controller unit spindle address number as described in the following table Note The Controller unit must be powered off and on again for the DIP switch changes to be initialized This can be beneficial if fastening data is being collected from multiple spindles whereas the data needs to be identified differently between each spin dle not set two spindles with the same address
7. Data No 41 1ST Time High Limit sec Setting range 0 999 9 Set the high time limit between the start of fastening and 15 1ST Torque or 23 1ST Angle When this time elapses before reaching the target the process is rejected Data No 42 Final Time High Limit sec Setting range 0 999 9 Set the high time limit between 15 1ST Torque or 23 1ST Angle and Fastening end When this time elapses before reaching the target the process is rejected Page 7 22 FUSION Operations Manual Chapter 7 System Operations Rev 3a Data No 43 1ST Time Low Limit sec Setting range 0 999 9 Set the low time limit between the start of fastening and 15 1ST Torque or 23 1ST Angle When the target is reached before this time has expired the process is rejected Data No 44 Final Time Low Limit sec Setting range 0 999 9 Set the high time limit between 15 1ST Torque or 23 1ST Angle and Fastening end When the target is reached before this time has expired the process is rejected Data No 45 Ramp up Time sec Setting range 0 9 9 This is the time constant from when the fastening operation starts until when the speci fied speed is achieved Data No 46 Ramp Down Time sec Setting range 0 9 9 This is the time constant from when the fastening operation stops until when the speed becomes ze ro Data No 47 Reverse Ramp up Time sec Setting rang
8. 51341 Celeste Shelby Township Michigan 48315 Phone 586 580 2622 Fax 586 580 2620 Website www lec usa com FUSIONE HS 3 SYSIEM OPERATION MANUAL cor WORK ere CEPT ACCEPT REJECT TORQUE ANGLE WORK COUNT O NO WORK FUSION POWER m me HFC EC 168 THIRD EDITION DECEMBER 2014 AUTOMATION SYSTEMS Certified ISO 9001 2008 WARNING All applicable national and local codes must be followed when installing and operating the equip ment 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 LLL Any questions regarding the contents of this document or any related matter should be directed to FEC INC at 586 580 2622 faxed to 586 580 2620 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 Histor Revision ud date Manual No Content of Revision 2005 July First Edition Original Operation Manual 2007 August FUSIONE HS 2 Revision 2 Updated format amp added relevant information
9. FUSION CC LINK V2 INPUT SIGNAL NC Normal Close NO Normal Open Remote Remote Output Signal Name Connection output Signal Name Connection RY RY NO RY n 2h 0 NO NO RY n 2h 1 NO NO RY n 2h NO NO RY n 2h NO NO RY n 2h NO NO RY n 2h 5 NO NO RY n 2h NO NO NO NO NO NO NO NO NO NO NO WORK SELECT 0 NO NO WORK SELECT 1 NO NO WORK SELECT 2 NO NO WORK SELECT 3 NO NO rE STOP 1 1 RESET REVERSE START BYPASS SELF CHECK OFF BATCH OK RESET WORK SELECT 4 A Input signals are permanently set Cannot be changed E Unused range in RY n 4h Oh to n 37h Fh is also reserved aution WORK SELECT 4 is effective after Fusion Firmware V5 00 Page 4 71 Chapter 4 System Setup and Wiring FUSION CC LINK V2 INPUT SIGNAL Remote Signal Name Connection Input Signal Name Connection RX END NO RX n 2 0 Torque Integer bitO NO ACCEPT NO 2 1 Torque Integer bit1 NO REJECT NO RX n 2 2 Torque Integer bit2 NO NO RX n 2 3 Torque Integer bit3 NO NO RX n 2 4 Torque Integer bit4 NO Job Cycle Accept NO RX n 2 5 Torque Integer bit5 NO NO RX n 2 6 Torque Integer bit6 NO NO RX n 2 7 Torque Integer bit7 NO WORK SELECT 4 NO RX n 2 8 Torque Integer bit8 NO NO RX n 2 9 Torque Integer bit9 NO Time 1 Reject NO RX n 2 A NO Time 2 Reject NO RX n 2 B NO WORK SELECT 0 NO RX n 2 C NO WORK SELECT 1 N
10. 8 Initial Speed WORK 01 thru 32 D No 50 Set Initial Speed for slow rotation while socket is rotating through the U opening Recommended setting 60rpm max 9 Reverse Speed WORK 01 thru 32 D No 54 Reverse speed is used to re align the socket after a fastening Recommended setting 60 100rpm max 10 Ramp Up Time WORK 01 thru 32 D No 45 Sets motor ramp up time from slow to higher speeds Recommended setting 1 0 1 5sec Can only be set in Supervisory security mode 11 Ramp Down Time WORK 01 thru 16 D No 46 Sets motor ramp down time from high to slower speeds Recommended setting 1 0sec Can only be set in Supervisory security mode 12 Socket Return Torque WORK 01 thru 32 D No 1A Uses Offset Torque Limit data since it is not used in Fusion Note D No 1 cannot be seen Sets the torque at which the socket returns and stops at after a fastening using the AFC software however Recommended setting 6 0 10Nm it will be transferred copied with the parameter data file Must be set by using Automatic Parameter Setup Function in AFC software or manually entered using the controller display keypad 7 6 2 Tubenut Head Operation When using a Tubenut head a special function is required to re align the socket after normal fastening operations and allow the socket to be placed onto the nut to be fastened The start trigger must be held ON for the complete fastening of the part
11. 0131 Jan 31 After ver 2 20 0 32 Hour amp Minute hhmm example 1759 17 59 0 33 Seconds 00ss example 0020 20 seconds RS232 Format 0 40 49 RS232 data alternate communication format See 4 8 4 for set up 1 32 00 FASTENING MODE METHOD STEPS See List on next pages 32 05 OPTION 1 32 06 OPTION 2 Torque Curve Store 0 enable 1 disable 32 10 FULL SCALE TORQUE CAL TORQUE 2096 32 11 PEAK TORQUE LOW LIMIT 32 12 PEAK TORQUE HIGH LIMIT Max Full Scale x 1 1 32 13 STANDARD STD TORQUE 32 14 SPEED CHANGE TORQUE Torque 32 15 1ST TORQUE 32 16 SNUG TORQUE 32 17 THRESHOLD THR TORQUE 32 18 CROSSOVER CROS TORQUE 32 19 TORQUE INHIBIT LIMIT Max Full Scale x 1 1 32 1A Not Used 32 1B BREAKAWAY TORQUE LIMIT Max Full Scale x 1 1 32 1C FINAL TORQUE LOW LIMIT 32 1D FINAL TORQUE HIGH LIMIT Max Full Scale x 1 1 32 1E 2ND RATE START TORQUE Max Full Scale x 1 1 32 20 ANGLE LOW LIMIT 32 21 ANGLE HIGH LIMIT Max 9999 deg 32 22 STANDARD STD ANGLE Max 9999 deg Angle 32 23 1ST ANGLE Max 9999 deg 32 24 CROSSOVER ANGLE Max 9999 deg 32 25 ANGLE CORRECTION 0 99 deg 32 26 DIFF ANGLE 32 27 DIFF ANGLE 32 30 1ST TORQUE RATE LOW LIMIT For all Rate settings 32 31 1ST TORQUE RATE HIGH LIMIT Max 5000 TN 32 32 2ND TORQUE RATE LOW LIMIT Setting 0000 in any of 32 33 2ND TORQUE RATE HIGH LIMIT The LOW rate settings 32 34 3RD TORQUE RATE HIGH LIMIT disables low rate judgment 32 35 3
12. 5 2 14 Input preset data 15 Verify normal function Confirm normal operation Page 4 2 FEC FUSION Operations Manual Chapter 4 System Setup and Wiring Rev 3 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 amp wiring requirements 4 2 1 CONTROLLER Unit Dimensions 20 200 FIG 4 2 1 Controller Unit Dimensions Controller weight is 8 6 Kg 18 9lbs Mounting 4 points rear panel Use M6 Screw or equivalent gt 9mm in length 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
13. To use the WORK count function program the number of desired Acceptable fastenings you wish in PARM 1 16 D NO 74 0 99 max Only acceptable fastenings will be counted towards the WORK ACCEPT If a fastening cannot be accepted during the course of the work piece fastening the WORK ACCEPT will NOT light and the input WORK OK RESET input B7 on TB1 terminal will have to be activated before starting the next work piece Once the WORK ACCEPT has been activated it will automatically be reset upon the next start signal Page 6 26 FEC Fusion Operations Manual Chapter 6 Fastening Instructions Rev 3 6 6 6 Torque Inhibit The Torque Inhibit function is used to ignore high torque spikes during initial starting of the motor or fastening process Under normal fastening operations peak torque will stop the fastening process if Standard Torque is reached This may not be desirable for applications with high starting torque and lower fastening torque Applications such as self tapping screws nylok nuts crushed fasteners and application with high starting inertia may require this function Torque Inhibit is set by the number of revolutions that is required to be ignored during the process The Torque Inhibit Limit is a torque limit used as protection in case the amount of torque monitored during the Torque Inhibit Revolution is too high If this torque limit is hit during the Torque Inhibit pro cess then the spindle will stop and a
14. 32 97 Sequence Stage 7 32 98 Sequence Stage 8 Max 999 9 sec Max 999 9 sec Max 300 0 sec Max 999 9 sec Max 300 0 sec 0 0 9 9 sec 0 0 9 9 sec 0 9 9 sec 0 0 0 50 pulses Max 99 9 Max 99 9 10095 10095 096 10095 0 99 30 Set to 180 to disable 1 5 80 30 Set to 180 to disable 1 5 30 Page 7 10 FUSION Operations Manual Chapter 7 System Operations Rev 3a 1 Display operation for Parameter selection PRESS tore UU Last Data at Parameter 32 Parm 16 shown TIGHTENING COUNT FIG 7 2 5 Parameter display D No selection Page 7 11 Chapter 7 System Operations System D No Explanation 2 Torque Unit WORK 00 D No 00 00 Nm 01 Kgm 02 03 Ft Lb 04 In Lb 3 ROM Version WORK 00 D No 01 Displays Controller ROM Version Not adjustable 4 Amplifier Version WORK 00 D No 02 Displays Servo Version Not adjustable 5 Fastening Function Version WORK 00 D No 03 The Fastening Function Version is entered into WORK 00 D No 03 Enter the Set no which corresponds to the Function Version desired from the table below Alternate Fastening Function mode selection An alternate function mode exists which allows setting of additional functions for the fusion controller The function version that is set in the controller will be displayed when viewing Work 00 D No 03 The last two digits of the
15. 7 3 Download Setup Mode Operation Bypass Mode Only The FUSION system has two operational states that are controlled by depressing the MODE and SET Buttons on the front of the Controller simultaneously or by the PLC By pass input The operational modes available in the Bypass State are identified below Under this condition the MODE and SET Buttons have been pressed simultaneously or the BYPASS external signal is active During the Bypass State the controller displays and allows setting of all available parameter presets 7 3 1 Download Mode selection Immediately after the bypass condition has been entered the unit is in the initial Download Setup mode with the unit number displayed on the Count D No Display The AFC User Console software allows the CONTROLLER Unit setup via a computers RS232 Port To program the CONTROLLER unit with the display programmer press the MODE key to change to the primary setup mode If the CONTROLLER unit is performing some data communication to an external computer the download mode will be maintained until the op eration is completed Refer to the AFC Console Manual for information about the Download Mode Pressing both the MODE amp SET keys at the same time puts the controller into BYPASS mode FIG 7 3 1 CONTROLLER Unit in Download mode Page 7 31 Chapter 7 System Operations 7 3 2 Setup selection Depressing the Mode button will init
16. Angle Integer bit 7 8 73 Angle Integer bit 8 Example 9 74 Angle Integer bit 9 Angle Integer bit 1 2 5 7 Logical 1 166 10 75 Angle Integer bit 10 2 11 76 Angle Integer bit 11 12 77 Angle Integer bit 12 13 78 Angle Integer bit 13 14 79 15 80 Data 16 81 2 3 31 128 From PLC to Fusion 2 Words 4 Bytes 32bits Data Bit No Description Comment 0 1 1 2 2 3 3 4 0 F4 5 5 6 6 7 Reset 7 8 8 9 9 10 10 11 0 11 12 12 13 Work Select 0 13 14 Work Select 1 14 15 Work Select 2 15 16 Work Select 3 16 17 Stop 17 18 Reset 18 19 Reverse 0 19 20 Start 20 21 Bypass 21 22 Disable Self check 22 23 23 24 24 25 25 26 26 27 0 27 28 28 29 Batch OK Reset 29 30 Work Select 4 30 31 31 32 Page 4 56 FUSION Operations Manual Chapter 4 System Setup and Wiring Rev 3 4 15 4 Fieldbus Interfaces Ethernet I P The Ethernet I P communication interface allows slave connection to PLC networks that support Ethernet communication via TCP IP Maximum I O data is 256 input bits amp 256 output bits FEC Inputs match the discrete input layout FEC Output location is programmed using the AFC User Console Software Communication speeds of 10 100M baud auto selectable are supported FEC integrates the Ethernet I P board manufactured by HMS Fieldbus Systems AB into the Multi 2 Unit s modular I O board For further
17. BYPASS Spindle Bypass Input Normal Open When active all functions of this spindle are bypassed and the Bypass output is active Programming of the Controller is enabled BANK SELECT 0 BANK SELECT 1 Bank Select Input Signals Normally Open 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 A5 WORKSELECT 1 Work Parameter Select Input Normally Open B5 WORKSELECTO These 5 inputs form a binary code which is capable of selecting up to WORK SELECT 3 32 different sets of Fastening Parameters Refer to Section 4 7 2 B6 WORKSELECT 2 Sequence Select Table A7 WORK SELECT 4 Note Work 4 was added Firmware version 5 00 amp higher Reset Batch count to the initial condition Count D NO display will be B7 WORK OK RESET If controller is setup for the work select from TB1 this input MUST be used to reset the batch count A8 USED A9 INPUT COMMON Input signal common Connection to 12 24 VDC required B9 OUTPUT COMMON Output signal common Connection to 0 VDC required A10 DC POWER 24v Internal auxiliary 24VDC power 0 5amp max B10 DC POWER Zero volt common for Internal auxiliary power Page 4 11 Chapter 4 System S
18. E SPECIAL F MINOR REVISION G OPTION 130 13 0Kgfm 127 5Nm 94 0ft Ib 200 20 0Kgfm 196 1Nm 144ft Ib M50 Only used on 015 Angle amp Pistol Tools M80 Used on all other tools A Angle S Straight P Pistol T Type Pistol BLANK Original Release 1 1st Generation BLANK z Normal Function 010 1 0Kgfm 9 8Nm 7 2ft Ib 015 1 5Kgfm 14 7Nm 10 8ft Ib 025 2 0Kgfm 24 5Nm 18 0ft Ib 040 4 0Kgfm 39 2Nm 28 9ft Ib 055 5 5Kgfm 53 9Nm 39 7ft Ib 060 6 0Kgfm 58 8Nm 43 3ft Ib 080 8 0Kgfm 78 4Nm 57 8ft Ib Two Digit Minor Rev Level Factory Use Only 01 Silver Tool Type Uses FEB 1309 Mxx cable 10 Gold Tool Type Uses C15 F7 Mxx cable BLANK Through hole in Square Drive P Plunger Detent in Square Drive Page 3 7 Chapter 3 System Description 3 2 2 FUSION Angle Straight Tool Components 5 TOOL MAJOR COMPONENT IDENTIFICATION ITEM ITEM AS MARKED ON UNIT DESCRIPTION MOTOR RESOLVER Provides feedback for speed regulation to the Servo Amplifier Provides angular rotation monitoring for fastening operation Totally enclosed DC permanent magnet motor TRANSMISSION Durable planetary gear transmission Refer to Chapter 2 for standard tools and gear ratios ANGLE HEAD Durable right angle head Refer to Chapter 2 for standard tools and gear ratios TRANSDUCER PREAMP Highly accurate str
19. FEC FUSION Operations Manual Chapter 4 System Setup and Wiring Rev 3 Interface Board Specifications Maximum settable size for the FEC board is 32 bytes 256 bits Input Output each See DeviceNet Signal Reference at the end of this chapter for I O Signal map NOTE Devicenet also support the data Messaging function CIP for resultant data transfer See the Ethernet I P chapter below for more detail Devicenet uses similar setup 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 sup port amp 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 Configuration FEC DeviceNet I O is pre configured according to the I O Signal Map See below Configu ration 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 usi
20. Final Time 9 FIG 6 2 3a Angle Monitoring Angle Control Page 6 16 FEC Fusion Operations Manual Chapter 6 Fastening Instructions Rev 3 For Torque Control operations the High and Low Angle limits are either set by the engineering speci fication for that specific fastener or by determining the acceptable limits from a study of known good and bad assemblies The High Angle limit will stop the fastening process for Torque Control opera tions if it is reached before attaining the desired torque TORQUE CONTROL REJECT TYPE CAUSES Increased joint compression Reduced joint friction High initial prevailing torque Incorrect parameter set up HIGH ANGLE LIMIT Reduced joint compression LOW ANGLE LIMIT Increased joint friction Reject condition caused by another monitor item reject Torque Angle Low Limit Angle High Limit Peak Torque High Limit Standard Torque etre tette tete t Peak Torque Low Limit Crossover tetti on M Snug Torque 1 Torque Threshold Torque Speed Ch T pee ange Torque Angle Time 1 Time Final Time FIG 6 2 3b Angle Monitoring Torque Control Page 6 17 Chapter 6 Fastening Instructions 6 2 4 Point to Point Torque Rate Monitoring The Fusion System is capable of performing 3 torque rate calculations The Point to Point torque rate method performs the calculati
21. Page 6 23 Chapter 6 Fastening Instructions 6 5 Torque Recovery The Torque Recovery function is used when the potential for joint relaxation and interaction exists Under this control method the fasteners are secured to Standard Torque and then held at Standard Torque for a programmed duration of pulses This pulse setting can be between 0 50 pulses Power is applied to the motor for this duration holding torque at the specified STD Standard Torque During Torque Recovery the tool will use Recovery Speed as its maximum Speed but will only rotate as a result of a drop in the Torque Torque Recovery is only available in Torque Con trolled Fastening due the fact that the use of Torque Recovery may cause addition rotation Angle of the fastener WARNING The Torque Recovery function will cause the motor to heat up at a rate faster than normal fastening due to high amperage draw Particular attention to mini mized duty cycle is recommended if using this function or premature motor failure could result Torque Recovery Pulses should be kept to a minimum for the application requirements Torque Recovery Pulses Torque Peak Torque High Limit Final Torque High Limit Standard Torque Final Torque Low Limit Crossover Torque Snug Torque 1 Torque Threshold Torque Speed Change Torque P 2 a Time Only 1 Time Final Time FIG 6 5 Torque Recovery lt gt WARNING Wh
22. reduced by the number of occupied stations minus one Status LEDs Page 4 68 FEC FUSION Operations Manual Chapter 4 System Setup and Wiring Rev 3 Normal Operation RUN Green OFF Network non participating or timeout status No power on module ON CRC error detection 2 Illegal station number or illegal baud rate selected ERRL OFF No power on module OFF Normal Operation Data being received RDLED Green No data reception No power on module 7 Data being transmitted SDLED Green No data transmission No power on module On Off Blinking 2 Jg Operation Communication is normal However CRC error is occurred from time to time due to noise Baud rate or station number setting have been changed when baud rate station number setting released at reset Received data is CRC error and can t respond Normal communication Data can t be received to the station Poling is responding or CRC error is occurred to refresh reception CRC error occurred to the station data Link does not work properly No station data or station data can t be received due to noise Data isn t received due to disconnection etc Power source is disconnected to H W is in the reset process e e o le eeooeeos o Illegality of communication speed
23. 1ST TORQUE RATE THRESHOLD CROSSOVER TORQUE FASTENING END CROSSOVER TORQUE FASTENING END 3RD TORQUE RATE CROSSOVER TORQUE FASTENING END For all control operations the High and Low Torque Rate limits are set by determining the acceptable limits from a study of known good and bad assemblies Page 6 18 FEC Fusion Operations Manual Chapter 6 Fastening Instructions Rev 3 Torque Crossover Torque 5d eee Standard Torque 2nd Rate High Limit 2nd Rate Low Limit 2 Rate Start Torque 1 Torque m 1st Rate 1st Rate High Limit Low Limit Threshold Torque hore hotte te afe ena esterni tite egre cebat Angle Time 1 Time Final Time FIG 6 2 4a Two Stage Point to Point Torque Rate Monitoring Torque Standard Torque 3rd Rate 3rd Rate High Limit Low Limit Crossover Torque isse ease eii inni i IN rettet a 2ndRate High Limit z 2nd Rate Low Limit 2 Rate Start Toraue 1 Torque e MG TE 1st Rate 1ST Rate Low Limit Threshold Torque Angle Time iTime oye Final Time FIG 6 2 4b Three Stage Point to Point Torque Rate Monitoring Page 6 19 Chapter 6 Fastening Instructions 6 2 5 Time Monitoring Time High Limits As outlined in the Fastening Control Method
24. 2 35 Torque Integer bit 2 0 999 max 1 3 36 Torque Integer bit 3 number LEFT of decimal only 4 37 Torque Integer bit 4 Example 5 38 Torque Integer bit 5 Torque Integer bit 2 4 7 Logical 1 6 39 Torque Integer bit 6 148 7 40 Torque Integer bit 7 8 41 Torque Integer bit 8 Total Torque including Torque deci 9 42 Torque Integer bit 9 mal word3 148 38 10 43 1 11 44 12 45 13 46 14 47 15 48 16 49 Torque Decimal bit 0 Outputs Fastening Torque Decimal 17 50 Torque Decimal bit 1 value using binary integer 18 51 Torque Decimal bit 2 0 99 max 1 19 52 Torque Decimal bit 3 number RIGHT of decimal only 20 53 Torque Decimal bit 4 Example 21 54 Torque Decimal bit 5 Torque Decimal bit 1 2 5 Logical 22 55 Torque Decimal bit 6 1 38 23 56 24 57 25 58 26 59 1 27 60 28 61 29 62 30 63 31 64 Page 4 55 Chapter 4 System Setup and Wiring DeviceNet Signal I O Map Continued Data Bit No Signal Description Comment 0 65 Angle Integer bit 0 1 66 Angle Integer bit 1 2 67 Angle Integer bit 2 2 3 68 Angle Integer bit 3 4 69 Angle Integer bit 4 Outputs Fastening Angle value using binary 5 70 Angle Integer bit 5 integer 6 71 Angle Integer bit 6 0 9999 max 7 72
25. 9 13 9 10 Parameter Error 9 14 9 10 1 Code 9 0 Parameter Error Missing speed preset 9 14 9 10 2 Code 9 1 Parameter Error Missing Speed or Time 9 14 9 10 3 Code 9 2 Parameter Error Parameter Select Error 9 14 9 10 4 Code 9 3 Parameter Error Missing Reverse Speed 9 14 9 10 5 Code 9 4 Parameter Error Torque Speed not set 9 14 9 10 6 Code 9 5 Parameter Error Torque Setup Error 9 15 9 10 7 Code 9 6 Parameter Error Angle Setup Error 9 15 9 10 8 Code 9 7 Parameter Error Reverse Torque over 9 15 9 11 AFC1500 SAN Unit Fastening Faults and Causes 9 16 9 11 1 Accept Conditions 9 16 9 11 2 Torque Reject Conditions 9 16 FUSION Operations Manual Chapter 1 Outline Rev 3 Chapter 1 Outline Page 1 1 Chapter 1 Outline 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 Chapter 1 Chapter 2 Chapter 3 Chapter 4 Chapter 5 Chapter 6 Chapter 7 Chapter 8 Chapter 9 Item Outline Specifications System Description System Setup and Wiring Power Up and Initial Checks Fastening Instructions System Operations Maintenance and Inspection Troubleshooting Contents Basic characteristics and requirements of the FUSION System General specifications of the FUSION System Description of standard and optional system components
26. Bail DIP SWITCH NUMBER Unit DIPSWITCH NUMBER 4 5 6 7 8 4 5 6 7 8 1 OFF OFF OFF OFF ON 16 ON OFF OFF OFF OFF 2 OFF OFF OFF ON OFF 17 ON OFF OFF OFF ON 3 OFF OFF OFF ON ON 18 ON OFF OFF ON OFF 4 OFF OFF ON OFF OFF 19 ON OFF OFF ON ON 5 OFF OFF ON OFF ON 20 ON OFF ON OFF OFF 6 OFF OFF ON ON OFF 21 ON OFF ON OFF ON 7 OFF OFF ON ON ON 22 ON OFF ON ON OFF OFF ON OFF OFF OFF 23 ON OFF ON ON ON 9 OFF ON OFF OFF ON 24 ON ON OFF OFF OFF 10 OFF ON OFF ON OFF 25 ON ON OFF ON 11 OFF ON OFF ON ON 26 ON ON OFF ON OFF 12 OFF ON ON OFF OFF 27 ON ON OFF ON ON 13 OFF ON ON OFF ON 28 ON ON ON OFF OFF 14 ON ON OFF 29 ON ON ON OFF ON 15 OFF ON ON ON ON 30 ON ON ON ON OFF 31 ON ON ON ON ON Page 4 28 FEC FUSION Operations Manual Chapter 4 System Setup and Wiring Rev 3 4 11 Tool Cable Connection e Tools are connected to the controller using one cable ducer preamp motor and resolver e Cables should be supported to reduce fatigue points to allow the cable to move but yet hold it in place stress point leading to premature cable failure WARNING Do not make motor connections with the power on Recommended cable length 75 or less Maxi
27. Control and PLC interface Optional Ethernet Programming amp Data collection Removes Front RS232 if installed Optional Fieldbus I O interfaces Input Output Control and PLC interface 1 2 1 1 1 2 x 1 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 te
28. FtLb etc must be the same for all terms Do not mix torque units in calculation or errors will result If the new CAL value is out of the adjustable range the Err message will be displayed Example Tool Full Scale value EXISTING CAL is 35 00 Nm STD torque is 25 0 Nm Master transducer mean for 10 piece run is measuring only 24 00 Nm FEC transducer mean for 10 piece run is measuring 26 0 Nm The new CAL value is obtained as follows 24 00 26 00 x 35 00 32 305 The FULL SCALE TORQUE CAL value must be corrected to 32 30 Nm and en tered at WORK 1 16 COUNT D NO 10 NOTE WORK 1 16 can have different Calibration values entered This provides for an improved accuracy rating over an extended torque range Notice An alternative method of checking calibration using a static torque device wrench or bench checker can be done using the Locked Spindle Mode method The motor can be electrically locked while the operator manually applies torque with the tool using the tool as a torque wrench and then comparing the readings from the FEC Controller data display vs the torque displayed from the master See 7 2 2 for a description of how to put the spindle into the Locked Spindle Mode Page 7 37 Chapter 7 System Operations 7 5 Optional Real Time Clock Module The Fusion system stores 10000 cycles of fastening results in its flash memory In order to add a Date Time stamp to this data an optional Real Time Clock
29. HUULI Wy Tee TEE nann IMU JED FIG 7 3 3 Parameter display D No selection Page 7 33 Chapter 7 System Operations 7 3 4 Data selection The value for digit 1 and 2 of the COUNT D NO display may only be changed when the blinking cursor is in the respected position The COUNT D NO value is changed with the T keys Data corresponding to the data number COUNT D NO display will appear in the DATA display Refer to section 7 2 5 If the cursor is in the 1st digit position by pressing the J or T keys the DATA number will be scrolled by tens If the cursor is in the 2nd digit position the DATA number scrolling will be one by one As noted in the Parameter Data List chart the preset values are not arranged in a perfect sequence and some numbers may be skipped When scrolling the DATA numbers it will scroll to the next existing value in the same or the following parameter number r1 r1 11 Lt nnmnri nnnn LILILILI 1 A 1 As tre ta I Ta d WH nn II Anm t UU WU 11 4 Veg pi tora E ILI FEL i 3nki gogo VCO f i 1 57 ri i I r1 Lore ty IBRU FIG 7 3 4 Data No changing Page 7 34 FUSION Operations Manual Chapter 7 System Operations Rev 3a 7 3 5 Data Edit mode operation Depressing the MODE button will bring up the pri mary setup mode The blinking cursor will be posi tioned in the right most digit in th
30. If the trigger is re leased during the fastening cycle the fastening will stop The fastening can be re started by simply squeezing the trigger again Use the procedures below to re align the Tubenut sock et First Time Power Up Socket Re alignment If the Tubenut socket is not aligned use the following procedure to re align the open socket Press the Reverse pushbutton Tool RED GREEN LED S will flash Press the start trigger Hold the start trigger until the socket is re aligned and the tool shuts off tool au tomatically shuts off NOTE If the socket is turning in the wrong direction to re align the head Re alignment must turn CCW for proper operation the Gear Head Selection is wrong WORK 00 D No 05 more on next page Page 7 41 Chapter 7 System Operations Return to Home Position after Fastening After fastening a part the tubenut socket must be re aligned in order to remove it from the part Use the procedure above to re align the socket if removal is desired Use this proce dure to re align the socket and remove the head from the part after a complete fastening Hold down start trigger until fastening is complete While still HOLDING the start trigger after fastening is complete lift socket off of the nut being fastened Release start trigger and the socket will re align automatically If the trigger is inadvertently released before the socket is re aligned follow the procedure above to re align
31. Input Size Output Size Inputs the same Input Size and Output Size as the Ethernet I P is configured Assembly Instance Inputs the same value as the following setting Module Properties LocalENB EJHERNET MODULE 1 1 onnection Madule Info ETHERNET MODULE Generic Ethernet Module Allen Bradley Parent LocalENB Name AFETEUD Connection Parameters Assembly Description Instance Size Input 100 je 15 k EX 8 bit Output Comm Format D ata Daas Address Host Name Address 192 Host Name Configuration 1 Bit Status Offline Cancel Help Page 4 63 Chapter 4 System Setup and Wiring Module Property Connection Request Packet Interval Inputs 50 0ms Module Properties LocalENB ETHERNET MODULE 1 1 General Connection Module Info Requested Packet Interval RPI 50 04 ms 1 0 3200 0 de Inhibit Module Major Fault On Controller If Connection Fails While in Run Mode Module Fault Status Offline Cancel The input signal and the output signal are added to Tag oR Strings iico son 8 STRING _ 2 MESSAGE 5 88 Predefined AFCT500 21 AB ETHERNET_MODULE_SINT_16Byles I 0 Gj Module Defined AFC1500_2 0 AB ETHERNET MODULE SINT 8Bytes D 0 YO Configuration 88 Backplane Compact
32. 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 15t Time Reject 1 18st Time Low Reject 1 Final Time Reject MSB 1 Final Time Low Reject Byte 5 Torque Rate Reject Byte LSB 1 1 Rate Low Reject 1 1 Rate High Reject 1 2 Rate Low Reject MSB 1 2 4 Rate High Reject Byte 6 Torque Rate Reject Byte LSB 1 3 Rate Low Reject 1 3 Rate High 1 Not Used MSB 1 Not Used Page 4 22 FEC FUSION Operations Manual Chapter 4 System Setup and Wiring Rev 3 Rear Panel RS232 Standard Communication Protocol Continued Torque Unit Output ASCII nA Data Hex Nm 0 30 Kgm 1 31 Kgcm 2 32 Ft Lb 3 33 In Lb 4 34 Torque Rate Decimal Decimal Output ASCII Place Data Hex 0000 0 30 000 0 1 31 00 00 2 32 0 000 3 33 Rate Sign Flag MSB LSB LSB 1 1 Rate Negative 1 2 Rate Negative 1 34 Rate Negative MSB 1 Not Used 5Fastening Mode Fastening Output ASCII Method Data Hex Torque Control 0 30 Angle Control 1 31 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
33. Normally this value shall be set as 0 Data No 30 1 Rate Low Limit Nm deg Data No 31 1 Rate High Limit Nm deg Setting range 0 Tool type s maximum torque rate Sets the high and low limits for the Torque rate measured between the two points 17 Threshold Torque and 15 1ST Torque or 23 1 Angle Judgment is conducted at the point when 15 1ST Torque or 23 1 Angle is achieved or when Fastening ends whichever occurs first Data No 32 2 Rate Low Limit Nm deg Data No 33 2 Rate High Limit Nm deg Setting range 0 Tool type s maximum torque rate Sets the high and low limits for the Torque rate measured between the two points 1E 2 d Rate Start Torque or 26 2 Rate Start Angle and 18 CROS Torque or 24 CROS Angle Judgment is conducted at the point when the 18 CROS Torque or 24 CROS Angle is reached or when Fastening ends whichever occurs first Data No 34 3 Rate Low Limit Nm deg Data No 35 3 Rate High Limit Nm deg Setting range 0 Tool type s maximum torque rate Sets the high and low limits for the Torque rate measured between the two points 18 CROS Torque or 24 CROS Angle and Fastening End Data No 40 Initial Time sec Setting range 0 999 9 During initial time the start of the fastening operation will be conducted at 50 Initial Speed When 40 Initial Time is set as 0 the operation will start in 51 Freerun Speed
34. 1 TORQUE RATE The system will temporarily stop at this point and can be set to synchronize with other spindles 3 Step Fastening Function Start Point Stop Point Time Preset Limits 1ST STEP START 1ST TORQUE 1ST TIME HIGH LOW LIMIT 1st TORQUE also serves as a shift point to TORQUE SPEED the monitoring stop point for 1 TORQUE RATE The system will temporarily stop at this point and can be set to synchronize with other spindles 2ND STEP 1ST TORQUE CROSSOVER TORQUE 3RD STEP CROSSOVER TORQUE FASTENING END For 3 Step Fastening 2Nb STEP and 3 STEP performed with the same preset FINAL TIME HIGH LOW LIMITS both must finish within the same combined timeframe Page 6 20 FEC Fusion Operations Manual Chapter 6 Fastening Instructions Rev 3 6 3 Speed Functions The Fusion system is user programmable for operations involving multiple speed settings The use of multiple speeds during the fastening process aids in socket engagement achieving cycle time op erator ergonomic issues and controlling the applied torque during all stages Speed functions work the same for Torque control and Angle control using any of the previously stated standard monitoring function Special conditions that affect these operations will be identified in the appropriate section 1 The system will fasten to the 1ST TORQUE ANGLE value during the specified 1ST TIME During 1ST time
35. 119 PEAK TORQUE JUDGMENT TOTAL JUDGMENT H Y4BH HIGHREJECT L 4CH LOWREJECT gt lt SEH FE ELT A 41H ABNORMAL S 53H STOP B 42H BYPASS AP E S stand alone genersion REJECT MARK is not included FINAL TORQUE ANGLE RATE TIME JUDGMENT H 48H HIGH REJECT L 4CH LOWREJECT Page 4 92 FUSION Operations Manual Chapter 5 Power Up and Initial Checks Rev 3 Chapter 5 Power Up and Initial Checks Page 5 1 Chapter 5 Power Up and Initial Checks 5 1 Before Powering On N WARNING Follow Lockout Tag out and other safety precautions when connecting or disconnecting cabling wiring and equipment Each item below lists the manual Section s that will provide a reference for that specific item Also refer to Section 4 5 Connection Diagram Caution Damage may occur if the 24 VDC and 0 VDC Commons are improperly connect ed 1 Verify CONTROLLER Unit DIP switch settings 4 10 e Verify that the eight 8 DIP switches visible through the rear panel removable plate of each unit are set to indicate the appropriate spindle number and options Section 4 10 CONTROLLER DIP Switch setting 2 Confirm Interface PLC connection 4 7 e Verify that the CONTROLLER unit I O Interface wiring is connected to the corresponding PLC terminals 3 Check connections between the tool and the CONTROLLER unit section 3 1 2 e Verify that the Singl
36. 3 Signal Connection Comment Angle Integer bitO Angle Integer bit1 Angle Integer bit2 Angle Integer bit3 Angle Integer bit4 Angle Integer bit5 Outputs Fastening Angle value using binary integer Angle Integer bit6 0 9999 max Angle Integer bit7 Example Angle Integer bit8 Angle Integer bit 1 2 5 7 Logical 1 166 Angle Integer bit9 Angle Integer bit10 Angle Integer bit11 Angle Integer bit12 Angle Integer bit13 Output No 09 Output No 10 Output No 11 Output No 12 Final Angle Integer 1234 deg 04D2 Page 4 87 Chapter 4 System Setup and Wiring Connection Comment Output No 13 Output No 14 Output No 15 Output No 16 Example Siemens PLC SFC14 is used 32 bytes are stored from M30 0 SFCIA Read Cons istent Data of a Standard DP lave DPRD DAT ENO WH16 100 4LADDR RET_VAL MW4 PHM 30 0 RECORD BYTE 32 LADDR Input address set by HW configuration Hexadecimal WORD form RET_VAL Storage place when error occurs RECORD Read output signal from FUSION Page 4 88 FEC FUSION Operations Manual Chapter 4 System Setup and Wiring Rev 3 Receive in Fastening Data message communication 2 CPU 315 PN DP S7 Version5 4 result data e
37. 3 Modbus Plus Interface 4 Profinet 6 Allen Bradley Remote I O Interface 9 DeviceNet Interface 10 Ethernet I P 13 Profibus Interface 14 CC Link Interface Blank Standard with Real Time Clock E Ethernet Data Output Toolsnet Connection B Ethernet Ready No Ethernet installed Blank Standard NPN I O Optional PNP 1 0 HFC EC 16 C BU EN R C D A MODEL B FIELDBUS INTERFACE C ETHERNET OPTIONS D CASE C Standard Gold Black Bezel D STD With Transformer EC rated E STD W No Front RS232 For Ethernet models Blank NPN 24VDC Discrete I O BU Base board only Anybus not installed CC CC LINK Ver2 PIO Profinet DN DeviceNet Interface EIP Ethernet I P PB Profibus Interface P PNP 24VDC Discrete I O EN Ethernet Option Baseboard Processor EB Ethernet Option Baseboard only Blank Standard Hanging style R Shelf top hinges opposite cover won t fall off Page 3 2 FUSION Operations Manual Chapter 3 System Description Rev 3 3 1 2 Controller Front Panel 0000 Oe iU L T oe WORK COUNT D NO WORK T A MON FUSION 2 HFC EC 16 Note Numbers correspond to item in following table Fig 3 1 2 Front Panel description Page 3 3 Chapter 3 System Description FRONT PANEL DISPLAY FEATURES ITEM ITEM AS MARKED ON UNIT DESCRIPTION Green
38. 3 NO 4 4 Angle Integer bit4 NO RX n 6 4 NO 4 5 Angle Integer bit5 NO RX n 6 5 NO 4 6 Angle Integer bit6 NO RX n 6 6 NO RX n 4 7 Angle Integer bit7 NO RX n 6 7 NO RX n 4 8 Angle Integer bit8 NO RX n 6 8 NO 4 9 Angle Integer bit9 NO RX n 6 9 NO RX n 4 A Angle Integer bit10 NO RX n 6 A NO 4 Angle Integer bit1 1 NO RX n 6 B NO RX n 4 C Angle Integer bit12 NO RX n 6 C NO RX n 4 D Angle Integer bit13 NO RX n 6 D NO RX n 4 E NO RX n 6 E NO RX n 4 F NO RX n 6 F NO RX n 5 0 RX n 7 0 RX n 5 1 RX n 7 1 RX n 5 2 RX n 7 2 RX n 5 3 RX n 7 3 RX n 5 4 RX n 7 4 RX n 5 5 RX n 7 5 RX n 5 6 RX n 7 6 RX n 5 7 RX n 7 7 RX n 5 8 RX n 7 8 RX n 5 9 RX n 7 9 RX n 5 A RX n 7 A RX n 5 B RX n 7 B RX n 5 C RX n 7 C RX n 5 D RX n 7 D RX n 5 E RX n 7 E RX n 5 F RX n 7 F Final Angle Integer Portion 1234 deg 04D2 A Output signals are permanenily set Cannot be changed Unused range in RX n 8h Oh to RX n 37h Fh is also reserved aution Page 4 73 Chapter 4 System Setup and Wiring CCLink V2 AFC Software Configuration Use the AFC user console software to configure the CCLink V2 in the Fusion Controller Configuration file 11 FIELDBUS CONFIGURATION CC LINK VERZ GENERAL SETUP Imi 0 CONFIGURATION FILE BROWSE SAVE BUS TYPE CC LINK VER2 COMM
39. 3 Rear Panel RS232 Communication Protocol 4 8 4 Rear Panel RS232 Alternate Communication Protocol 4 8 5 Rear Panel RS232 Alternate Communication Protocol Table of contents Page 1 1 1 2 1 3 1 5 1 6 2 1 2 2 2 3 2 4 2 5 2 6 2 7 3 1 3 2 3 2 3 3 3 5 3 7 3 7 3 8 3 9 4 1 4 2 4 3 4 3 4 4 4 5 4 5 4 6 4 7 4 8 4 9 4 9 4 10 4 11 4 12 4 13 4 15 4 16 4 18 4 18 4 19 4 20 4 24 4 25 Table of contents 4 9 Torque Angle MON DB9 external monitoring connector 4 26 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 47 4 15 3 Fieldbus Interfaces DeviceNet 4 51 4 15 4 Fieldbus Interfaces Ethernet
40. 4 5 5 Job Cycle Accepted Total Accept for Sequence Function 6 6 7 7 10 8 Work Select 4 Selected echo 11 9 12 10 Time 1 Reject 1 00 13 11 Time 2 Reject 14 12 Work Select Bit 0 Selected echo 15 13 Work Select Bit 1 Selected echo 16 14 Work Select Bit 2 Selected echo 17 15 Work Select Bit 3 Selected echo 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 Rate High Reject 1 04 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 49 Chapter 4 System Setup and Wiring Signal Map Continued From PLC to Fusion 4 Bytes 32 Bits Octal Bit Description Comment 0 0 1 1 2 2 3 3 O 00 4 5 5 6 6 Reset 7 7 10 8 11 9 12 10 13 11 0 00 14 12 Work Select 0 15 13 Work Select 1 16 14 Work Select 2 17 15 Work Select 3 0 0 Stop 1 1 Reset 2 2 Reverse 3 3 Start eu 4 4 Bypass 5 5 Disable Self check 6 6 7 7 10 8 11 9 12 10 13 11 0 01 14 12 Batch OK Reset 15 13 Work Select 4 16 14 17 15 Software Configuration Configuration related to Allen Bradley Remote I O is configurable using the AFC User Con sole Software Configuration should be s
41. 8 Angle Integer bit T 2 5 7 Logical 1 74 Angle Integer bit 9 1 166 2 75 Angle Integer bit 10 9 3 76 Angle Integer bit 11 4 77 Angle Integer bit 12 5 78 Angle Integer bit 13 6 79 7 80 06 Byte 81 08 10 15 128 SOL ERO Page 4 44 FEC FUSION Operations Manual Chapter 4 System Setup and Wiring Rev 3 Profibus AFC Software Configuration Use the AFC User Console software to configure the Fusion controller Fieldbus Setup HFC EC 16 BUS PB is preset with the standard Fieldbus setting values Before changing the settings inside please make backups Caution Fieldbus Setup screen AFC software alti xi GENERAL SETUP E z CONFIGURATION AILE Eu Vac an BUS TYPE 5 COMMUNICATION ie ove UPLOAD DOWNLOAD VERIFY BROWSE Browse Fieldbus configuration files SAVE Save Fieldbus configuration files UPLOAD Upload Fieldbus set up from Fusion controller BUS TYPE will automatically switch per uploaded type DOWNLOAD Download Fieldbus set up to Fusion controller Cycle power after download VERIFY Verify Fusion controller set up with AFC software set up BUS TYPE Choose PROFIBUS When Fieldbus setting is finished hit the SAVE button to save to a file The Fieldbus setting is downloaded using the DOWNLOAD button and or can be downloaded from the PARAMETER COMMUNICATIONS screen by select Caution i
42. Caution Page 4 75 Chapter 4 System Setup and Wiring MELSEC Q Series Parameter Setting Example Start up GX Developer Prepare PC Series QCPU mode Project gt Parameter gt Network Parameter gt Set List of CC Link Example of PLC setting using 3 Fusion systems 3 CCLINK connections No of boards module v Boards Blank no setting 1 Start 1 0 No 0000 Operational setting Operational settings AZ pei iP 4 EN Master station data link type PLC parameter auto start Remote net Ver 2 mode dz yr connect count IIa po Remote inputf RX EN HEX Remote output RY YlO0 BEER Remote reaister R wir D1000 Remote registerfFw w D400k 7 L Ver 2 Remote input FiX Ver 2 Remote outputfR Y 0 Ver 2 Remote register E wr Sse Ver 2 Remote register Aww r Special relay SB 5 0 Special register S w 5 0 Retry count Automatic reconnection station count Stand by master station No E Scan mode setting Asynchronous BEEN el Delay infomation setting o Station information setting Remote device station initial setting Interrupt setting Station information Initial settings SSS RENE Interrupt settings 1 Select Remote Net Ver 2 Mode at Mode Select 2 Se
43. Equipment installation procedure dimensions Input and Output signal descriptions and requirements for PLC programming Preliminary power on and operational tests Basic fastening operations and presetting procedures Instructions for the input of preset data and monitoring explanations Guide for preventive maintenance Descriptions of fastening rejects abnormal operation faults and corrective actions Page 1 2 FUSION Operations Manual Chapter 1 Outline Rev 3 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 e Compact Design The controller can be set on a tabletop shelf or back panel mounted using the mounting holes on the controller back cover 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 e Front
44. I P 4 57 4 15 5 Fieldbus Interfaces CC Link Ver 2 4 66 4 15 6 Fieldbus Interfaces Profinet 4 79 4 15 7 Fieldbus Interfaces Message Output Format 4 90 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 Table of contents 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 7 1 4 Fastening Presetting Result Display Controls 7 4 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 amp Data Explanation 7 9 System D No Explanation 7 12 Batch Sequence Function 7 27 7 2
45. Incr TQ 30H 0 4 Clock Year 30H 0 38 Peak Torque 39H 9 72 2 Rate Incr TQ 32H 2 5 Clock Year 37H 7 39 Peak Torque 39H 9 73 2 Rate Incr TQ 35H 5 6 2FH 40 Peak Torque 39H 9 74 2 Rate Incr Ang 30H 0 7 Clock Month 30H 0 41 Final Torque 31H 1 75 2 Rate Incr Ang 31H 1 8 Clock Month 38H 8 42 Final Torque 39H 9 76 2 Rate Incr Ang 0 9 2FH 43 Final Torque 39H 9 77 2 Rate Incr Ang 30H 0 10 Clock Day 81H 1 44 Final Torque 39H 9 78 3 Rate Incr TQ 30H 0 11 Clock Day 35H 5 45 Final Angle 31H 1 79 3 Rate Incr TQ 30H 0 12 Time Hour 31H 1 46 Final Angle 39H 9 80 3 Rate Incr TQ 31H 1 13 Time Hour 32H 2 47 Final Angle 39H 9 81 3 Rate Incr TQ 30H 0 14 3AH 48 Final Angle 39H 9 82 3 Rate Incr Ang 0 15 Time Minute 34H 4 49 18 Rate 31H 1 83 3 Rate Incr Ang 0 16 Time Minute 35H 5 50 1 Rate 39H 9 84 3 Rate Incr Ang 32H 2 17 51 1 Rate 39H 9 85 3 Rate Incr Ang 31H 1 18 Time Second 33H 3 52 1 Rate 39H 9 86 15 Time 30H 0 19 Time Second 30H 53 2 d Rate 31H 1 87 15t Time 30H 0 20 Spindle Number 30H 0 54 2 Rate 39H 9 88 1 Time 36H 6 21 Spindle Number 31H 1 55 2 9 Rate 39H 9 89 1st Time 35H 5 22 JudgmentFlag 4FH 56 2rd Rate 39H 9 90 2nd Time 30H 0 23 JudgmentFlag 57 3 Rate 31H 1 91 2
46. 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 e 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 e Parameter Selection e Totally digitized system eliminates analog potentiometers e Upto 32 sets of parameters can be stored into Flash ROM e battery backup of memory is required e 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 e Communication and I O Interface 1 Programming and Display Front Panel Input Output Manual interface RS232 Front Panel Input output Programming and Data collection RS232 Rear Panel Output Printer or data collection device T A MON Front Panel Output Analog Torque and Angle analysis Discrete I O Terminal Rear panel
47. Lights to indicate that the spindle has completed an 1 ACCEPT acceptable fastening cycle Flashes for an final accept during a Batch Count Green Lights to indicate that the spindle has completed an acceptable group of fastenings Reached Batch Count No 3 REJECT 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 S ORRE fastening Data 5 ANGLE Yellow Indicates the Data Display LED is displaying Angle fastening Data Four digit 7 segment LED display which function is dependent 6 Display upon the D NO selected ABN is displayed here during an Abnormal condition 7 WORK 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 7 field is being displayed and as required will display an Abnormal Sv COUNT Ne Sub code Displays Fastening Count during Batch Count function FRONT PANEL CONTROL FEATURES 9 ICAL 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 1 MODE Display mode selection pushbutton 14 ISET Data change conf
48. Metal chips and or debris has migrated inside CONTROLLER Unit through vent holes 2 Flash ROM IC chip has malfunctioned RECOVERY 1 Remove CONTROLLER Unit and blow or shake out debris 2 Replace and return unit to FEC for repair Code 4 1 SYSTEM MEMORY ERROR FLASH ROM READ ERROR Communications error to internal CONTROLLER Flash ROM during READ attempt 9 5 3 This abnormal is caused from 1 Metal chips and or debris has migrated inside CONTROLLER Unit through vent holes 2 Flash ROM IC chip has malfunctioned RECOVERY 1 Remove CONTROLLER Unit and blow or shake out debris 2 Replace and return unit to FEC for repair 3 Code 4 2 SYSTEM MEMORY ERROR SERVO AMP FLASH ROM ERROR Communications error to internal CONTROLLER Servo Amp flash ROM This abnormal is caused from 1 Metal chips and or debris has migrated inside CONTROLLER Unit through vent holes 2 Flash ROM IC chip has malfunctioned RECOVERY 1 Remove CONTROLLER Unit and blow or shake out debris 2 Replace and return unit to FEC for repair Page 9 8 FUSION Operations Manual Chapter 9 Troubleshooting Rev 3 9 6 Servo Amplifier Response Resolver 9 6 1 Code 5 0 SERVO AMPLIFIER REPLY ERROR NO REPLY FROM RESOLVER The controller is attempting to turn the motor but is not receiving any signals back from the resolver to indicate that the tool is actually turning This abnormal is caused from 1 The motor resolver cable is damaged
49. Note Optional PNP version I O available active true high current sourcing See next page for wiring sample diagram Page 4 16 FEC FUSION Operations Manual Chapter 4 System Setup and Wiring Rev 3 This diagram represents the OPTIONAL PNP version I O connections to a PLC PNP current sourcing Active true high The 24VDC power can be supplied from the FUSION controller terminals A10 B10 if total consumption is less than 0 5A OPTIONAL PNP VERSION FUSION CONTROLLER PLC INPUT BOARD 2 FUSION CONTROLLER TB1 UN a OUTPUT m 2 Z 200 v x 2 2K v FUSION OUTPUT 3 OUTPUT a D 2 vr N 7 24 es 2 Z Vw INPUT EE m Z x v INPUT e TIT FIG 4 7 5a Optional PNP version PLC Wiring Sample Page 4 17 Chapter 4 System Setup and Wiring 4 8 RS 232 Data communication ports The FUSION system programming and monitoring can be performed utilizing a PC Laptop or Industrial based system Communication is performed via an RS232 port located on the front of the unit This port provides communication to the AFC User Console Software cost with a system purchase An additional port is available on the rear panel of the controller that can provide RS232 out put data to a variety of collection devices 4 8 1 Front P
50. 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 OFF Disabled ON Enabled Note TB1 terminal must be enabled See Section 7 2 4 Page 4 12 FEC FUSION Operations Manual Chapter 4 System Setup and Wiring Rev 3 4 7 3 Bank Select Table only 8 physical outputs Bank Select inputs are used to multiplex the output signals allowing up to 32 signals from 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 BANE SEL PLC CONTROLLER UNIT BANK DATA INPUT BANK SEL 1 SEL 0 Output NAME OF NO B4 4 A11 B14 SIGNAL Output when the fastening result is REJECT DATA 7 REJECT Indicates that the spindle has failed the fastening A14 limits This output remains active until the START signal or RESET signal is input Output when the fastening result is a ACCEPT DATA 6 ACCEPT Indicates that the spindle is within the fastening B14 limits This output remains active until the START signal or RESET signal is input Output when an Abnormal condition occurs DATA 5 indicates that the System has detected an internal A13 ABNORMAL fault and can no longer proceed An Abnormal condition must be corrected before the System will resume norm
51. Start point of 1 torque rate monitoring section 6 2 3096 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 Start point of 3PP torque rate monitoring section 6 2 SROSSOVER TURGE Synchronization point for 3rd STEP STANDARD TORQUE Engineered product fastening specification 1ST TIME HIGH LOW LIMIT Acceptance range to reach 1ST TORQUE setting FINAL TIME HIGH LOW LIMIT range to go from 1ST TORQUE to STANDARD Torque Standard Torque Crossover Torque SUG Torque 3 18 Torque ria Es Threshold Torque Speed Change Torque 3 Angle Time 1 Time Final Time FIG 6 1 1c Torque Control Functions for Three Step Fastening Page 6 5 Chapter 6 Fastening Instructions 6 1 2 Angle Control Method In Angle Control method fastening is performed based upon attaining a desired torque value and then rotating the fastener a specified number of degrees while monitoring the Torque of the fastener and time Additional monitor items limits can be set to enhance the systems ability to deter mine if the fastener was properly secured Section 6 2 Fastening can be performed from 1 to 3 incremental steps that will successively secure the fastener to a specified torque or angle value b
52. Threshold Torque 30H 0 175 3 Rate Start Ang 30H 0 213 Rev Hi Limit 30H 138 Threshold Torque 30H 0 176 3 Rate Start Ang 30H 0 214 EndOfText 03H 139 Crossover Torque 30H 0 177 3 Rate Start Ang 30H 0 140 Crossover Torque 36H 6 178 34 Rate Start Ang 0 Byte Numbers 2 106 actual fastening data Byte Numbers 107 213 PRESET limit data Date amp Time only with clock RTC module installed in Fusion Controller 1 5See next page s for explanation Page 4 21 Chapter 4 System Setup and Wiring Rear Panel RS232 Standard Communication Protocol Continued 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 Output ASCII Status Data Hex Accept 4 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 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
53. Work Select Bit 0 Selected echo 5 14 Work Select Bit 1 Selected echo 6 15 Work Select Bit 2 Selected echo 7 16 Work Select Bit 3 Selected echo 0 17 Reject 1 18 Accept 2 19 Abnormal 2 3 20 Ready 4 21 Busy 5 22 Torque High Reject 6 23 Torque Low Reject 02 7 24 Bypass 0 25 Angle High Reject 1 26 Angle Low Reject 2 27 Rate High Reject 3 3 28 Rate1 Low Reject 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 7 1 34 Torque Integer bit 1 Outputs Fastening Torque using binary in 2 35 Torque Integer bit 2 as dri 4 3 36 Torque Integer DIS number LEFT of decimal only 4 27 Torque nteger 212 5 orque Integer bit RE 6 39 Torque Integer bit 6 Torque integer bit 2 4 7 Logical 1 148 03 7 40 Torque Integer bit 7 Total Torque including Torque decimal 0 41 Torque Integer bit 8 word3 148 38 1 42 Torque Integer bit 9 2 43 3 44 5 F4 5 5 46 6 47 7 48 E Tous Decimal Pito Outputs Fastening Torque Decimal value 2 51 Torque Decimal bit 2 E e 6 3 Se ETORQUe Decimal ol 3 number RIGHT of decimal only 4 53 Torque Decimal bit 4 Example 5 54 Torque Decimal bit 5 Torque Decimal bit 1 2 5 Logical 1 38 6 55 Torque Decimal bit 6 7 56 04 0 57 1 58 2 59 3 60 4 61 5 62 6 63 7 64 4 60 FEC FUSION Operations Manual Chapter 4 System Setup
54. and Wiring Rev 3 Data Bit No Signal Description Comment 0 65 Angle Integer bit O 1 66 Angle Integer bit 1 2 67 Angle Integer bit 2 8 3 68 Angle Integer bit 3 4 69 Angle Integer bit 4 Outputs Fastening Angle value using binary 5 70 Angle Integer bit 5 integer 6 71 Angle Integer bit 6 0 9999 max 7 72 Angle Integer bit 7 8 73 Angle Integer bit 8 Example 9 74 Angle Integer bit 9 Angle Integer bit 1 2 5 7 Logical 1 2 166 10 75 Angle Integer bit 10 9 11 76 Angle Integer bit 11 12 77 Angle Integer bit 12 13 78 Angle Integer bit 13 14 79 15 80 Data 16 81 10 15 31 128 AFC Software Configuration The Anybus board is set up by sending a Fieldbus Configuration File fcf containing ini tialization messages from the Fusion Unit to the board during power up This string of da ta initializes different characteristics required for the board to communicate over the Ethernet I P network In this string is configuration data which sets the length of I O data as well as length of messages Resultant Fastening data Since the board is only initial ized during power up the Fusion Unit MUST have the power cycled OFF ON after the fcf file is downloaded To download the fcf file select Field Bus Setup from the Axis pull down menu Select the appropriate Bus Type and click Browse to locate the c
55. avoid mounting at or near the top where internal enclosure heat is most extreme Do not install in a location subject to continuous vibration Page 4 3 Chapter 4 System Setup and Wiring 4 3 Unit Arrangement 260 z 260 CONTROLLER OPENS IN THIS AREA 8 CONTROLLER OPENS IN THIS AREA Z exo WORK COUNT D hO WORK WORK COUNT D N0 WORK T A 1 A MoN d d di b FUSION FUSION C POWER POWER q v OS ss Ly LJ kp ABs i hog lod REJECT WORK COUNT D hO WORK WORK COUNT D N0 WORK T A Pc T A oh gt gt FUSJON FUSION POWER POWER qv o B 2 See preceding page for actual unit width FIG 4 8 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 require ments 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 Chapter 4 System Setup and Wiring Rev 3 4 4 Nutrunner Tool Specifications 4 4 1 Tool dimensions and mounting specifications are critical in determining the design of the sus pension reaction equipment r
56. 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 After Connection to an Ethernet network the Ethernet sta tus 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 communication can take place Ethernet Status LED Link MEET Active necne pee m ETHERNET Link LED is 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 intro duction of Open communication networks known as Fieldbus the direct interfacing to these networks became necessary FEC integrated many of these Fieldbus interfaces di rectly 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 Devicenet Ethernet I P CClink amp Allen Bradley Remote l O others available Contact FEC for additional Fieldbus requirements The fieldbus interface boards are integrated directly to internal I O signals which eliminate associ ated I O wiring
57. copying distribution or use of the information contained herein for other than its intended purpose is strictly prohibited For the safety of operator and equipment 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 Introduction wmm 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 in
58. end and on the last Remote Local de vice between the DA amp DB terminals Termination Termination of the CC Link requires a terminating resistor at each end of the fieldbus Connect 120 ohm resistor between the DA amp DB terminals if this is the last connection Re member that the CC Link master also needs to be terminated Baud Rate Switch 156k FB INIT 625k This rotary switch is used to specify the baud rate of the module This can also be specified in the FB INIT mailbox p M command In this case the switch must be set to 9 Que 87 ae This setting MUST match the setting of the Master module This switch must be set before power is and cannot be changed during operation Station Number Switches These two rotary switches are used to specify the station number of the module Two digit decimal The Upper rotary switch closest to the Baud Rate Switch sets the tens digit 10x and the bottom rotary switch sets the ones digit 1x Valid settings range from 1 up to 641 Example To set station number 24 place the tens digit switch on 2 and the ones digit switch on 4 This can also be specified in the FB INIT mailbox command In this case the switches must be set to 99 h This switch must be set before power is on and cannot be changed during operation 1 If more than one station is occupied by the module the highest possible station number is
59. function version correspond to the two digits to the right of 18 in the table below Ex Display 1 03 corresponds to set up of 1803 To make a change when the function version is being displayed D No 03 Depress SET and MODE buttons at the same time PROGRAM mode Depress MODE button Display should show Work 00 D No 03 Depress SET button The cursor will blink on the leftmost digit Use the 4 and T buttons to enter 18xx whereas the xx is the desired setting 18 must always be entered as the leftmost digits 6 Depress the SET button to enter the change into memory 7 CHNG will appear in the display use the J and T buttons to change NO to YES in the display 8 Depress SET to confirm and enter the change to memory 9 1 Qu Tor Nc Depress SET and MODE buttons at the same time return to RUN mode 0 System MUST be re booted in order to change the function mode Shown below are the available options for setting of this Data No Set No AFC S W Comm Speed Tool Type Work Select Method 1800 Comm Speed 38400bps Rev Sw Slide twisttype Work Select from Terminal TB1 1801 Comm Speed 38400bps Rev Sw Slide twist type Work Select from Front Panel 1802 Comm Speed 38400bps Rev Switch PB type Work Select from Terminal TB1 1803 Comm Speed 38400bps Rev Switch PB type Work Select from Front Panel 1810 Comm Speed 9600bps Rev Sw Slide t
60. in order for the fastening data to be output If it connected to the RTS signal if data is to be dumped at every fastening Connection with hardware handshake with DTR signal UNIT BACK PANEL USER D SUB 29N Connection without handshake data dumped without DTR signal UNIT BACK PANEL USER D SUB PN D SUB 29N Page 4 19 Chapter 4 System Setup and Wiring 4 8 3 Rear Panel RS232 Standard Communication Protocol Communication protocol from the rear panel RS232 port is as follows Speed Parity Data Bits Start Bit Stop Bit Error Control The data format from the Fusion system is a formatted ASCII output 9600bps None 8 Bit 1 Bit 2 Bit None to a serial printer computer or other peripheral device tening using the Standard Format This can be connected 214 bytes of data is output per fas The data format is described below Example m Example me Example exte ASCI iData EE Description ascii Data Eug Description AS Data 1 Start Of Text 02H 35 Cycle Count 35H 5 69 1 Rate Incr Ang 32H 2 2 Parameter No 20H 36 Cycle Count 37H 7 70 2 d Rate Incr TQ 0 3 Parameter No 31H 1 37 Peak Torque 31H 1 71 2 Rate
61. ing specification for that specific fastener or by determining the acceptable limits from a study of known good and bad assemblies The High Torque limit will stop the fastening pro cess for Angle Control operations if it is reached before attaining the desired angle ANGLE CONTROL REJECT TYPE CAUSES Reduced joint compression PEAK TORQUE HIGH LIMIT Increased joint friction Incorrect parameter set up Increased joint compression Reduced joint friction PEAK TORQUE LOW LIMIT High initial prevailing torque Incorrect parameter set up Reject condition caused by another monitor item reject Torque MM Peak Torque High Limit r Peak Torque Low Limit Crossover Torque Snug Torque T Torque e ete em es 1 Threshold Torque g G4 ML v B M Speed Change Torque m 1 os 1 Angie Standard Angle 1 Time Final Time FIG 6 2 1b Peak Torque Monitor Angle Control Page 6 13 Chapter 6 Fastening Instructions 6 2 2Final Torque Monitoring Torque Monitoring is a continuous process whenever the system is operating Final Torque monitor ing uses the torque value detected at the completion of fastening e In Torque Control method the Final Torque value and Peak Torque values will be identical except in cases where Torque Recovery Section 6 5 is enabled In Tor
62. is fully depressed until the trigger is released or until the fastening cycle is complete When the trigger is fully depressed the tool will operate as programmed completing each speed change step that has not elapsed Alternative Start input available though use of PLC inputs on terminal TB1 e REVERSE The Reverse switch for the FUSION Controller is located on the Handheld tool This push button switch enables Reverse back out operations When depressed the Tool LED display will flash to indicate Reverse back out mode selection Depressing the Start trigger switch while in Reverse back out mode will cause the tool to run the opposite direction of the Fas tening operation Alternative Reverse input available though use of PLC inputs on terminal TB1 Page 7 2 FUSION Operations Manual Chapter 7 System Operations Rev 3a e CAL Calibration Transducer calibration check push button Depress this push button to obtain the CAL volt age level from the tool pre amplifier This level is compared to the data stored in memory The calibration voltage level is converted to the full scale torque according to the parameter setting and is shown the DATA display e RESET Used to reset the FUSION controller unit If this key is pressed during fastening the process will stop and all the fastening data and output signals will be reset At the same time the Ze ro level of the torque transducer will be checked Alternative Res
63. module can be added to the controller This module is added into the back of the controller inside of the access panel at the upper right side When this clock module is added the date amp time will be attached to the stored data every cycle This function is available in Firmware version 2 20 or later The AFC software will be required for restoring stored data from controller Clock module model ANG RTC Backup power source Electric double layer capacitor Backup memory duration Approx 10000 hours Backup power charge time Approx 1hour If the controller power is turned off for more than 2 months the clock backup power will be lost amp the time settings will be lost The Clock can be set using the front display amp keypad the same method as changing param eter data See the table below for parameter numbers Work Data Item Example 00 30 Year yyyy 2005 Year 2005 00 31 Month amp Date mmdd 0131 January 31st 00 32 Hour amp Minute hhmm 1759 17 59 00 33 Seconds 0055 0020 20 second Seconds will be set as 00 when Hour amp Time Data 32 is changed Ge Note Clock may be off approx 10 seconds month Adjust as required AFC Software version 5 16 or after added function to program Date Time from software Page 7 38 FUSION Operations Manual Chapter 7 System Operations Rev 3a 7 6 Tubenut Head Set up Tubenut heads are used for applicat
64. or not connected 2 When the resolver motor or the controller malfunctions 3 If there is excessive binding in the fastener transmission or the spindle assembly keeping the motor from turning RECOVERY 1 Verify that the motor cable is connected and not damaged 2 Connect all spare tool cables to the existing tool 3 Exchange tool and or controller with known working units Reinitialize the system after exchanges 4 Inspect and correct any binding in the spindle assembly transmission or fasteners Page 9 9 Chapter 9 Troubleshooting 9 7 Servo Type Error 9 7 1 Code 6 0 SERVO TYPE ERROR SERVO TYPE MISMATCH The CONTROLLER Unit model does not match the connected motor type 1 Verify the servo type tag with the motor type tag Page 9 10 FUSION Operations Manual Chapter 9 Troubleshooting Rev 3 Servo Amplifier Error 9 9 1 Code 8 1 SERVO AMPLIFIER ERROR SERVO IS OVER HEATED The CONTROLLER servo circuit has overheated This abnormal is caused from 1 The controller servo drive circuit has failed 2 If the environment temperature is more than 122 degrees Fahrenheit 50 degree centi grade without any air flow 3 Source voltage is very close to the limit and the environment temperature is also close to the limit RECOVERY 1 Replace the controller 2 Provide additional cooling to the enclosure 3 Verify and correct the source voltage as required 9 9 2 Code 8 4 SERVO AMPLIFIE
65. pacity 5 Torque Inhibit Limit WORK 01 thru 32 D No 19 When using the Tubenut function the Torque Inhibit Limit parameter sets the MAX amount of torque that can be sensed during the Torque Inhibit Revolu tion setting This is used to set the max torque to be sensed during the start of rotation of the socket or until the socket U opening moves to a closed position This will protect from damage anything being inserted into the path of the socket as it rotates in the OPEN space If this torque value is exceeded during the Torque Inhibit Revolution Work 01 thru 16 D No 61 a REJECT will result This cannot be set too low or nuisance REJECTS will occur during normal motor start up Recommended setting 75 1 5Nm NOTE This setting will vary by tool size and Tubenut head configuration WARNING Do set this ABOVE the recommended setting or per sonnel injury may result 6 Torque Inhibit Revolutions WORK 01 thru 32 D No 61 Set Torque Inhibit Revolution so that the torque can be checked during motor start up Just enough revolution for the socket to close the U opening Recommended setting 3rev Page 7 40 FUSION Operations Manual Chapter 7 System Operations Rev 3a 7 Initial Time WORK 01 thru 32 D No 40 Set Initial Time so that revolution time speed is slow during motor start up the time that the socket is rotating in the socket U opening Recommended setting
66. page and the abbreviated format shown below This function is available in firmware versions 2 22 or later abbreviated output format The table below describes the data set up for enabling and configuring the 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 ODh CR 1 0Ah LF 3 0Dh 0Ah CR amp 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 1Bit 1 2Bit 00 45 Parity 0 None 1 Even 2 Odd 00 46 Torque data 0 Nodata 1 data 00 47 Angle data 0 No data 1 Enable data 00 48 Cycle Time data 0 Nodata 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 Spindle Work Cycle Count Peak Torque Final Angle p 23H 31H 31H 30H 31H 32H 31H 32H 2EH 33H 34H 31H 31H 32H 2EH 33H Data 4 1 1 0 1 2 1 2 3 4 1 1 2 3 Byte 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Desc Not Used Cycle Time Judge 30H 30H 30H 30H 30H 30H 30H 30H 31H 32H 2EH 33H 4
67. setup Full Scale Torque x 1 1000 4 digit display with floating decimal point 0 1 Degree 1024 pulses motor rev 0 1 degree Forward Max count 9999 degree Reverse Max count 1999 degree 0 Full Scale 1 0 5 of Full Scale value Maximum Page 2 5 Chapter 2 Specifications 2 4 1 Nutrunner Tool Specification Table Mainly two tool models have been used to date and is designated in the model number of the tool itself A 01 at the end of the tool model number indicates the original model these models are silver in color A 10x at the end of the model designates the newest models these models are gold in color The two models require different tool CABLES from the controller to the tool The original models use FEB 13xx Mxx cable s The newer models use C15 F7 Mxx cables There is one controller for all size tools however the newer model tools gold in color may not be recognized by older silver controllers due to TOOL ID information not existing in the controller firmware In this case request a controller firmware upgrade by contacting FEC J19NY LHSIVYLS JOLSId TOOL TYPE RPM T T 0 58 8 60 600 4 amp 4 5208 1 19 V 0 _ 78 4 80 800 679 sso 1 38 12 gt fo 15 woof 1 14 se roof 1 14 se T 055 80 5 sas 5s 550 se 769 s08 1 v
68. technical information on the Ethernet I P interface go to the HMS website www hms se Ethernet I P Hardware jeuJ8ui3 SNLVLS Item Description 1 Ethernet Connector 2 Configuration Switches 3 Status LEDs 4 Page 4 57 Chapter 4 System Setup and Wiring Fieldbus Interface Connection Pin Signal 1 Noe _ _ _ _ _ _ _ _ 3 RD om oer om e e e o Le 4 Normally left unused to ensure signal integrity these pins are tied 5 together and terminated to PE via a filter circuit in the module 7 Normally left unused to ensure signal integrity these pins are tied 8 together and terminated to PE via a filter circuit in the module Configuration DIP Switch ERE m o m E o m om AM 957 Status LEDs This switch is not used for FEC IP configuration and should be set to all OFF The IP address is set up using the AFC Software see below Fieldbus Configuration feature LED State Description Off 2 Module Status A major unrecoverable fault has been Red solid detected A minor recoverable fault has been Red flashing detected Off No power to device or no IP ad dress has been set Online One or more connections Green solid tablished ic 4 Activity Green Flashes e
69. terminal block to the controller and reassemble the terminal block to the new controller 3 Turn the controller on the cover hinges 90 degrees and Lift up on the controller unit to remove 4 Verify the new controller unit dip switches are set the same as the unit being replaced Refer to Section 4 10 5 Verify the SAN Units have the same configuration hardware and software 6 Install the new controller in reverse order of removal 7 Apply power and confirm operation After approximately 5 seconds the controller will finalize the Power On Self Test POST The new Controller will require reentry of the preset data Refer to Chapters 6 and 7 Page 8 7 Chapter 8 Maintenance and Inspection 8 3 2 Replace Nutrunner tool Do not attempt to replace a component of the tool the tool must be replaced as a complete assembly The tool type identification can be found on the identification tag affixed to the tool and on the System TOOL TYPE preset value WARNING DO NOT CONNECT OR DISCONNECT CABLES OR OTHER SYSTEM COMPONENTS WITH POWER APPLIED 1 Verify all System power is off 2 Twist connector on the tool in the CCW direction and pull connector from tool 3 Replace tool and plug in connector aligning the key in the connector to the keyway in the tool 4 Twist connector in the CW direction to the fully locked position 5 Power up controller and confirm no ABN abnormal is displayed in the LED disp
70. 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 e 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 e Batch Counting The Batch Count function allows multiple fastening accepts to be counted for an overall Work Accept of the work piece e Parameter Sequence Up to an 8 Step Sequence can be programmed when additional sequencing or parameters are required by applications or processes Page 1 5 Chapter 1 Outline c pO p vd 1 4 System requirements To ensure the most effective and extended use of all equipment adhere to the following specifications e 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 mou
71. the parameter number that is being selected by the PLC is configured in the controller 2 Check that the reverse speed preset is not 0 or out of the specified speed range of the tool 9 10 3 Code 9 2 PARAMETER ERROR PARAMETER SELECT ERROR The parameter selected was empty RECOVERY 1 Verify that the parameter number that is being selected by the PLC is configured in the controller 2 Check that the fastening presets are not 0 or out of the specified range for the tool 9 10 4 Code 9 3 PARAMETER ERROR MISSING REVERSE SPEED The Reverse speed preset is missing RECOVERY 1 Verify that the parameter number that is being selected by the PLC is configured in the controller 2 Check that the reverse presets are not 0 or out of the specified range for the tool 9 10 5 Code 9 4 PARAMETER ERROR TORQUE SPEED NOT SET The Torque speed preset is missing RECOVERY 1 Verify that the parameter number that is being selected by the PLC is configured in the controller 2 Check that the Torque speed is not set as 0 or out of the specified range for the tool Page 9 14 FUSION Operations Manual Chapter 9 Troubleshooting Rev 3 9 10 6 Code 9 5 PARAMETER ERROR TORQUE SETUP ERROR One of the Torque presets is out of range RECOVERY 1 Verify that the Torque presets are in range for the tool size 2 Check that the torque presets are not 0 or setup as specified in 6 1 1 9 10 7 Code 9 6 PARAMET
72. the socket Page 7 42 FUSION Operations Manual Chapter 8 Maintenance and Inspection Rev 3 Chapter 8 Maintenance and Inspection Page 8 1 Chapter 8 Maintenance and Inspection 8 1 Inspection Items A scheduled inspection is recommended to keep the FUSION System in the best condition A preventive maintenance routine should be set up Recommended inspection schedules are given for each item WARNING Follow Lockout Tagout and other safety precautions when connecting or disconnecting cabling wiring and equipment Always verify the System is disabled prior to touching any moveable components 8 1 1 Nutrunner Tool 8 1 Recommended Schedule Quarterly It is important to keep the nutrunner tools clean and properly adjusted to ensure correct fas tening and accurate system outputs Inspect each tool and ensure the following conditions exist All environmental conditions are within the specified ranges The duty cycle is within specifications and the motor is producing normal heat levels The tool is producing normal levels of noise and vibration no irregular noise The tool is free from excessive contamination and foreign matter The tool is securely mounted with mounting bolts properly tightened The Tool cable is securely connected to the tool 2 Tool Cable Recommended Schedule Quarterly This cable connects the tool to the Controller unit Ensure the following conditions are met The cables are fr
73. thus reducing overall assembly labor In fieldbus systems the communica tion 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 net work or not The COUNT D NO LED on the front of the controller indicates the fieldbus link status The two decimal points will il luminate when the Fieldbus link is DISABLED Check all connections and configurations for proper set up FUSION Page 4 38 FUSION Operations Manual Chapter 4 System Setup and Wiring Rev 3 4 15 1 Fieldbus Interfaces Profibus DP The Profibus DP commun
74. too extreme for an operator to handle The motor ramp down time is extended allowing a gradual relief of the applied torque to the operator s hands thus reducing the affect and fatigue of di rect torque reaction See the AFC User Console software manual for additional set up information 6 6 4 VariSpeed Varispeed automatically adjusts the fastening speed based on the type of joint that is being fastened This eliminates motor overload conditions typically on very soft joints high rotational angle and de creases system cycle time When the system senses a decreasing torque rate soft joint prior to reaching 1 Torque Angle the motor speed is automatically increased to an optimal speed for that particular torque rate When the system senses an increasing torque rate hard joint prior to reach ing 1st Torque Angle the motor speed is automatically decreased to an optimal speed for that particu lar torque rate The speed is automatically controlled during the fastening process based on the torque rate See the AFC User Console software manual for additional set up information 6 6 5 Work Count Batch Counting For applications requiring multiple Accept fastenings for a given part before a total Work work piece accept is output the Work Accept count function can be used This allows an operator to fasten multiple times the number of accepts is programmable before a total WORK ACCEPT is output amp displayed on the WORK ACCEPT LED
75. 0 45 C 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 e 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 FUSION Operations Manual Chapter 1 Outline Rev 3 e 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 e 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 e Loose FUSION System components must be individually packaged in an approved anti static container or wrap to prevent damage from electrostatic discharge e
76. 0H Data 0 0 0 0 0 0 0 0 0 1 2 3 Byte 31 31 31 32 Desc ASCII Hex ODH OR OAH OR OAH Data CR LF CR LF Definition of Judge Byte 30 9 Accept G Stop E Low Time Reject F Time Reject Bypass Angle High Reject Angle Low Reject Torque High Reject Torque Low Reject A Abnormal X Other Reject Page 4 24 FEC FUSION Operations Manual Chapter 4 System Setup and Wiring Rev 3 4 8 5 Rear Panel RS232 Alternate Communication Protocol An alternate communication protocol is available upon set up in a different Fastening Func tion Mode See 7 2 5 Fastening Function Version Work 00 D No 03 If the system is set up in a DDK mode this protocol becomes the Standard Communication Protocol This alternate protocol has 79 bytes of data per fastening Byte 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Spindle Work Desc Cycle Count Number Number noe 30H 30H 30H 31H 20H 20H 30H 31H 20H 20H 20H 31H 20H 20H Data 0 0 0 1 0 1 1 Byte 15 16 17 18 19 20 21 22 23 24 25 26 27 28 Desc Peak Torque Judge Final Angle Judge VERE 31H 32H 2EH 33H 34H 4CH 20H 20H 20H 20H 35H 30H 48H 20H Data 1 2 3 4 L 5 0 H
77. 2 Communication Status Green 2 flashes Blink Factory ID tool Configuration Error Too many modules 3 Module Status Red 1 flash from IO controller config Too large Configuration Mismatch no module wrong module Red 3 flashes No station name or no IP address as signed Red 4 flashes Green 1 flash Diagnostic data available Page 4 81 Chapter 4 System Setup and Wiring 5 12 2 User Console Software Settings The Anybus board is set up by sending a Fieldbus Configuration File fcf containing ini tialization messages from the Fusion Controller to the Profinet board during power up This string of data initializes different characteristics required for the board to communi cate over the Profinet network In this string is data which sets the length of I O data as well as length of messages Resultant Fastening data Since the board is only initialized during power up the controller MUST have the power cycled OFF ON after the fcf file is downloaded To download the fcf file select Field Bus Setup from the AXIS pull down menu Select the appropriate Bus Type and click Browse to locate the correct fcf file if one has previously been saved After the file has been selected click download to send the file data to the Anybus Profinet board If no file exists or if the settings need to be changed after the Bus Type has been se lected click on the Setup Tab
78. 2 Follow the ZERO VOLTAGE ERROR abnormal help procedure Code 1 5 TORQUE TRANSDUCER STARTED ON CAL ERROR CONDITION The start signal was input while a Cal voltage abnormal condition existed RECOVERY 1 Interlock the PLC circuit to disable the start signal during an existing abnormal condition 2 Follow the CAL VOLTAGE ERROR abnormal help procedure Page 9 4 FUSION Operations Manual Chapter 9 Troubleshooting Rev 3 9 2 7 Code 1 6 TORQUE TRANSDUCER ZERO LEVEL SELF CHECK ERROR Zero level voltage loaded to memory from tool EEPROM during initialization does not match the actual zero level during a self check with the self check function enabled This abnormal is caused from 1 When the tool transducer is sensing excessive torque due to pressure on the tool body 2 If the controller or the transducer cable is located in an electric or magnetic noise field 3 When the torque transducer Tool cable or the controller malfunctions RECOVERY 1 Check that the tool has no external force applied to it 2 Verify that the cable or controller is not located near any high voltage transient power sources Relocate as required and reinitialize 3 Exchange tool cable tool and or controller with known working units Reinitialize the sys tem after each exchange and make note of any change in the location of the abnormal 4 Replace the defective component Page 9 5 Chapter 9 Troubleshooting 9 3 Torque Over Abno
79. 3048 meter 230K 762 meter Belden 9463 or equivalent Communications Type Master Slave AB Remote I O connector COM line Shield COM line Status LED INDICATOR HELD Status LEDs Error Normal Operation ON Red Bus off Error Active Communication Active Power Off Page 4 48 FUSION Operations Manual Chapter 4 System Setup and Wiring Rev 3 Dip Switch Setting Address setting DIP switch lil inii ad WB LSB Address 0 Address 1 ON j OFF OFF OFF OFF Address2 ON ON OFF OFF j OFF Address3 eooo de e e gu ou 3 ON OFF ON Address57 OFF ON OFF ON jAddress58 JON OFF ON JON JON Addrss59 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 Baud rate setting DIP switch SW1 SW2 Baudrae 57 6K 115K _____ JON 380K PONTOON sd 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 Octal Bit Signal Description Comment 0 0 End 1 1 Accept 2 2 Reject 3 3 1 00
80. 6 Status Display 7 30 7 3 Download Setup Mode Operation 7 31 7 3 1 Download Mode selection 7 31 7 3 2 Setup Mode selection 7 32 7 3 3 Parameter Number Selection 7 33 7 3 4 Data selection 7 34 7 3 5 Data Edit Mode Operation 7 35 7 3 6 Parameter Copy 7 36 7 4 Calibration adjustment 7 37 7 5 Optional Real Time Clock Module 7 38 7 6 Tubenut Head Setup 7 39 7 6 1 Recommended Parameter Setup for Tubenut Head 7 40 7 6 2 Tubenut Head Operation 7 41 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 Table of contents 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 transduce
81. 6 total bytes max Data transmission The module only supports cyclic I O data transmis sion Note Limited Coded Binary Integer data is sent in the cyclic I O data a Profibus Connector I Termination Switch 8 RN Node Address Switch LED Status Indicator Page 4 40 FEC FUSION Operations Manual Chapter 4 System Setup and Wiring Rev 3 Profibus Status LED Profibus connector D Sub Not Connected O Not Connected _ Pin 3 B Line Positive RxD TxD accord ing to 5485 Spec Request to send Pin 5 GND Bus Isolated GND from RS 485 side EF CERN spen to RS485 Spec Profibus Status LED Status LEDs Red Indicates faults on fieldbus side LED 4 Flashing Red Config Error in out length set Fieldbus Diagnostics sec at module initialization does not match length in network config Flashing Red Error in user parameter data 2sec parameter length content does not match network length content Flashing Red Error in initialization of Profibus LED 2 Green Module online and Normal Communicator oK e Module is not offline Red Module is offline on the fieldbus Note LED 1 Not Used Page 4 41 Chapter 4 System Setup and Wiring 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 addr
82. 9 2nd stop synchronization point for multiple step fastening operations End point for 2nd torque rate calculation 1E 2 Rate Start Torque or 26 2 Rate Start Angle is the beginning Start point for 3 Torque Rate calculation Fastening End is the stop point Torque 35 Rate 3 High Limit mee 34 Rate 3 Low Limit Angle 24 CROS 22 Standard Data No 19 Torque Inhibit Limit Nm Kgm Setting range 0 10 Calibration torque x 1 1 Limit for ignoring the Torque value sensed during fastening start due to inertia When the ini tial Torque exceeds the Torque Inhibit Limit during 61 Torque Inhibit Revolutions an ABNORMAL will be generated and fastening will end Page 7 20 FUSION Operations Manual Chapter 7 System Operations Rev 3a Data No 1B Breakaway Torque Limit Nm Kgm Setting range 0 10 Calibration torque x 1 1 When this torque is exceeded during Reverse 2 or 3 operations an Abnormal will be generated that will stop the operation Data No 1C Final Low Torque Nm Kgm Data No 1D Final High Torque Nm Kgm Setting range 0 10 Calibration torque x 1 1 For Angle Method sets the High and Low limits for Torque at the point that the final Fastening Angle is achieved For Torque Method during Torque Recovery sets the High and Low limits for Torque at the point that the final Fastening is completed Data No 1E 2ND Rate Start T
83. 9 Time 30H 0 24 JudgmentFlag 58 3 Rate 39H 9 92 2 9 Time 32H 2 25 JudgmentFlag 30H 59 3 Rate 39H 9 93 2nd Time 37H 7 26 JudgmentFlag 60 34 Rate 39H 9 94 Rundown Revs 30H 0 27 Judgment Flag 30H 61 Rate Sign Flag 30H 0 95 Rundown Revs 31H 1 28 Batch Count 30H 0 62 1 Rate Incr TQ 0 96 Rundown Revs 31H 1 29 Batch Count 34H 4 63 1 Rate Incr TQ 30H 0 97 Rundown Revs 35H 5 30 Torque Unit 30H 0 64 1 Rate Incr TQ 32H 2 98 Offset Torque 30H 0 31 Torque Decimal 32H 2 65 1 Rate Incr TQ 30H 0 99 Offset Torque 30H 0 32 Rate Decimal 33H 3 66 1 Rate Incr Ang 0 100 Offset Torque 30H 0 33 Cycle Count 31H 1 67 1 Rate Incr Ang 31H 1 101 Offset Torque 30H 0 34 Cycle Count 33H 3 68 1 Rate Incr Ang 32H 2 102 Fastening Mode 30H 0 Page 4 20 FEC FUSION Operations Manual Chapter 4 System Setup and Wiring Rev 3 Byte Description Byte Description meee sud Description ESSE 103 Cal Value 32H 2 141 Crossover Torque o 179 1 Rate Lo Limit
84. 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 3 Chapter 2 Specifications Page 2 1 Chapter 2 Specifications 2 4 Main Specifications Power Supply Voltage e Single Phase 100 240 VAC 10 50 60 Hz Auto Switching Supplied with 100 120VAC Cable 5meter Installation Requirement e No Vibration should be applied directly to the Controller Securely mount controllers to a fixed point Range of Operation e Duty cycle below 50 reference Section 2 2 Duty Cycle Calculation Operating Conditions e Temperature 0 50 32 122 F e Humidity 2096 90 no condensation shall be present In cases where equipment may be used outside of the prescribed conditions forced cooling heating is required for operation Storage Conditions e Temperature 5 55 23 131 F no freezing e Humidity Below 90 no moisture Shipping Conditions e Temperature 5 55 23 131 F no freezing e Humidity Below 90 no condensation shall be present e Packing Pack controllers in sealed from open air bags Apply light oil to any steel portion of the tool unit to prevent rust corrosion Page 2 2 FEC FUSION Operations Manual Chapter 2 Specifications Rev 3 2 2 Duty Cycle Calculation Duty Cycle is rated as a percentage of th
85. Byte 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 Desc Final Torque Judge 1st Rate Judge jh 31H 32H 2EH 33H 34H 20H 20H 20H 30H 2EH 31H 32H 33H 20H 20H 20H Data 1 2 3 4 0 1 2 3 Byte 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 Desc 2nd Rate Judge 3rd Rate Judge go 30H 2bEH 31H 32H 33H 20H 20H 20H 30H 2EH 31H 32H 33H 20H 20H 20H Data 0 1 2 3 0 1 2 3 Byte 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 Desc 1st Time Judge 2nd Time Judge Final LF Judge ros 20H 31H 30H 2EH 30H 20H 20H 20H 20H 20H 32H 2EH 20H 20H 20H 58H ODH OAH Data 1 0 0 2 0 X Final Judgment Reject 58H Judge High Reject 48H L Low Reject 4CH Hex Accept 4FH A Abnormal 41H S Stop 53H B Bypass 42H 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 amp Speed signals to external equipment for monitoring purposes X Y Plotter etc The signals output from this con nector are the same signals that the system receives during the fastening process This connector is not required for the system to operate In Out Description None None Angle Pulse Angle
86. CCEPT ABNORMAL READY BUSY Torque Hi Reject Torque Low Reject BYPASS Angle Hi Reject Angle Low Reject Rate 1 Hi Reject Rate 1 Low Reject Rate 2 Hi Reject Rate 2 Low Reject Rate 3 Hi Reject Rate 3 Low Reject Output No 02 Output No 03 Output No 04 Page 4 85 Chapter 4 System Setup and Wiring Signal Connection Comment Output No 05 Torque Integer bitO Torque Integer bit1 Torque Integer bit2 Torque Integer bit3 Torque Integer bit4 Torque Integer bit5 Torque Integer bit6 Torque Integer bit7 Output No 06 Torque Integer bit8 Torque Integer bit9 Outputs Fastening Torque using binary integer 0 999 max number LEFT of decimal only Example Torque integer bit 2 4 7 Logical 1 148 Total Torque including Torque decimal Output No 7 below 148 38 Output No 07 Torque Decimal bitO Torque Decimal bit1 Torque Decimal bit2 Torque Decimal bit3 Torque Decimal bit4 Torque Decimal bit5 Torque Decimal bit6 Outputs Fastening Torque Decimal value using bina ry integer 0 99 max number RIGHT of decimal only Example Torque Decimal bit 1 2 5 Logical 1 38 Output No 08 Page 4 86 FEC FUSION Operations Manual Chapter 4 System Setup and Wiring Rev
87. ECTED Connection point for discrete inputs and outputs I O When wired in the entire connector can be removed by loosening the 4 TB1 upper and lower retaining screws Refer to chapter 4 for detailed descriptions of I O signal 5 Ground Lu Ground terminal for connection to the Back Panel Cover s 9 ground wire 6 RTC Connection 8 pin plastic connector Real Time Clock Connection 7 ISYNC Connection 4 pin plastic connector Sync Connector 8 Interface option Mtg Interface adapter port Optional Fieldbus or Ethernet board 9 Breaker Electrical Leakage Breaker Ground Fault detector l on O off 10 Fieldbus Interface slot Optional Slot for Fieldbus Interface Devicenet Profibus CCLink Ethernet I P Profinet etc 11 Ethernet Connection Optional Slot for Ethernet interface Used for Ethernet connection with the AFC programming monitoring software PC and or Ethernet Data Server 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 FUSION Operations Manual Chapter 3 System Description Rev 3 3 2 FUSION Tool 3 2 1 FUSION Tool Part Number Breakdown HFT 051 M80 A 1 E 1 01 A B CDEFG A MAXIMUM TORQUE B MOTOR C TOOL TYPE D MODEL REVISION
88. ER ERROR ANGLE SETUP ERROR One of the Angle presets is out of range RECOVERY 1 Verify that the Angle presets are in range for the tool size 2 Check that the Angle presets are not 0 or setup as specified in 6 1 2 9 10 8 Code 9 7 PARAMETER ERROR REVERSE TORQUE OVER The Reverse torque is more than 1 5 times the Full Scale Torque RECOVERY 1 Verify that the preset value is correct 2 If the value is correct check the application The size of the tool is not adequate for this application or the fastener being reversed may be over torqued Page 9 15 Chapter 9 Troubleshooting 9 11 FUSION CONTROLLER Unit Fastening Faults and Causes 9 11 1 Torque Accept Conditions The Accept LED will light for the following reasons 1 The previous fastening was completed within all preset limits TORQUE ANGLE 1st RATE 2nd RATE and TIME 9 11 2 Torque Reject Conditions The Reject LED will light for the following reasons The final fastening torque is not between the low and high Torque limits low and high angle limits low and high rate 1 2 and 3 or the time 1 or final time limits set in the parameter presets Page 9 16
89. FF ON Over current OFF Resolver abnormal ON OFF ON ON Controller unit overheated ON ON OFF OFF ON ON OFF ON Internal voltage level abnormal ON ON ON OFF Input voltage abnormal ON ON ON ON Overload OFF No error Page 4 15 Chapter 4 System Setup and Wiring 4 7 5 PLC Wiring Sample This diagram represents standard I O connections to a PLC NPN current sinking Active true low The 24VDC power can be supplied from the FUSION controller terminals A10 B10 if total consumption is less than 0 5A Standard current flow shown PLC PLC INPUT BOARD 2 2K FUSION CONTROLLER TBI OUTPUT WT 40ma max 2 2K WT x FUSION v OUTPUT OUTPUT Wr QUT COMMON PLC OUTPUT BOARD 24VDC COMMON WAzZ WV 5 3K INPUT Tm FUSION INPUT y 3 3K INPUT mir Tr 24 VDC POWER SUPPLY FIG 4 7 5 PLC Wiring Sample The standard controller 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 sinking outputs normally high pull the input device signal low 0 Inputs are sourced normally high and activated when pulled low 0 VDC
90. FUSION Operations Manual Chapter 3 System Description Rev 3 3 2 3 FUSION Pistol HOON TOOL MAJOR COMPONENT IDENTIFICATION ITEM ITEM AS MARKED ON UNIT DESCRIPTION MOTOR RESOLVER Provides feedback for speed regulation to the Servo Amplifier Provides angular rotation monitoring for fastening operation Totally enclosed DC permanent magnet motor TRANSMISSION Durable planetary gear transmission Refer to Chapter 2 for standard tools and gear ratios TRANSDUCER PREAMP Highly durable compact design minimizes space requirements Intelligent transducer design uses an ID Chip to verify integrity of fastening operations CABLE CONNECTOR 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 START SWITCH 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 REVERSE SWITCH Momentary Reverse selector switch or Twist Ring 10 models Depressing the Reverse selector switch places the tool in the Reverse Backout mode The Accept R
91. G 6 1 2d Angle Control Functions for Three Step Fastening Page 6 11 Chapter 6 Fastening Instructions 6 2 Monitoring Functions The Fusion System is user programmable to select and set the monitoring limits for torque angle time up to three independent torque rate areas and special functions describe below 6 2 1 Peak Torque Monitoring Torque Monitoring is a continuous process whenever the System is operating Peak Torque monitor ing uses the maximum torque value detected during Fastening e In Torque Control method the Peak Torque High and Low Torque limits are set based upon the engineering specification for the specific fastener TORQUE CONTROL REJECT TYPE CAUSES Re hit of pre secured fastener PEAKTORQUE elon EI Incorrect parameter set up PEAK TORQUE LOW LIMIT Reject condition caused by another monitor item reject Torque t Peak Torque High Limit Standard iniret AEE e e PP NE t Peak Torque Low Limit Crossover Torque Siig Torgue a 1 Torque Threshold Torque Speed Change Torque P 9 Angle Time I 1 Time Final Time FIG 6 2 1 Peak Torque Monitor Torque Control Page 6 12 FEC Fusion Operations Manual Chapter 6 Fastening Instructions Rev 3 e For Angle Control operations the High and Low Torque limits are either set by the engineer
92. In case any abnormality occurs remove the cause and ensure safety before resetting and restarting the equipment Failure to observe this instruction may cause injury Table of Contents Chapter 1 Outline 1 1 About This operations manual 1 2 Features 1 3 Functions 1 4 System requirements Chapter 2 Specifications 2 1 Main Specifications 2 2 Duty Cycle Calculation 2 3 Controller Unit Specifications 2 4 Capability 2 4 1 Nutrunner Tool Specification Table 2 4 2 Nutrunner Decimal Point Display Table Chapter 3 System Description 3 1 Controller 3 1 1 Controller Part Number Breakdown 3 1 2 Controller Front Panel 3 1 3 Controller Back Panel 3 2 Fusion Tool 3 2 1 Fusion Tool Part Number Breakdown 3 2 2 Fusion Angle Straight Tool Components 3 2 3 Fusion Pistol Tool Components Chapter 4 System Setup and Wiring 4 1 Design and Build Procedure 4 2 Component Dimensions 4 2 1 Controller Unit Dimensions 4 3 Unit Arrangement 4 4 Nutrunner Tool Dimensions 4 4 1 Straight Tool 4 4 2 Right Angle Tool 4 4 3 Pistol Tool 4 5 Connection Diagrams 4 6 Power Requirements and Connections 4 6 1 Controller Unit 4 7 Wiring PLC I O 4 7 1 Explanation of Controller Unit I O 4 7 2 Work Parameter Select Table 4 7 3 Bank Select Table 4 7 4 Bank Output Servo Error Table 4 7 5 PLC Wiring Sample 4 8 RS 232 Data Communication Ports 4 8 1 Front Panel DB9 PC Connection for AFC User Console Software 4 8 2 Rear Panel DB9 PC Connection RS232 4 8
93. Logix System 0 1769 L32E test Input Signals PLC Fusion 1769 132 Ethernet Port LocalENB FEC 2 0 Ethernet 1769 L32E Ethernet Port LocalENB Output Signals PLC gt Fusion Aa ELHERNEI MOD 00 CompactBus Local 8 0 CompactBus Local g 1 1769 IQ16F A Input 8 2 1769 0V16 8 Output 1760 Monitor Taas Page 4 64 FEC FUSION Operations Manual Chapter 4 System Setup and Wiring Rev 3 Receiving message communication FUSION OUTPUT gt PLC INPUT e Generation of Tag When you perform message communication a Read is necessary Generate a Read Tag us ing the PLC software Local 1 C 1769 1016 0 Local AB 1759 0116 1 0 Local2 C 4B 1769_D016 C 0 _ Local 2 1769 0016 1 0 Local 2 0 4B 1769_D016 0 0 Read_Data SINT Decimal MESSAGE READ_TAG2 MESSAGE AFC1500_2 1 AB ETHERNET MODULE SINT 15Bytes l 0 AFC1500 2 0 AB ETHERNET MODULE SINT 8Bytes O 0 AFC1500 2 C AB ETHERNET_MODULE C 0 2l e Message Command MSG With the PLC ladder editing screen a MSG message command must be used to get transfer the Message data MS Type CIP Generic Message Control Read_Tag e Properties of the MSG command MSG properties are set using Message Configuration and Communication Please refer to the following list for Configuration Establish Communication by pointing the messag
94. MINOR Revision Chapter 2 Page 2 4 Chapter Rev 2 1 now SOOO sane FUSIONE HS Updated Power Consumption Running amp Idle MINOR Revision Chapter 4 Page 4 48 4 53 Chapter Rev 2 1 now 20087 JUN FUSIONS Hag Added DeviceNet Interface 2014 Dec FUSIONE HS 3 MAJOR Revision Updated with all changes since 2008 2015 Oct FUSIONE HS 3 Chap 7 rev Updated Tubenut Op Parameters pg7 39 Manual Numbering Convention FUSIONE HS 3 Version Number Major Revision Level E English Verion HS Controller unit Hardware S Spanish Version peraan Manus HM Multi Main Unit Hardware Operation Manual HM ENET Ethernet Manual for Multi Main Unit SW Software Manual Japanese Version furnished by DDK uses DDK numbering convention Introduction Thank you for purchasing our Electric Servo Nutrunner FUSION System 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 equipment Items not described in this instruction manual shall be considered unavailable The product specification and appearance described in this instruction manual is subject to change without notice All rights reserved Any disclosure
95. ND all Field Ground FG Connections and terminals including the ground pin on the POWER CORD NEVER operate this equipment WITHOUT the ground pin on the power cord grounded Failure to observe this instruction may cause electric shock Use the equipment under the following conditions Ambient temperature 0 C 45 Avoid freezing Ambient humidity 90 RH or lower Avoid moisture Atmosphere Indoors Avoid direct sunlight No corrosive gases or flammable gases No oil mist dust water salt iron powder Avoid direct vibration or shocks Failure to observe this instruction may cause a ground fault and malfunction Confirm and adjust all parameters before operation in order to prevent unexpected movement of the equipment Failure to observe this instruction may cause injury false operation and malfunction The equipment may experience sudden torque reaction when operated by hand while engaged to a part Grasp tool firmly with firm footing when operating Additionally be sure the work piece is securely clamped from any movement during torqueing operations Failure to observe this instruction may cause injury Do not turn ON and OFF the equipment repeatedly Failure to observe this instruction may cause malfunction Do not use the equipment at torque higher than the maximum torque Failure to observe this instruction may shorten equipment life or cause malfunction due to the high temperature caused by overload
96. NUG TORQUE TAT TORGUEANGEE Used for RATE TIME settings and TORQUE SPEED initiation SNUG TORQUE Angle Control Start Point CROSSOVER B m TORQUE ANGLE Start point of 3PP torque rate monitoring section 6 2 STANDARD ANGLE Engineered product fastening specification 1ST TIME HIGH LOW LIMIT Acceptance range to reach 1ST TORQUE ANGLE setting Acceptance range to go from 1ST TORQUE ANGLE to FINAL TIME HIGH LOW LIMIT STANDARD ANGLE Page 6 8 FEC Fusion Operations Manual Torque Chapter 6 Fastening Instructions Rev 3 Crossover Torque Snug Torque 1 Torque Threshold Torque Speed Change Torque Angle Time Standard Angle 1 Time Final Time FIG 6 1 2b Angle Control Functions for Two Step Fastening 1 step Torque NOTE When performing multiple step Angle control fastening the rotation Angle should be performed as one continuous operation There should be no intermediate stop synchroniza tion points once Snug Torque has been sensed and rotation angle is being controlled Under special conditions multiple steps can be performed using intermediate Torque or Angle stop synchronization points as shown below Torque Crossover Torque 1 Angle Snug Torque Threshold Torque Speed Change Torque Angle Time Standard Angle _ 1 Time Final Time FIG 6 1 2c Angle Control Functions for Two Step Fastening 1 step Angle Page 6 9 Chap
97. O RX n 2 D NO WORK SELECT 2 NO RX n 2 E NO WORK SELECT 3 NO RX n 2 F NO RX n 1 0 REJECT RX n 3 0 Torque Decimal bitO RX n 1 1 ACCEPT RX n 3 1 Torque Decimal bit1 RX n 1 2 ABNORMAL RX n 3 2 Torque Decimal bit2 RX n 1 3 READY RX n 3 3 Torque Decimal bit3 RX n 1 4 BUSY RX n 3 4 Torque Decimal bit4 RX n 1 5 Torque Hi Reject RX n 3 5 Torque Decimal bit5 RX n 1 6 Torque Low Reject RX n 3 6 Torque Decimal bit6 RX n 1 7 BYPASS RX n 3 7 RX n 1 8 Angle Hi Reject RX n 3 8 RX n 1 9 Angle Low Reject RX n 3 9 RX n 1 A_ Rate 1 Hi Reject RX n 3 A 1 Rate 1 Low Reject RX n 3 B RX n 1 C Rate 2 Hi Reject RX n 3 C RX n 1 D Rate 2 Low Reject RX n 3 D RX n 1 E Rate 3 Hi Reject RX n 3 E RX n 1 F Rate Low Reject RX n 3 F Example of Torque data Peak Torque Integer Portion Decimal Portion 12 34 Nm 000C 0022 Peak Torque Integer Portion Decimal Portion 123 4 Nm 007B 0004 nteger portion is LEFT of decimal Decimal Portion is Right of Decimal Page 4 72 FEC FUSION Operations Manual Chapter 4 System Setup and Wiring Rev 3 Remote In put Remote In Signal Name Connection put Signal Name Connection RX RX RX n 4 0 Angle Integer bitO NO RX n 6 0 NO RX n 4 1 Angle Integer bit1 NO RX n 6 1 NO RX n 4 2 Angle Integer bit2 NO RX n 6 2 NO RX n 4 3 Angle Integer bit3 NO RX n 6
98. ORMAL 9 9 5 The CONTROLLER servo power supply circuit has detected improper input voltage either above or below the specified limits This abnormal is caused from 1 The controller internal power supply has failed 2 Source voltage is out of the limit and or the environment temperature is also close to the limit 3 One or more phases of input power is missing RECOVERY 1 Replace the controller 2 Provide additional cooling to the enclosure 3 Verify and correct the source voltage as required 9 5 Code 8 9 SERVO AMPLIFIER ERROR OVER SPEED 9 9 6 The resolver signal received at the CONTROLLER indicates an over speed condition This abnormal is caused from 1 The resolver cable or resolver has failed RECOVERY 1 Check resolver using method in 8 2 2 2 Replace resolver cable to spare cable 3 Replace tool assembly 9 6 Code 8 10 SERVO AMPLIFIER ERROR OVER LOAD I SQUARE T 9 9 7 The duty cycle of the fastening application is too severe for this size of tool or for the param eters currently setup RECOVERY 1 Reduce duty cycle Increase tool downtime or off time and or increase torque speed to reduce the amount of time running at high torque slow speed 2 If the problem remains a larger tool assembly may be required for this application Please contact FEC 7 Code 8 11 SERVO AMPLIFIER ERROR RESOLVER SIGNAL ERROR The resolver signal received is not correct RECOVERY 1 Check the ca
99. PIN DESCRIPTION TRx TRx GND 12VDC TORQUE OUT 12VDC m In O lt 4 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 sta tors electrically shifted 90 degrees generate a sine wave and a cosine wave signal Both sig nals are processed by the controller to define position and speed of the motor PIN DESCRIPTION ROTOR R1 STATOR S2 STATOR S1 ROTOR R2 STATOR 4 STATOR 53 SHIELD 202 I lt 00 Page 4 32 FEC FUSION Operations Manual Chapter 4 System Setup and Wiring Rev 3 4 12 Firmware Flash Connector CN8 Upgrades or revisions to Firmware are handled easily with the on board Flash connector lo cated behind the access panel on the bottom of each controller Unit There is no need to remove or disassemble the unit Flash adapter CONTROLLER ROM containing the new firmware can be connected to connector CN8 with the power off to the unit 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 fi
100. Pulse Monitor Angle CW CCW CW CCW Monitor GND Ground None Current Monitor 10V 10V 10V HFC EC 16 16 Speed Voltage Monitor Torque Monitor Max Torque 2 5V 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 OV 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 OV or 5V A 5v High signal is output during CW revolution and OV Low signal is output during CCW revolution Angle and direction are output as shown below TOOL TATION PULSES o 4 26 FEC FUSION Operations Manual Chapter 4 System Setup and Wiring Rev 3 4 10 Controller Unit DIP Switch Setting In a multiple controller unit system it may be beneficial to address the controllers for organi zational purposes The number is set using the DIP switch located behind the access panel on the back panel of the unit CON 1 swt DIP switch located on printed circuit board through access panel at the back of unit 8L9G Z lg BYPASS a RUN
101. R ERROR OVER CURRENT The CONTROLLER servo circuit experienced a current overload This abnormal is caused from 1 The controller servo drive circuit has failed 2 If the environment temperature is more than 122 degrees Fahrenheit 50 degree centi grade without any air flow 3 Source voltage is very close to the limit and the environment temperature is also close to the limit 4 Maximum torque is being run or exceeded by the tool every cycle 5 Speed may be too low or too high during torque speed RECOVERY 1 Replace the controller 2 Verify proper cooling for the enclosure 3 Verify and correct the source voltage as required 4 Verify proper torque or work piece 5 Adjust torque speed setting 9 9 3 Code 8 5 SERVO AMPLIFIER ERROR INTERNAL POWER SUPPLY The CONTROLLER servo power supply circuit is not working properly or the input voltage is above the maximum limit This abnormal is caused from 1 The controller internal power supply has failed 2 Source voltage is very close to the limit and the environment temperature is also close to the limit 3 If the environment temperature is more than 122 degrees Fahrenheit 50 degree centi grade without any air flow RECOVERY 1 Replace the controller 2 Provide additional cooling to the enclosure 3 Verify and correct the source voltage as required Page 9 11 Chapter 9 Troubleshooting 9 9 4 Code 8 6 SERVO AMPLIFIER ERROR INPUT VOLTAGE ABN
102. RD TORQUE RATE HIGH LIMIT Continued on next page Page 7 9 Chapter 7 System Operations Time 32 40 INITIAL TIME 32 41 1ST STEP TIME LIMIT 32 42 FINAL TIME LIMIT 32 43 FIRST TIME LOW LIMIT 32 44 FINAL TIME LOW LIMIT 32 45 RAMP UP TIME Consult FEC be 32 46 RAMP DOWN TIME fore changing 32 47 ___ REVERSE RAMP UP TIME these items 32 48 TORQUE RECOVERY PULSES 32 50 INITIAL SPEED 32 51 FREE RUN SPEED 32 52 SLOW DOWN SPEED Speed 32 53 TORQUE SPEED 32 54 REVERSE 1 SPEED 32 55 RECOVERY PULSE SPEED 32 56 Not Used 32 60 FREE RUN REVOLUTIONS 32 61 TORQUE INHIBIT REVOLUTIONS 32 62 Not Used Revolutions 32 63 REVERSE 2 REVOLUTIONS 32 64 REVERSE 3 REVOLUTIONS 32 68 Not used 32 69 Not used 32 70 FULL SCALE CURRENT VALUE 32 71 HIGH CURRENT LIMIT Current 32 72 LOW CURRENT LIMIT 32 73 FASTENING CURRENT LIMIT 32 74 Accept Batch Count 32 80 CW Stop Limit Angle 32 81 CW Swing Pause Angle 32 82 CW Servo Lock Time Pistol Tool 32 83 CW Motor Restart Time 32 86 CCW Stop Limit Angle 32 87 CCW Swing Pause Angle 32 88 Angle Head Torque Variation 32 89 CCW Motor Restart Time 32 90 Sequence Operational Mode 32 91 Sequence Stage 1 32 92 Sequence Stage 2 32 93 Sequence Stage 3 Sequence 32 94 Sequence Stage 4 32 95 Sequence Stage 5 32 96 Sequence Stage 6
103. SET and MODE buttons will have no effect when NO appears If no button is pushed within five seconds the new data will be ig nored and the system will exit the Data Edit mode is changed all torque settings D No 00 1E and speed settings D No 50 56 will be Note ap When the Torque Unit PARM 0 and D NO 00 or the Tool Type PARM 0 and D No 20 cleared Page 7 35 Chapter 7 System Operations 7 3 6 Parameter copy To speed parameter data entry it may be beneficial to copy from one parameter set to an other parameter set This is especially the case if only minor changes are required Use the procedure below for the parameter copy function using the display e When the system is in Setup mode select Data number 01 of Parameter 00 Tar This data corresponds to the ROM ver LJ 71 sion and is non adjustable data LIT Lj e Press the Set button and the cursor will jump to the left digit position of the 4 digit data display There will be a deci mal point between the second and third 27 digit The first two digits specify which f Hm parameter number is to be copied FROM HF LII and the two digits after the decimal point mmm 1 specify which parameter number is being 4 copied e Edit the numbers to change the dis play to get the desired source and target FT 4f 1 1 parameter numbers The example to the ce ELIE left shows parameter 1 being copied to mmm I parameter 2 LjJLILI e Pres
104. Speed Torque Speed Time Revolution 1 Time Final Time Torque Standard Torque 1 Torque Speed Change Torque Angle Time 1 Time des Time FIG 6 36 Ideal Relationship of Speed and Torque Page 6 22 FEC Fusion Operations Manual Chapter 6 Fastening Instructions Rev 3 6 4 Reverse Functions The Fusion system is capable of reverse operations using the reverse pushbutton on the Fusion tool or via the PLC input at TB1 Terminal The PLC input can be used for automated reverse operations The motor will reverse as long as the reverse signal or manual button is enabled One reverse speed is available per parameter up to 16 Time Revolutions Reverse Speed RPM FIG 6 4a Fusion Reverse Function The reverse function on a stand alone SAN Unit is set with one speed setting Reverse Speed The duration of the reverse would be controlled from an external source PLC using the Reverse input or manual reverse pushbutton amp trigger combination The Reverse pushbutton must first be enabled Then depress the start trigger for the desired reverse duration Depress the Reverse pushbutton again to disable the reverse mode REVERSE PUSHBUTTON 5 j yep Ex CN ae N LED LIGHT RING FLASHFS WHFN IN RFVFRSF MODF FIG 6 4b Tool LED Function
105. UE 1ST TIME ends and FINAL TIME begins 1ST TORQUE is the shift point to TORQUE SPEED 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 1 torque rate monitoring section 6 2 3096 of STANDARD TORQUE hee Used for RATE TIME settings and TORQUE SPEED initiation SNUG TORQUE Angle Monitoring Start Point section 6 2 CROSSOVER TORQUE Start point of 3PP 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 UE range to go from 1ST TORQUE to STANDARD Page 6 2 FEC Fusion Operations Manual Chapter 6 Fastening Instructions Rev 3 Torque Standard Torque Crossover Torque Snug Torque 1 Torque Threshold Torque Speed Change Torque Angle Time 1 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 Ex amples Connecting Rod Main Bearing Cap any
106. UNICATION meg eve UPLOAD DOWNLOAD BROWSE Browse Fieldbus configuration files SAVE Save Fieldbus configuration files UPLOAD Upload Fieldbus set up from Fusion controller BUS TYPE automatically DOWNLOAD Download open net set up to Fusion controller Cycle power after download VERIFY Verify Fusion controllerset up vs AFC User Console Software set up BUS TYPE Choose CC LINK VER2 Once Fieldbus setting is configured hit SAVE to SAVE the configuration to a file A The Fieldbus setting is downloaded using the PARAMETER COMMUNICATIONS Caution screen Cycle power after download File Extension Information Item Extension Parameter PAR Fieldbus setting FCF Page 4 74 FEC FUSION Operations Manual Chapter 4 System Setup and Wiring Rev 3 CCLink SETUP Tab FIELDBUS CONFIGURATION CC LINK VER2 BEI x GENERAL CC Link Ver 2 Station Information PLC CC Link Ver 1 Master Station Extended Cyclic Setting 8 CYCLES hd Occupied Stations 4 STATIONS i Remote 1 0 RX RY 896 POINTS Remote Register RVVw RVVr 128 WORDS Extended cyclic setting 8 cycles G Occupied station 4 stations Remote I O RX RY 896 points Remote Register RWw RWr 128 words 256 bytes When PLC master module is CC Link Ver1 00 check the CC Link Ver 1 Master Station box in the setup screen
107. able 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 una voidable In these situations a shorter extension cable can be provided with the expecta tion 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 FUSION Operations Manual Chapter 4 System Setup and Wiring Rev 3 4 11 2 Considerations for Cable Trolleys e 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 e 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
108. ach time a packet is trans mitted or received Page 4 58 FEC FUSION Operations Manual Chapter 4 System Setup and Wiring Rev 3 Input Output Signal Mapping Input Signals From PLC to Fusion 4 Words 8 Bytes 64bits Word Byte Bit No Description Comment 0 1 1 2 2 3 3 4 0 5 5 6 6 7 Reset Abort Job Resets initial condition 01 LE 0 9 1 10 2 11 1 3 12 4 13 Work Select 0 5 14 Work Select 1 6 15 Work Select 2 7 16 Work Select 3 0 17 Stop 1 18 Reset 2 19 Reverse 2 3 20 Start 4 21 Bypass 5 22 Disable Self check 6 23 7 24 02 0 25 1 26 2 27 3 3 28 4 29 Batch OK Reset 5 30 Work Select 4 6 31 7 32 Input Word 03 04 have no signals assigned and are not shown Page 4 59 Chapter 4 System Setup and Wiring Output Signals From Fusion to PLC 8 Words 16 Bytes 128 Bits Word Byte Bit No Signal Description Comment 0 1 End 1 2 Accept 2 3 Reject 3 4 0 IRE SH E 5 6 Job Cycle Accepted Total Accept for Sequence Function 6 7 01 EAE 0 9 Work Select 4 Selected echo 1 10 2 11 Time 1 Reject 1 3 12 Time 2 Reject 4 13
109. age from the torque transducer is displayed a ae Peak torque The peak torque measured since the last time the display mode was switched to Real Time Display Mode This is reset when the display mode is changed from the Real Time Display Mode Lock Spindle Mode When SET is depressed during this display the motor is locked for up to one TORS minute allowing the spindle to be checked with a torque wrench while displaying the reaction torque on the data display Press RESET to unlock the Mo tor before one minute has expired WARNING Do not repeat this procedure repetitively or the mo tor will overheat sil B LI LII ER cem E Angle rotation The real time angle of rotation of the tool output shaft in the fastening direction CW measured since the last time the display mode was switched to Real Time Display Mode 1999 to 9999 LLIL Thermal Overload Level Between 0 100 100 overload FIG 7 2 2 Real time display selection Page 7 6 FUSION Operations Manual Chapter 7 System Operations Rev 3a _ D NO Left digit 7 2 3 Fastening Results Display Mode i ME RAE In Fastening results display mode when COUNT D NO shows _0 6 data can be ob tained by pressing the 4 and 7 keys to scroll the COUNT D NO until the desired DATA item is displayed The following information will be displayed in the DATA
110. ain gage transducer Highly durable compact design minimizes space requirements Intelligent transducer design uses an ID Chip to verify integrity of fastening operations CABLE CONNECTOR 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 START SWITCH 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 REVERSE SWITCH Momentary Reverse selector switch or Twist Ring 10 models 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 LED DISPLAY RING 360 degree LED display ring Green indicates an accept condition Red indicates a Reject condition Flashing Red and Green indicate Reverse Backout mode Solid Red and Green during power on for verification Alternating Red Green indicates RESET signal being input Page 3 8
111. aken when disassembling the tool assembly Small parts and wiring can easily be lost or damaged 2 DISASSEMBLE TRANSMISSION Refer to the appropriate transmission assembly drawing while disassembling the transmission for cleaning 3 CLEAN TRANSMISSION PARTS Clean all parts with an appropriate solvent such as mineral Spirits to remove all excess grease and contamination Parts should be carefully wiped dry with a lint free cloth to remove any residue Allow the parts to dry thoroughly in an area free from contami nation 4 INSPECT TRANSMISSION PARTS Examine all gears pins bearings etc for signs of exces sive wear Replace any part that failed or appears it may fail 5 LUBRICATE TRANSMISSION PARTS Reassemble the transmission in a contaminant free ar ea Re pack all bearings and grease all gears Do not pack the transmission housing with excessive grease over greasing could damage the tool and cause it to stall Recommended grease Sunoco Sunaplex 992 EP or equivalent 6 REASSEMBLE TRANSMISSION Refer to the appropriate transmission assembly drawing while reassembling the transmission If needed rotate the gears to aid in the assembly process If the transmission does not rotate freely after re assembly then disassemble the transmission again to iso late and correct the cause 7 RE ASSEMBLE TOOL f needed rotate the output shaft to align the transmission planetary gears with the motor output shaft If the transmission does n
112. aking 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 align ment 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 in creased 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 prac tices 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 c
113. al operation OFF OFF DATA 4 Output when the system is in READY condition to B13 READY operate and inputs are enabled This signal is inactive off when the BUSY output is active on DATA 3 Output after a START signal is received and A12 BUSY active until the fastening cycle is complete and the READY signal is output DATA 2 TQ HIGH REJECT Output when Fastening resulted in a Torque High B12 Reject DATA 1 TORQUE LOW REJECT Output when Fastening resulted a Torque Low A11 Reject DATA 0 Output when the spindle is bypass either via B11 BYPASS PLC input or the Controller Unit front panel switch DATA 7 A14 NOT USED DATA 6 1ST TIME OVER REJECT Output when Fastening resulted in a 1st Time B14 Reject DATA5 FINAL TIME OVER Output when Fastening resulted in a Final Time B13 REJECT Reject WORK 0 A12 WORK 1 DATA2 work 2 Output confirmation of WORK SELECT 0 4 Pins B12 A5 B5 A6 B6 amp A7 input selections DATA 1 11 WORK DATA 0 B11 WORK 4 Page 4 13 Chapter 4 System Setup and Wiring SEE PLC CONTROLLER UNIT BANK DATA INPUT BANK SEL1 SELO Output NAME OF NO B4 4 A11 B14 SIGNAL BESS ENON DATA7 ANGLE HIGH REJECT Output when Fastening resulted in an Angle High A14 Reject DATA 6 ANGLE LOW REJECT Output when Fastening resulted in an Angle Low B14 Reject DATA 5 Output when Fastening resulte
114. and station number setting up CC Link Specification Page 4 69 Chapter 4 System Setup and Wiring MESSAGE MAXIMUM 32BYTES 256BIT 8BYTES 64BIT 128WORDS 256BYTES DEFAULT S2BYTES 256BIT 8BYTES 64BIT 128WORDS 256BYTES Number of Input 64points Fixed assignment XCan t be changed Making Secure RY n 4 0 RY n 7 F territory not used pecifications Double Quadruple 32 points 32 points 64 points 128 points 30 points 30 points 62 points 126 points for local for local for local for local station station station station Remote 1 O 64 points 128 points sos pons ves Occupies Remote 4 points 8 points 16 points 1 station register RWw spans s2pons register RWr ii Remote I O 64 points 96 points 384 points Remote sons epos 192pomis spon Occupies Remote i 16 point int 2 stations RWw spans snos eene Remote 8 points 32 points 64 points register RWr eps pons szpon seen Remote 1 0 i 1 n 640 points RX RY ee sees eorr Occupies Remote 12 points 24 points 48 points 96 points 3 stations e Remote 48 points 96 points Remote I O 128 points 448 points 896 points Remoto zapos pons pA Remote 16 points 32 points 64 points 128 points register RWw register RWr pot 4 70 FEC FUSION Operations Manual Chapter 4 System Setup and Wiring Rev 3
115. anel DB9 RS232 PC Connection for AFC User Console Software PIN SIGNAL DESCRIPTION 1 NOT USED 2 RXD RECEIVE DATA 3 TXD TRANSMIT DATA 4 DTR DATA TERMINAL READY ALWAYS ON 5 GND SIGNAL GROUND 6 DSR NOT USED 7 RTS REQUEST TO SEND ALWAYS ON 8 CTS CLEAR TO SEND 9 NOT USED Note Cabling length should be kept to a minimum Max 50 Feet and avoid routing near high signal noise areas such as AC Motor invertors speed controllers or strong RF signals Standard DB9 Null Modem cables can be used for this connection to a PC running the AFC User Console Software No special cabling is required These are standard Null Modem cables which can be purchased at most computer stores See the AFC User Console Manual for more information Available for download on the FEC website www fec usa com Page 4 18 FEC FUSION Operations Manual Chapter 4 System Setup and Wiring Rev 3 4 8 2 Rear Panel DB9 RS232 PC Connection Fastening Data Output Connector DB 9P Male Mating Connector DB 9S Female PIN SIGNAL DESCRIPTION 1 NOT USED 2 RXD NOT USED 3 TXD TRANSMIT DATA 4 DTR DATA TERMINAL READY ALWAYS ON 5 GND SIGNAL GROUND 6 DSR NOT USED 7 RTS REQUEST TO SEND ALWAYS ON 8 CTS CLEAR TO SEND 9 NOT USED the data will be overwritten in a First In First Out FIFO process The CTS signal may be Note The CTS signal needs to be activated
116. ard 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 PLC PROFIBUS master Cyclic communication wb LL slave Other PROFIBUS slave Page 4 39 Chapter 4 System Setup and Wiring Termination Termination of the fieldbus requires a terminating resistor at each end of the fieldbus 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 posi tion GSD File Each device on a Profibus network is associated with a GSD file containing all necessary in formation 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 Profibus Specifications 9 6K 12M baud auto selected Nodes 126 Note Node 126 is reserved for commissioning purposes onl 200m max at 1 5Mbit s extendable with repeaters Shielded Copper Twisted Pair or fiber optic Communications Type Master Slave EIA RS485 Protocol Version Ver 1 10 Maximum Cyclic I O Size 244bytes In 244 bytes out max 41
117. arious 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 Peces i ETHERNET LEES E CROSSOVER CABLE RSe3ec FUSION CONTROLLER BACK VIEW 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 con figured 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 Fu sion Ethernet Module Set Up Procedure from FEC for more detail PC Ethernet Set up IP address 192 168 10 40 Subnet mask 255 255 255 0 Default Gateway 192 168 10 1 Once the PC is configured and connected to the Ethernet Module using an Ethernet cross over cable you can use your web browser Ex Internet Explorer to configure the Ethernet module including the network IP address Station Name etc Open t
118. art at X100 and Y100 this must be added to the addresses and therefore 100h 378h 478h is specified for the X area and the Y area as shown in the PLC Logic diagram below to enable Station 1 s link For Station 2 s link the starting address X Y480 is added to the 888 378h bit for that station which is address 480h 378h X Y7F8 For Station 3 s link the starting address X Y800 is added to the 888 378h bit for that station which is address X YB78 Page 4 77 Chapter 4 System Setup and Wiring PLC Logic example that would be required to enable the CC Link in the three systems listed above e Location of Handshaking Bits According to Size Configuration Y478 STA 1 CC LINK LINK ENABLE 24th bit 18h 56th bit 38h 88th bit 58h 120th bit 78h 24th bit 18h 88th bit 58h 152th bit 98h 216th bit D8h 56th bit 38h 184th bit B8h 312th bit 138h 440th bit 1B8h 120th bit 78h 376th bit 178h 632th bit 278h 888th bit 378h Location of Initial Data Processing Request and Initial Data Processing Complete Bits h hexadecimal Page 4 78 FEC FUSION Operations Manual Chapter 4 System Setup and Wiring Rev 3 4 15 6 Profinet Interface The Profinet communication interface allows slave connection to PLC networks that support Profinet communication via TCP IP Maximum I O data is 512 input bits amp 512 output b
119. ast 16 bits of both the Inputs and outputs no matter what size is configured is the CCLINK system setting area and this is where the link must be enabled Below is an example of CC Link configuration settings made by GX Developer software and how memory is allocated This configuration has 3 sets of AFC3000 controllers connected with 4 oc cupied stations 8 extended cyclic cycles I O 896 Points Message 72 Words Item Fusion Fusion Fusion System 1 System 2 System 3 CC Link Station Number 1 5 9 Configured Size 4 occupied stations 8Cyclic cy 896 880 896 880 896 880 cles useable useable useable EM STOP First bit of PLC output Y100 Y480 Y800 Total Reject First bit of AFC3000 Output X100 X480 X800 Part ID message output to AFC3000 Controllers D4000 D4072 D4144 Fastening result message from AFC3000 con D1000 D1072 D1144 trollers CC Link Request address X478 X7F8 XB78 CC Link Enable address Y478 Y7F8 YB78 In the case of the first Fusion System 1 shown in the table above the PLC program is set so that when the 888th 378h bit Initial Data Processing Request in the CC Link Reserved sys tem area X area is turned ON the output at the 888th 378h bit Initial Data Processing Complete of the system area Y area is set ON Note See pages 8 amp 14 for CCLINK handshaking signal location Since the X Y starting address of System 1 is configured to st
120. attention due to the nature of their small design with standing high forces These heads are typically designed for a maximum of 250 000 cycles or less and should be inspected more frequently than a standard tool life cycle is depend ant upon the torque it is used at Typically these heads should be inspected and greased every 10 000 cycles During this in spection the inspection time may be lengthened or shortened depending on the conditions seen during the first few inspections this will very by application Inspect each tool and ensure the following conditions exist e The head is producing normal levels of noise and vibration no irregular noise e The head is free from excessive contamination and foreign matter e The head turns freely with no binding e The head is securely mounted to the tool with mounting bolts properly tightened e All covers screws and bolts are in place and securely tightened on head e The head is sufficiently lubricated approx 1 5 oz of grease each application Do NOT over grease Auxiliary Head Lubrication Information Description Part Number Grease Gun GG K97 Lubriplate Grease 140z GR 132 A Lubriplate Grease 6 lb can GR 132 B Page 8 3 Chapter 8 Maintenance and Inspection 8 2 Basic Operational Tests WARNING Follow Lockout Tagout and other safety precautions when connecting or disconnecting cabling wiring and equipment When performing the fo
121. ay see 7 2 5 3 Program proper tool number into CONTROLLER Unit or change tool to proper tool Code 3 2 STARTED WITHOUT TOOL CONNECTED The start signal was applied while a TOOL IS NOT CONNECTED abnormal condition exist ed RECOVERY 1 Interlock the PLC circuit to disable the start signal during an existing abnormal condition 2 Follow the TOOL IS NOT CONNECTED Code 3 3 abnormal help procedure Code 3 3 PREAMPLIFIER TOOL IS NOT CONNECTED Communications error between the tool preamplifier and the controller This abnormal is caused from 1 The tool cable is not connected 2 If the controller or the transducer cable is located in an electric or magnetic noise field 3 When the torque transducer Tool cable or the controller malfunctions RECOVERY 1 Verify that the tool cable is properly connected 2 Verify that the cable or controller is not located near any high voltage transient power sources Relocate as required and reinitialize the system 3 Exchange Tool cable tool and or controller with known working units Reinitialize the sys tem after each exchange and make note of any change in the location of the abnormal 4 Replace the defective component Page 9 7 Chapter 9 Troubleshooting 9 5 System Memory Errors 9 5 1 Code 4 0 SYSTEM MEMORY ERROR FLASH ROM WRITE ERROR 9 5 2 Communications error to internal CONTROLLER Flash ROM during WRITE attempt This abnormal is caused from 1
122. bes the code for the four numbers and how they relate to the type of fastening method and steps preferred Zero s will display as blank off digits if there is no number 1 2 or preceding them Ex ample 0020 will display as _ _ 20 or 0121 will display as 121 When entering new fas tening method all four digits should be entered and SET Fastening Method 0 Torque Control 1 Angle Control Fastening Steps 0 or BLANK 1 Step w continuous snug Tq angle count start 1 1 Step Fastening 2 2 Step Fastening Stops at 1 3 Step Fastening Stops at 1 and CROS Tq Fastening Direction 0 or BLANK CW clockwise Fastening 1 COW counterclockwise Fastening Reverse Operation 0 or BLANK Not Used 1 Slow Reverse Start 1 5 sec 20 RPM 2 Varispeed 3 Both 1 amp 2 Normal Snug angle count vs Continuous Snug Tq Angle Count Angle count with normal SNUG mode XX11 Angle value is not counted up when torque is below SNUG TORQUE In case Standard Angle is 90 SNUGTQ Angle count using continuous SNUG TQ angle count Method XX01 Once SNUG TORQUE is reached angle value is counted up regardless of the torque v alue In case Standard Angle is 90 9 90 SNUG TQ Page 7 15 Chapter 7 System Operations Fastening Torque Angle Rate Time Speed Revolutions Current Pistol Parameter Parame
123. ble look for loose connectors for visible damages to the cable 2 Replace with known good tool Page 9 12 FUSION Operations Manual Chapter 9 Troubleshooting Rev 3 9 9 8 9 9 9 Code 8 14 SERVO AMPLIFIER ERROR MOTOR CONTROL CIRCUIT ERROR An abnormality occurred in the Motor Control circuitry in the controller RECOVERY 1 Check that the GROUND is connected on the controller supply power 2 Internal tool or cable damage Replace Cable Replace Tool 3 Cycle power to OFF leave off for more than 10 seconds and Turn on power 9 Code 8 15 SERVO AMPLIFIER ERROR POWER ON ERROR The Controller power on was not completed successfully RECOVERY 1 Turn off power Wait 10 sec minimum and power back on Page 9 13 Chapter 9 Troubleshooting HERSTELLER C C 9 40 Parameter Error 9 10 1 Code 9 0 PARAMETER ERROR MISSING SPEED PRESET Some speed preset is not setup in the parameter number selected or the wrong parameter number has been selected by the PLC RECOVERY 1 Verify that the parameter number that is being selected by the PLC is configured in the controller 2 Check that the reverse speed preset is not 0 or out of the specified speed range of the tool 9 10 2 Code 9 1 PARAMETER ERROR MISSING TIME or SPEED PRESET Some Time or Speed preset is not setup in the parameter number selected or the wrong pa rameter number has been selected by the PLC RECOVERY 1 Verify that
124. board manufactured by HMS Fieldbus Systems into the Multi Unit modular I O board For further technical information on the DeviceNet interface go to the HMS website www hms se Further DeviceNet information can be found through the Open DeviceNet Vendors Association ODVA www ODVA org System Structure PLC DeviceNet master Remote I O communication DeviceNet slave Other DeviceNet slave Page 4 51 Chapter 4 System Setup and Wiring Devicenet Hardware oS WN gt 2 a an 00002000 OoO000000 Oo 27 gs RES ir gr OH 4 1 31092 Interface Board with DeviceNet Daughter Board Item Description 1 Application Connector 2 DeviceNet Connector 3 Configuration Switches 4 Status LEDs 4 Red flashing 9 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 DeviceNet Specifications Maximum Distance Twisted pair for signal and power Allen Bradley or equivalent Thin Cable 1485 1 Thick Cable 1485C P1 A Communications Type Master Slave Page 4 52
125. chnology 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 Fastening Results Data Storage Fastening Data results are stored in internal FLASH memory of each controller Approx 10 000 data cycles and can be uploaded using the AFC Programming Monitor Software Past Torque Curves are stored in RAM memory and can be uploaded as long as power has not been turned off to the controller Once power is turned off previous Torque curves stored are erased Torque curves are automatically stored after each cycle when power remains On Page 1 4 FUSION Operations Manual Chapter 1 Outline Re
126. d in a 1st Torque B13 1ST RATE HIGH REJECT Rate High Reject 3 ON OFF DATA 4 1ST RATE LOW REJECT Output when Fastening resulted in a 1st Torque B13 Rate Low Reject DATA 3 Output when Fastening resulted in a 2nd Torque A12 2ND RATE HIGH REJECT Rate High Reject DATA 2 2ND RATE LOW REJECT Output when Fastening resulted in a 2nd Torque B12 Rate Low Reject DATA 1 A11 NOT USED DATA 0 B11 NOT USED DATA 7 Outputs when an abnormal condition occurs 14 CERO CAL ERR during the SELF CHECK CAL and Zero DATA 6 PSET ERR Outputs when an abnormal condition occurs in B14 the parameter setting DATA 5 RES ERR Outputs when an abnormal condition occurs in B13 the resolver DATA 4 B13 TOOL ERR Outputs when a tool related abnormality occurs 4 ON ON DATA 3 SV ERR Outputs when a servo abnormality occurs see A12 SV ERR 0 2 codes below pora SV ERROR 0 DATA 1 Outputs a detailed code when a SV AMP ERR is A1 SV ERROR 1 output Error code is output in three bits See DATA 0 Section 4 7 4 B11 SV ERROR2 Page 4 14 FEC FUSION Operations Manual Chapter 4 System Setup and Wiring Rev 3 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 ERR SV AMP ERR 2 1 0 Data 4 _ Data 7 Data 6 Data 5 DESCRIPTION ON OFF OFF OFF ON OFF O
127. display section for the displayed D NO D No 0 PEAK TORQUE 1 FINAL ANGLE 2 1ST TORQUE RATE 8 2ND TORQUE RATE 4 1STSTEP TIME _5 FINAL STEP TIME 6 CYCLE TIME 7 FASTENING MODE 8 3RD TORQUE RATE 9 NOT USED 0 FASTENING MODE 1 FASTENING STEPS 2 NOT USED 3 SELF CHECK ON enabled OFF disabled 4 REVERSE FLAG ON Reversed OFF Not Reversed CAUSE OF FASTENING STOP 0 RESET NO DATA AFTER REVERSE 1 ABNORMAL SIGNAL 5 2 BYPASS SIGNAL 3 STOP SIGNAL 4 REJECT 5 ACCEPT 6 TORQUE JUDGE iq H L FINAL H L PEAK 7 ANGLE JUDGE AN HL _ JUDGE r 157 H L 2ND 79 9 TIME JUDGE ti HIL 1ST FINAL 0 1ST INCREMENT TORQUE 1 2ND INCREMENT TORQUE 1ST FINAL TORQUE 1ST PEAK TORQUE 4 FINAL TORQUE ANGLE AT PEAK TORQUE 6 PEAK CURRENT FIG 7 2 3 Fastening results display selection Page 7 7 Chapter 7 System Operations 7 2 4 Parameter Display Mode The FUSION system can store up to 16 different sets of parameters that can be selected for fastening operations via the and keys Horizontal arrows or by PLC input signals WORK SELECT 0 see section 4 7 2 In addition to parameter 1 16 there is a PARAMETER 0 that contains con figuration data common to all parameters Parameter display mode displa
128. e 0 9 9 This is the time to increase rotation speed when conducting reverse operations Page 7 23 Chapter 7 System Operations Data No 48 Torque Recovery Pulses Setting range 0 50 pulses In Torque Method Fastening after the fastening operation has reached the target torque the torque will be held at Standard Torque for this duration of pulses depending on the setup below Unless this function is required to compensate for relaxation in the fastener set the torque recovery value at 0 0 and do not perform the torque recovery process 1 to 39 If set between 1 39 once STANDARD TORQUE is reached the number set be tween 1 39 pulses will be performed Recovery Pulse 1 to 39 TIMES 40 to 50 If set 40 50 pulsing will start after reaching 1 Torque until Standard Torque is achieved The number of extra pulses once Standard Torque is reach is deter mined by the 1 digit of the 2 digit number EXAMPLE When setting 43 once first torque is reached pulsing begins 3 additional pulses are performed once Standard Torque is reached The 3 in 43 STANDARD TORQUE 1ST TORQUE Recovery Pulse 3 TIMES NOTE Setting 50 will perform the maximum recovery pulses of 10 in this mode TORQUE SPEED should be set 60 150rpm Setting of 100 150rpm is optimal The function may become unusable over 150rpm Please set D No 83 and D No 89 to 30 when using the recovery
129. e COUNT D NO LE field and depressing it again will bring it to the left digit avs of the field Use the J and T buttons to select the p mio desired COUNT D NO number which is to be edited ol FT gt a sid After you have selected the Parameter number and Den the Data number you would like to edit press the Sen SET button to enter the Data Edit mode The blink m ing digit will now appear at the left digit of the DATA Li field You can move one digit to the right each time n you press the MODE button pressing the but ton four times you leave the Data Edit mode and re P turn to the Setup mode without saving any changes Use the and t buttons to increase or decrease tu the digit that is blinking uL uu After changes have been made pressing the SET button will save the changes and exit to the Setup mode d If the entered values are out of range limits Err will ERZ fe 7 appear and the new data will be ignored In this case return to the parameter number selection using the MODE key and enter data that is acceptable FIG 7 3 3 Setup mode operation When the Torque Unit number PARM 0 D NO 00 or the Tool Type PARM 0 D NO 20 is changed the DATA display will show CHNG the D NO display will show NO Use the vertical arrow buttons to choose YES or NO YES means that the data will be entered if the confirmation SET button is pressed The
130. e cable resolver motor and transducer connecting the tool and CONTROLLER unit is secure If using multiple systems ensure that the correct cable is connected to the appropriate TOOL and CONTROLLER unit e the layout contains moveable parts visually inspect all components to ensure that 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 appropriate adjustments WARNING 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 occur 4 Check the input voltage 3 1 2 4 6 e Verify input power is properly connected 4 6 1 e Ensure input power voltage to the CONTROLLER Units is 100 230 VAC NOTE After a CONTROLLER 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 disa ble the CONTROLLER unit as a safety precaution If a CONTROLLER unit does become disabled keep the power off for five 5 minutes then power on again to reset the fault Page 5 2 FUSION Operations Manual Chapter 5 Power Up and Initial Checks Rev 3 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 requir
131. e path to the FUSION Ethernet Module Message Configuration Read Tag Message Configuration Read_Teg Confguaten Conmseceter Tag Neg Toe Seven Get tributo Sign Sexe Cour Had Cee WSC m Mt Imtance 1 Andael d RET New Tag aee Me E UO Conhgu stor il Backplane LompactLogs Synes ffa 0 1769 20 tet 7694227 Ethemet Pot Loca HB amp there 17931225 Errat Pot Loc ENB 9 ETHERNET MODULE AFCISOD ETHERNET MODULE AFCTSOQ 2 5 GB Compacts Loosi 9 Di Conpsctw Lod 8 10170040167 A ros Message CIP Generic Service Type Get Attribute Single Service Code E Class BO Instance 1 Attribute 1 5 Destination The controller tag C should be selected Page 4 65 Chapter 4 System Setup and Wiring 4 15 5 CC Link Interface Version 2 FEC integrates the CC Link board Version 2 setting manufactured by HMS Fieldbus Sys tems AB into the Fusion Unit s modular I O board when CC link must send both I O and Message Data For further technical information on the CC Link Version 2 interface go to the HMS website www hms se NOTE The FEC CC Link V2 module is configured as a Remote Device Station when set ting up the parameters in the PLC program For detailed information on the Mitsubishi CC Link Network see the Mitsubishi User Manua
132. e 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 Idle 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 2 3 Controller Unit Specifications HFC EC 16 Silver Unit COMMON Adel HFC EC 16C Gold Unit Motor Model RM80 RM50 Controller Supply Voltage Single Phase 100 240 VAC 50 60 Hz Approx 100 watts hour Power Consumption Running 99 Capacity 50 Duty Power Consumption Idle Approx 37 watts hour Inrush Current Power on 11A 1 3A Current During Fastening S If the equipment is powered on and off repeatedly internal circuit protection devices 80 Torque Hard Joint 30deg rotation may trip due t
133. each This is done using the Messaging function CIP in the PLC Each PLC uses a different method to acquire the data please see the PLC manuals on how to program the PLC to re fastening cycle ceive the data The output message format is preset and cannot be changed See the following for an example of the message format Note The message data is available only on the Fieldbus type below DeviceNet CC Link V2 EtherNet IP Profinet IO Profibus DPV1 REI PRISER re er Temir rere re pue Fastening result data DeviceNet CC Link V2 EtherNet IP Profinet lO Profibus DPV1 CC 5262008 s ual 1 Page 4 90 FEC FUSION Operations Manual Chapter 4 System Setup and Wiring Rev 3 Fastening Message Output Format ASCII 182bytes Fixed Length Accept Fastening Normal Format ves VALLE on 2 VALLE 35 3 s 10 101 102 03 14 105 106 10 106 109 110 1 12 13 184 15 11 117 1 113 120 121 122 123 124 125 126 127 128 123 130 131 12 IST RATE INC 20H 20H 31H 2EH 32 15 18 147 18 18 TOTAL JUDGNENT OM GFH ACCEPT Page 4 91 Chapter 4 System Setup and Wiring Reject Fastening Reject or Abnormal SIGH MILLE on VALLE REJET MARK x 59 2 FE ECT cause first M 118
134. ed 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 sys tem 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 ad justed 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 e 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 e 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 displayed See NOTE 1 below NOTE 1 If the Zero and or Cal check results in an ABNORMAL LED output from the CONTROLLER unit refer to Section 9 for guidance WARNING vERIFY THERE ARE NO PERSONNEL OR OBSTRUCTIONS IN THE TOOL AREA PRIOR TO ACTIVATING A SPINDLE OR OTHER MOVEABLE COMPONENT 3 Check manual reverse operation A Setthe Tool assembly to Reverse Mode 1 Momentarily depress the Reverse pushbutton switch on the Tool Assembly 2 The Tool Assembly light ring
135. ee from unnecessary binding force and tension and are free to move The cables are in good condition sufficiently insulated no cuts with no indication of broken wires The cables are free from excessive contamination and foreign matter The cables are securely connected to the Controller unit and to the nutrunner connectors are tight The cables are free from heat distortion and are not warm or hot to the touch The cables and cable connectors are securely and correctly fastened See 4 11 1 for Cable Installation Guidelines Page 8 2 FUSION Operations Manual Chapter 8 Maintenance and Inspection Rev 3 8 1 3 Controller Unit Recommended Schedule Quarterly The Controller Unit requires careful use and handling Inspect each Controller unit and en sure the following requirements are met e The environmental conditions are within specifications e There is no moisture oil or foreign matter on the unit e The unit is securely mounted with appropriate clearance on all sides e All screws for the cover of the unit and for mounting are correctly tightened e The input power remains within specifications at all times e The unit is not producing any abnormal excessive heat e Unit cables on the back and the underside are securely fastened and without damage 8 1 4 Auxiliary Tool Heads Crowsfoot Tubenut Hold amp Drives etc Recommended Schedule Monthly External auxiliary heads require special
136. efore attaining the final number of degrees of rotation Angle Control method is primarily used when greater control of clamp load is required Angle Control specs are developed through testing of the joint and fastener characteristics and therefore should not be attempted unless testing is performed NOTE All setting recommendations are based upon common fastening applications Applications that experience high Prevailing torque excessive joint compression or other unique characteristics must be set with these characteristics in mind NOTE When performing multiple step Angle control fastening the rotation Angle should be performed as one continuous operation There should be no intermediate stop synchronization points once Snug Torque has been sensed and rotation angle is being controlled Under special conditions multiple steps can be performed using in termediate Torque or Angle stop synchronization points One Step Fastening One Step fastening will be used primarily for joints that have no requirement to synchronize with another spindle during the final stage of the rundown Angle control commences at SNUG TORQUE All angle values are referenced from this point 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 ANGLE The system will fasten to the 1ST TORQUE ANGLE value during the specified 1ST TIME 1ST TORQUE ANGLE m
137. eg kg Unit HFT 015M50 A 15 00 1090 5 000 1 6 HFC EC 16 HFT 015M80 S 15 00 1895 5 000 1 4 HFC EC 16 HFT 025M80 A 25 00 1218 5 000 1 7 HFC EC 16 HFT 040M80 A 40 00 735 5 000 1 7 HFC EC 16 HFT 015M50 A1 15 00 1215 5 000 1 6 HFC EC 16 HFT 025M80 A1 25 00 1070 5 000 1 7 HFC EC 16 HFT 040M80 A1 40 00 648 5 000 1 9 HFC EC 16 HFT 060M80 A 60 0 446 5 000 1 95 HFC EC 16 HFT 080M80 A 80 0 330 50 00 3 7 HFC EC 16 HFT 130M80 A 130 0 203 50 00 3 8 HFC EC 16 HFT 015M80 S1 15 00 5 000 1 4 HFC EC 16 HFT 040M80 S 40 00 694 5 000 1 4 HFC EC 16 HFT 040M80 T 40 00 694 5 000 3 1 HFC EC 16 HFT 015M50 P1 15 00 5 000 1 1 HFC EC 16C HFT 035M80 P1 35 00 778 5 000 1 37 HFC EC 16C HFT 010M50 S1 10 00 5 000 1 3 HFC EC 16 HFT 025M80 S1 25 00 5 000 HFC EC 16 HFT 055M80 S 55 00 5 000 16 HFT 080M80 S 80 00 5 000 16 h h h jejejeje ejje HFT 015M50 P 5 000 16 Note The list above contains the tool numbers for Standard tools Tools in GREEN are special and no longer used Page 7 14 FUSION Operations Manual Chapter 7 System Operations Rev 3a 9 Fastening Mode and Fastening Steps WORK 1 32 D No 00 The fastening mode is entered into WORK 1 16 D No 00 Enter the Set Value number which corresponds to the fastening method desired The figure below descri
138. eject 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 LED DISPLAY RING LED display ring Green indicates an accept condition Red indicates a Reject condition Flashing Red and Green indicate Reverse Backout mode Solid Red and Green during power on for verification Page 3 9 Chapter 3 System Description Blank Page Page 3 10 FEC FUSION Operations Manual Chapter 4 System Setup and Wiring Rev 3 Chapter 4 System Setup and Wiring Page 4 1 Chapter 4 System Setup and Wiring 4 4 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 per formance WARNING Follow Lockout Tagout and other safety precautions when connecting and or disconnecting cabling wiring and equipment No Items Comments geron Keep torque range between 30 and 75 of tool 241 capability for best performance and to capacity for 1 Select correct tool size future fastening specification revisions 441 Verify fastener location and tool clearance 44 2 concerns Determination of suspension and reaction 2 Determine tool suspension requirements is dependent upon end user 4 4 reaction requirements standard ergonomic design guid
139. elines and 4 4 3 preferred supplier lists Different controller options are available Ensure 3 Select correct Control Unit ihe correct ones selected 3 4 Select the circuit Circuit protection for Controller Units should be 4 5 protectors separate from other units 4 6 Select a PLC which will facilitate direct connection 4 7 5 Select an adequate PLC the FUSION System I O 24 VDC true low 6 Design or review PLC A PLC logic program can be written using signal 47 logic descriptions and timing charts provided Keep clearances among units according to the 7 Determine Controller recommended installation layout End user 4 2 mounting requirements specific input should be used to determine 4 3 mounting requirements 8 Set Controller Unit dip Check the setting before connecting the Unit switches 9 Mount the Controller Units Refer to recommended installation layout M 10 Wi Connect the power cables VERIFY VOLTAGE 46 Ire power connections TO APPLYING POWER Connect all I O wiring VERIFY VOLTAGE 4 7 PE Wire VO connections SOURCE PRIOR CONNECTION Connect Tool extension yERIEy POWER IS OFF then connect cables for 12 cables js every motor encoder and preamplifier Appendix A i reset ES VERIFY WIRING AND THE VOLTAGE OF ALL 5 1 qupmen POWER SUPPLIES PRIOR TO POWERING UP Set the preset data for torque angle speed time Chapter 6 etc Chapter 7
140. en a Fusion tool is held in the hand of an operator the Torque Recov ery function will cause additional or unexpected torque reaction to be applied to the operator Be careful when using this function when held in the hand of an operator or operator harm may result Page 6 24 FEC Fusion Operations Manual Chapter 6 Fastening Instructions Rev 3 6 6 Added Functions Additional functions are available as standard features integrated within the Fusion controller These functions may be helpful in special applications or for maintenance reasons See below for additional functions 6 6 1 Current Monitoring Control The current monitoring function works as a redundant protection for the torque transducer operations By sensing the current drawn by the motor the system can establish an alternate reference to the signals generated by the torque transducer preamplifier It is intended to detect problems with the mo tor that would not be detected by the torque transducer and also as a maintenance tool to determine if there is a problem before the system will shut down This function allows the user to set Low Current and High Current Limits If the current drawn by the motor overrides the High Current Limit or does not achieve the Low Current Limit the System acti vates the Current Warning PLC Output Signal without halting the System s operation This current warning signal prompts of a potential failure in the system that requires
141. equired 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 sys tem possible damage to the tool assembly or operator injury Customer specific ergonomic guidelines and preferred supplier lists should be used in deter mining suspension reaction equipment requirements WARNING Torque tools generate large amounts of torque that can cause injury when held in the hand of an operator sure all precautions are taken to ensure torque reaction devices are installed to absorb or suppress reaction torque from oper ators It is recommended that some type of torque reaction device is employed for torque over 10Nm to prevent repetitive operator injury Straight Tool Clamp area only FIG 4 4 1 Straight Tool MODEL TYPE NM 4t Ib SPEED Length Ke Ab Square HFT 010M50 S1 10 98 72 1800rpm 3325 13 28 3 8 HFT 015M80 S1 10 14 7 10 8 600 rpm 3525 14 32 3 8 HFT 025M80 S1 10 24 5 18 1 1000 rpm 352 5 14 32 3 8 HFT 040M80 S 10 39 2 28 9 690 rpm 4155 1 4 3 2 3 8 HFT 055M80 S 10 53 9 39 7 508rpm 393 3 076 6 1 2 HFT 080M80 S 10 784 578 3151pm 393 3 0 66 1 2 Mounting Tool may be mounted by using a clamp collar located on the area shown in the draw
142. ess 1 99 in decimal for mat The Upper rotary switch closest to the D sub sets the ten digit X 10 and the bot tom 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 Configura tion of the Profibus Master MUST match the configuration of the FEC Profibus slave Inthe 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 con figuration 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 mod ules Module 1 is inputs module 2 is outputs Profibus I O Signal Mapping Input number 8 bytes 64 bits Permanently set Output number 16 bytes 128 bits Permanently set Input Signals From PLC to Fusion 4 Words 8 Bytes 64bits Word Byte Bit No Description Comment 0 1 1 2 2 3 3 4 0 PE 5 6 6 7 Reset Abort Job Resets initial condition 01 PB 0 9 1 10 2 11 1 3 12 4 13 Work Select 0 5 14 Work Select 1 6 15 Work Select 2 7 16 Wo
143. et as required by your Remote I O network and downloaded to the Fusion controller ER 22 SET AS Offa VO SETUP BAUD RATE 57 4 KBIT5 SECOND RACK ADDRESS 0 RACK SRE 12 RACK 12881 S IN 1288175 OUT STARTING QUARTER 151 LAST RACK LAST RACK RESTAT LOCKOUT REINITIALIZE COMMUNICATION FAULT vo opt Page 4 50 FUSION Operations Manual Chapter 4 System Setup and Wiring Rev 3 4 15 3 Fieldbus Interfaces DeviceNet DeviceNet Interface The DeviceNet communication interface allows slave connection to an industrial DeviceNet net work 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 amp 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 di rectional 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 amp 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 commu nications adapter profile no 12 It is acting as a group two only server on the DeviceNet net Work FEC integrates the DeviceNet
144. et input available though use of PLC inputs on terminal TB1 7 1 2 Fastening Indicators e ACCEPT LED Green Solid Light indicates when the fastening results are within the defined limits Flashing Light indicates when the fastening results for a batch fastening step are within the defined limits The Batch fastening count will be displayed in the COUNT D NO display e WORK ACCEPT LED Green Indicates when the fastening results for a batch fastening operation are within the defined lim its for all steps of the batch operation For Batch count settings of 1 or more 99max e REJECT LED Red Indicates when the fastening results are out the defined limits or that an Abnormal has oc curred refer to Display for Abnormal code e TORQUE Yellow Indicates when the Data Display is set for viewing of Fastening Peak Torque COUNT D NO is set to 0 while in the Run State e ANGLE Yellow Indicates when the Data Display is set for viewing of Final Angle COUNT D NO is set to _1 while in the Run State 7 1 3 Fastening Preset Result displays e COUNT D NO Data number indicator 2 digits Indicates the Display mode and data type number Indicates the Current Fastening count during a Batch count fastening operation Count reset performed via PLC input Displays the Unit number during power up U 01 U 32 e DATA Data value indicator 4 digits During the Run State the display mainly shows the results of faste
145. etup and Wiring OUTPUT SIGNALS A14 BANK DATA 7 B14 BANK DATA 6 A13 BANK DATA 5 Bank Data Output Signals Normally Open B13 BANK DATA 4 These output signals designate various fastening conditions and re A12 BANK DATA 3 sults as determined by Bank Select 0 amp 1 Pins A4 amp B4 inputs Re B12 BANK DATA2 fer to 4 7 3 Bank Select Table for output data descriptions A11 BANK DATA 1 B11 BANK DATA O B15 a Future Programmable Dry Contact Relay output Big Relay Contact A Rating 0 3A 125VAC or 1A 30VDC Cycle End Dry Contact Relay output ie Output when Reverse Mode is active and Operator activates start trig ger used as operator Auxiliary Output Batch Accept Dry Contact Relay output B17 Relay Contact Output after the number of accepts programmed in the Work Count B18 WORK OK parameter is met D No 74 Rating as above Output can be pro grammed as either Pulse or State type using the AFC software A17 Relay Contact Accept Pulse 300 500 msec Dry Contact Relay output used to A18 OK PULSE replace a QL click style torque wrench Rating as above 4 7 2 Work Parameter Select Table PARAMETER WORK SELECT 3 WORK SELECT 2 WORK SELECT 1 WORK SELECT 0 NO PIN A6 PIN B6 PIN A5 PIN B5 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
146. firmly mounted and will not come lose or fall during operation Failure to observe this instruction may cause malfunction The power source shall be provided with safety measures such as breakers and circuit protectors Failure to observe this instruction may cause fire and malfunction Do not use tools or controller units that are damaged or missing parts Failure to observe this instruction may cause fire injury and malfunction Do not subject the equipment to excess shock and impact Failure to observe this instruction may cause malfunction Route all wiring s properly and firmly Failure to observe this instruction may cause injury false operation and malfunction Operate the equipment within the specified power supply voltage Failure to observe this instruction may cause injury electric shock fire and malfunction When operating the equipment in the following conditions take sufficient measures to shield the equipment Location where electrical noise is generated Location where the equipment is subjected to a strong electric field or magnetic field Location near a high power wire Failure to observe this instruction may cause injury false operation and malfunction Safety Precautions Operation Adjustment Caution gt O gt 09 Never operate the equipment with wet hands or while standing in a wet location Failure to observe this instruction may cause electric shock Properly GROU
147. gle is being controlled Under special conditions multiple steps can be performed using in termediate Torque or Angle stop synchronization points FUNCTION RECOMMENDATION COMMENT SPEED CHANGE TORQUE 30 of SNUG TORQUE THRESHOLD TORQUE Start point of 1 torque rate monitoring section 6 2 8096 of SNUG TORQUE Used for RATE TIME settings and TORQUE SPEED initiation SNUG TORQUE Angle Control Start Point CROSSOVER Start point of 3PP torque rate monitoring section 6 2 TORQUE ANGLE Synchronization point for 3rd Step STANDARD ANGLE Engineered product fastening specification 1ST TIME HIGH LOW LIMIT Acceptance range to reach 1ST TORQUE ANGLE setting Acceptance range to go from 1ST TORQUE ANGLE to FINAL TIME HIGH LOW LIMIT STANDARD ANGLE Page 6 10 FEC Fusion Operations Manual Chapter 6 Fastening Instructions Rev 3 NOTE When performing multiple step Angle control fastening the rotation Angle should be performed as one continuous operation There should be no intermediate stop synchroniza tion points once Snug Torque has been sensed and rotation angle is being controlled Under special conditions multiple steps can be performed using intermediate Torque or Angle stop synchronization points as shown below Crossover Torque Angle Snug Torque 1 Torque Threshold Torque Speed Change Torque Standard lt Angle 10 Time Final FI
148. he Tool ACCEPT and REJECT lamp will light to indicate the performance of the Zero Check During a RESET signal the tool Red Green LED s will alternately light 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 between cycles due to the potential for data loss During RESET the connected tools RED GREEN LED will alternate B1 STOP Emergency Stop Input Normally Open 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 Note This signal can inversed Signal must be ON configured using the AFC Software Sequence Tab in Graphic Parameter Setup Screen A2 START Start Cycle Input Normally Open 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 B2 REVERSE Reverse Spindle Rotation Input Normally Open The spindle will rotate in an opposite direction for as long as this signal is activated on and maintained input disabled during RESET A3 SELF CHECK DISABLE Input signal used to disable the performance of the automatic Self Check function at the beginning of the fastening cycle B3
149. he display will automati cally change to the Abnormal Abn display mode displaying the abnormal code and sub code While the Controller Unit is in cycle it will display the cycle status The display will indicate where the cycle is in its fastening sequence The fol lowing abbreviations will be displayed in the data rinm display LILJ 1 In Initial Speed 1E 1 Step End 2 next mat T1 Fr Freerun Speed 2d 2 4 Step End LI SL Slowdown Speed 2E 2 Step End 3 next Tq Torque Speed 34 Step Lo Varispeed High Speed UA Varispeed Final Speed r1 Reverse when the D No displays one digit in the right hand location and one two or three dashes in the left hand location The results details can be scrolled by using the 7 and 1 keys to change the D No This mode does not function while the Nutrunner is Busy Refer to 7 2 3 1 The Fastening results display mode is active LJ The Parameter display mode is active when the D No displays digits in both the right and left hand locations The parameter data can be scrolled by using the 1 and 4 keys to change D No Refer to 7 2 4 The Real time display mode is active when one digit is active in the right hand display only When the power is turned on the default display mode is the REAL TIME display mode The dis play contents can be scrolled by using the 7 and 4 keys to change D NO Refer to 7 2 2 FIG 7 2 1 Run State Display Modes The Cont
150. he right side of the blinking character This code refers to some specific type of failure detailed in the tables shown in the following sections e Abnormal Sub code display The number shown at the most right position in the COUNT D NO display area is a sub code that can be used in conjunction with the Abnormal failure code to further narrow down the cause of the fault See the following sections DATA LINKING HARACIER OW Example of Abnormal Code 9 Sub Code 0 Abnormal Code Table ABNORMAL CODE DESCRIPTION Torque Transducer Error Over Torque Error Tool EEPROM error System Memory Error Servo Amplifier Reply Error Servo Type Mismatch Error NOT USED Servo Amplifier Error o0 Parameter Error Abnormal sub codes and specific actions for troubleshooting are detailed in the following section WARNING DO NOT CONNECT OR DISCONNECT CABLES OR OTHER SYSTEM COMPONENTS WITH POWER APPLIED Page 9 2 FUSION Operations Manual Chapter 9 Troubleshooting Rev 3 9 2 Torque Transducer Abnormals Calibration Error 9 2 1 9 2 2 When the CAL switch is pressed on the Fusion front panel E is shown if the FULL SCALE preset value is missing or a wrong tool is connected RECOVERY 1 Program correct Full Scale Preset value for the tool connected 2 Exchange tool cable tool and or controller with known working u
151. he web browser and put this address in the address bar 2 http 192 168 10 40 This screen should appear Ay FEC INC FUSION SYSTEM NETWORK GATEWAY SETUP Microsoft Internet Explorer provic 0 x File Edit View Favorites Tools Help c 0 Back ar Stop Refresh Search Favorites Media History Mail Print Address e http 1 1 99 sj ee IE be FOSON Protocol DISABLED v Sation Name FEC FUSIO Station ID Number ct System Number oo Spindle Number VIN ASSOCIATION Connection DISABLED Speed 1200 z z gt gt 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 IP configuration setup of the Fusion Ethernet Module can be reset to default by putting a jumper wire between pin and 5 of the Fusion Ethernet I O Power amp I O connector at power up Power down put jumper in and power up jumper can be removed after resetting IP address 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 Tag the Etherne
152. i Limit 34H 4 158 Standard Angle 30H 0 196 2 d Rt Sign Flag 30H 0 121 Final TQ Hi Limit 39H 9 159 1 Angle 30H 0 197 3 4 Rate Lo Limit 30H 0 122 Final TQ Hi Limit 38H 8 160 1 Angle 30H 0 198 3 4 Rate Lo Limit 30H 0 123 Standard Torque 31H 1 161 1st Angle 30H 0 199 3 Rate Lo Limit 124 Standard Torque 32H 2 162 1 Angle 30H 0 200 3 4 Rate Lo Limit 125 Standard Torque 30H 163 Crossover Angle 30H 0 201 3 Rate Hi Limit 31H 1 126 Standard Torque 30H 0 164 Crossover Angle 30H 0 202 3 Rate Hi Limit 39H 9 127 1st Torque 30H 0 165 Crossover Angle 30H 0 203 3 Rate Hi Limit 39H 9 128 1 Torque 36H 6 166 Crossover Angle 30H 0 204 3 Rate Hi Limit 39H 9 129 1 Torque 30H O 167 Correction Angle 30H 0 205 3 Rt Sign Flag 30H 0 130 18 Torque 30H 0 168 Correction Angle 30H 0 206 R D Rev Lo Limit 30H 0 131 Snug Torque 30H 0 169 Correction Angle 30H 0 207 R D Rev Lo Limit 30H 0 132 Snug Torque 35H 5 170 Correction Angle 30H 0 208 R D Rev Lo Limit 30H 0 133 Snug Torque 30H 0 171 2 Rate Start Ang 30H 0 209 R D Rev Lo Limit 30H 0 134 Snug Torque 30H 0 172 2 Rate Start Ang 30H 0 210 Rev Hi Limit 30H 0 135 Threshold Torque 30H 0 173 2 Rate Start Ang 30H 0 211 R D Rev Hi Limit 30H 0 136 Threshold Torque 32H 2 174 2 Rate Start Ang 30H 0 212 R D Rev Hi Limit 30H 0 137
153. iate the Setup mode Immediately after the setup mode is established a blinking number will appear in the COUNT D NO display The cursor blinking mode will move between the 2 digit positions each time the MODE button is pressed The blinking character can be increased or decreased using the and 7 but tons The COUNT D NO characters will display the data corresponding to the Parameter data list 7 2 5 The DATA characters will display the actual value of the COUNT D NO as itis currently set You may edit the currently indicated data using the Data Edit mode Press the SET button to enter into the Data Edit mode on the indicated COUNT D NO that you want to change See 7 3 4 and 7 3 5 for detail M LI LI Finn ffir eee LILILILI FIG 7 3 2 Setup mode D No selection Page 7 32 FUSION Operations Manual Chapter 7 System Operations Rev 3a 7 3 3 Parameter selection All 16 Parameter sets can be setup using the programmer Data corresponding to the se lected parameter number will be displayed in the DATA display The diagram below de Scribes the selection Selection of the FUSION system 16 different sets of parameters for programming purposes is accomplished by depressing the and Cursor key Hori zontal arrows while in primary setup mode addition to parameter 1 16 there is a PARAMETER that contains configuration data common to all parameters ramo IE HITIT
154. ication interface allows slave connection to an industrial Profibus DP 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 amp 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 detect ed rom the master and no user setup is required Module amp Network status LED s provide network diagnostics The Fusion Profibus supports Cyclic I O only Messaging CIP is not supported Maximum configurable I O is 32 bytes 256bits input 32 bytes 256 bits output FEC uses 16 Bytes 128bits for Fusion OUTPUTS Fusion to PLC which includes Binary In teger output of both Fastening Torque amp Angle Fusion INPUTS PLC to Fusion uses 4 Bytes 32 bits The I O signal map defines the 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 bo
155. ing above Tolerance for diameter of inside of clamp must be 0 1 to 0 2mm of diameter of the clamping area so damage to the tool nut does not occur Note Dimensions shown are subject to change without warning due to design improvements Page 4 5 Chapter 4 System Setup and Wiring 4 4 2 Right Angle Tool 254 Clamp area only FIG 4 4 2 Right Angle Tool MODEL TYPE TORQUE speen Lenath Weight Square NM ft Ib Kg Lb Drive mm HFT 015M50 A1 10 14 7 10 8 1215 rpm 365 1 6 3 5 3 8 HFT 025M80 A1 10 24 5 18 1 1070 rom 385 1 7 3 8 3 8 HFT 040M80 A1 10 39 2 28 9 648rpm 410 1 9 4 2 3 8 HFT O60M80 A 10 58 8 43 4 446rpm 410 1 9 4 2 1 2 HFT 080M80 A 10 78 4 57 8 325 459 3 6 7 9 1 2 HFT 130M80 A 10 127 5 94 0 195 rpm 459 3 6 7 9 1 2 HFT 200M80 A 10 196 1 144 5 132rpm 492 4 5 9 9 5 8 Mounting Tool may be mounted by using a clamp collar located in the area shown in the drawing above Warning Tolerance for diameter of inside of clamp must be 0 1 to 0 2mm of diameter of the clamping area so damage to the tool nut does not occur Note Dimensions shown are subject to change without warning due to design improvements Page 4 6 FEC FUSION Operations Manual Chapter 4 System Setup and Wiring Rev 3 4 4 3 Pistol Tools The FEC Pistol
156. ing range 0 10 Calibration torque 1 0 Set the torque value that switches slow down speed to torque speed SPEED 60 Freerun Revolutions _SsSJ gt Fastening gt 40 Initial Time 51 Freerun Speed 52 Slowdown Speed 50 Initial Speed 53 Torque Speed 15 1st torque 23 1st angle 14 Speed Change Torque 54 Reverse Speed Even if Freerun Revolutions are not achieved the speed will change to Slow Down Speed when Speed Change Torque is detected Data No 15 1ST Torque Nm Kgm Setting range 0 10 Calibration torque x 1 0 Data No 23 1ST Angle deg Setting range 0 9999 13T stop synchronization point for multiple step fastening operations End point for 1 torque rate calculation 17 Threshold Torque is beginning Shift point for changing to Torque Speed 53 Torque Speed End of 1 Time and beginning of Final Time Page 7 18 63 Reverse Revolutions FUSION Operations Manual Chapter 7 System Operations Rev 3a Data No 16 SNUG Torque Nm Kgm Setting range 0 10 Calibration torque x 1 0 Snug Torque is only available as a control start point when 00 Fastening Mode is set for Angle Control method Angle of rotation Judgment is conducted from Snug Torque to Fastening end when this torque value is achieved for all fastening methods The Angle when this torque value is achieved is considered the 0 start
157. inspection but allows the sys tem to continue until a suitable time is available to inspect the system The Fastening current limit allows a limit for maximum current draw during a fastening cycle If this is set below Full Scale Current then the current will not exceed this value during a fastening cycle This function is mainly for protecting a motor during Torque recovery applications If the Fastening Current Limit is exceeded and the motor stops turning a Resolver Abnormal fault may occur The Full scale current limit is an automatically set reference value This is generated based upon the motor servo used and should not be changed FULL SCALE CURRENT HIGH CURRENT LIMIT FASTENING CURRENT LIMIT LOW CURRENT LIMIT CURRENT TIME ANGLE Fig 6 6 1 Current Monitor function Page 6 25 Chapter 6 Fastening Instructions 6 6 2 Angle Correction An Angle Correction preset is available for correcting angle reading disparities during calibration us ing a certified master transducer with Angle Monitoring capabilities Under normal conditions this is not used This may be necessary in applications requiring crowsfeet right angle drives belt or chain drives etc Setting range is from 99 to 99 degrees See the AFC User Console software manual for additional set up information 6 6 3 Reduced Fastening Reaction This function is mainly for manual or hand held applications where torque reaction during motor stop ping is
158. ion Default disabled Sets limit for torque variation caused by an angle head in an angle tool system internally monitors torque variation An ABN 2 2 occurs when this is set and variations goes over this set amount Data No 89 CCW Motor Resume Time Pistol Pulse Function msec Setting Range 0 500 Used to set the motor resume time in the CW direction Page 7 26 FUSION Operations Manual Chapter 7 System Operations Rev 3a Data No 90 Sequence Operational mode Data number 90 must be set in order to enable the Batch or Sequence function Other Functions are set also with Data 90 Accept Relay Output Timing xxx1 xxx0 QL OK Pulse 300ms Data No 90 xxx1 QL OK Pulse 800ms Stop Input xxx2 0000 xxx0 Normally Open Stop Input xxx2 Normally Closed Stop Input Total Accept Relay Output xxx4 xxx0 Solid Output Signal xxx4 Pulse Output Signal Add numbers to determine setting number ex QL OK Pulse 800ms xxx1 Pulse Output Signal xxx4 0005 Batch Function Enable xx1x 0 Batch Function Disable xx1x Batch Function Enable Auto Reverse Between 1 amp 2nd Step fastening 2 step xx2x 0 Auto Reverse OFF xx2x Auto Reverse ON Auto Reverse Between 2 amp 3 Step fastening 3 step xx4x 0 Auto Reverse OFF xx4x Auto Reverse ON Note Batch function must be Enabled for Auto Reverse to work Add numbers to determi
159. ions that require a socket to be inserted around a tube to fasten an accompanying tubenut They require a special function to re align the U shaped Socket back to it s open position in order to remove the nutrunner from the tube after fas tening When using an optional Tubenut head special programming options MUST be set up to enable the Tubenut socket automatic return function along with various other considera tions Tubenut head applications inherently present safety concerns especially in the area of the open U shaped socket The opening of the U shaped socket presents a PINCH POINT while rotating WARNING KEEP ALL BODY PARTS AWAY FROM THE TUBENUT HEAD SOCKET OPENING DURING OPERATION OR PERSONAL INJURY MAY RESULT PLEASE CONSULT YOUR PLANT SAFETY PERSONNEL BEFORE USING THIS HEAD All safety precautions MUST be followed to ensure safe operation and operator safety lt gt WARNING Keep away from this area during operation Page 7 39 Chapter 7 System Operations 7 6 1 Recommended Parameter Set up for Tubenut Head The following parameters are recommended for setting up the Tubenut head function 1 Fastening Function Version WORK 00 D No 03 Change to version for Tubenut head tool 1 00 1 01 1 10 1 11 See page 7 12 for function version change procedure 2 External Gear Ratio WORK 00 D No 04 Default is 1 000 If the gear ratio is other than 1 1 then the gear ratio must be ad
160. irmation 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 Optional DB9 connector for Torque Angle monitor OE AMON Analog outputs for use with external analysis equipment 19 IPC RS232 communications port for interfacing with the AFC user console software Removed if Ethernet option installed Controllers with Ethernet option OR HFC EC 16B versions do NOT include these two ports Page 3 4 FEC FUSION Operations Manual Chapter 3 System Description Rev 3 3 1 3 Controller Back Panel Note Numbers correspond to item in following table Fig 3 1 3 Back Panel Description Page 3 5 Chapter 3 System Description 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 twisting the outside ring 90 degrees Clockwise and Counter Clockwise respectively DB9 connector for fastening result data Output only Utilized for 2 RS232C connection to a PLC printer personal computer etc Primary power supply input connection Input for 100 240 VAC single phase 50 60Hz 3 AC100 240 VAC AUTO SWITCHING DO NOT RUN WITHOUT GROUND CONN
161. iscrete Inputs Outputs or optional fieldbus connection is available for external controllers PLC or PC Control Serial RS232 or optional Ethernet is available for resultant fastening data output Additionally the front panel provides easy access for RS232 connection with a computer running the AFC User Console software Page 4 8 FEC FUSION Operations Manual Chapter 4 System Setup and Wiring Rev 3 4 6 Power Requirements and Connections 4 6 1 Controller Unit The Controller uses a standard computer power cord which connects to the AC power con nector located at the back of the unit and to a standard wall outlet The unit operates on single phase power 100 240VAC 50 60Hz Power consumption is 80watts while idle amp 1200watts max Torque Inrush current at power on is 11amps 2 WARNING Do not disconnect power cable while system is in cycle PIN NUMBER DESCRIPTION FRAME GROUND 100 240 VAC 50 60Hz 100 240 VAC 50 60Hz M 5 JL Y JY AC100 240V Wy ANTA Wy AD a Fig 4 6 1 Controller Unit Power Connector NOTE After a Controller 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 Controlle
162. its FEC Inputs match the discrete input lay out FEC Output location is programmed using the AFC User Console Software FEC integrates the Profinet board manufactured by HMS Fieldbus Systems AB into the Multi 2 Unit s modular I O board For further technical information on the Ethernet I P interface go to the HMS website www hms se Profinet Structure PLC PROFINET IO master IPEA PES PROFINET IO slave Other PROFINET IO slaves Page 4 79 Chapter 4 System Setup and Wiring Profinet Hardware 1 Cable connector NO2 Sf8 2 Status LED Indicator SNLYLS Profinet Interface Connections Pin Signal Note A Ib n 2 T _ 4 Normally left unused to ensure signal integrity these pins are tied 5 together and terminated to PE via a filter circuit in the module 7 Normally left unused to ensure signal integrity these pins are tied 8 together and terminated to PE via a filter circuit in the module Page 4 80 FEC FUSION Operations Manual Chapter 4 System Setup and Wiring Rev 3 Status LEDs State Description 1 Link Activity Online Run Green solid Connection established J Ocontroller in RUN Online Stop Green 1 flash Connection Established in STOP Off _ No power or not initialized Green solid Initialized no error
163. joint may cause this limit to be reached Adjust the limit in this case a joint fluctuating between hard and soft multiple times while fastening Page 9 6 FUSION Operations Manual Chapter 9 Troubleshooting Rev 3 9 4 Tool EEPROM Errors 9 4 1 9 4 2 9 4 3 9 4 4 Code 3 0 PREAMPLIFIER TOOL ID CHECKSUM ERROR Communication data Checksum error between the Preamplifier and the CONTROLLER Unit Data is not reliable due to data error This abnormal is caused from 1 If the controller or the transducer cable is located in an electric or magnetic noise field 2 When the torque transducer Tool cable or the controller malfunctions RECOVERY 1 Verify that the cable or controller is not located near any high voltage transient power sources Relocate as required and reinitialize the system 2 Exchange Tool cable tool and or controller with known working units Reinitialize the sys tem after each exchange and make note of any change in the location of the abnormal 3 Replace the defective component Code 3 1 PREAMPLIFIER TOOL TYPE ERROR The connected tool type does not match the tool type programmed into the controller This error may occur in the multi tool type application or when controllers are replaced and not reprogrammed with the correct configuration RECOVERY 1 Verify the tool type name from the tool identification tag 2 Compare the tool tag name with the setup value located on Data Displ
164. justed here or angle readings will not be correct when fastening ex If gear ratio is 1 1 132 then 1 132 should be entered here 3 Gear Head Selection WORK 00 D No 05 Firmware Ver 2 33 or higher Select the version of Tubenut head you are using CW or CCW This is de termined by the direction the NUTRUNNER must rotate in order to rotate the tubenut head in the FASTENING direction and is dependant on the gearing in the tubenut head Without the tubenut head attached to the nutrunner slowly rotate the tubenut socket in the CW direction and take notice of which direction the square drive is turning on the other end of the head If it ro tates in the SAME direction use the CW setting If it rotates in the OPPOSITE direction use the CCW setting 00 Normal Default Disables Tubenut Function 01 CW Tubenut Head Enables CW Tubenut Function 03 CCW Tubenut Head Enables CCW Tubenut Function WARNING Setup proper CW CCW rotation PRIOR to running the tool with the Tubenut head attached or Tubenut Head damage may occur The Tubenut head stop detail which re aligns the open slot in the socket gear may be bro ken if too much force is applied 4 Full Scale Torque WORK 01 thru 32 D No 10 This value will need to be adjusted to make up for torque loss through the tubenut gearing This should be determined by using the calibration ad justment method Section 7 4 This value changes with tool size and ca
165. l 134872 Control amp Communication Link System Master Local Module CCLink V2 Hardware DB SLD OLX 31VM Invg 111 50115 Item Description 1 Station Number Setting Switch 2 Communication Speed Setting Switch 3 Status LEDs 4 4 CC Link Connector Page 4 66 FEC FUSION Operations Manual Chapter 4 System Setup and Wiring Rev 3 CC Link Specifications Cable Shielded Copper Twisted Pair Mitsubishi BA1SJ61 m m Meters Belden 8102 or equivalent Communications Type Master Slave EIA RS485 HDLC Standard Maximum Cyclic I O 896 inputs 896 outputs max Size set in groups of 256 I O Size Occupied Stations I O Configuration I O addressing set by PLC TO FROM commands in Logic Actual I O addressing must be assigned in the PLC logic See the Mitsubishi User Manual 13J872 Control amp Communication Link System Master Local Module for logic reference Ref Section 10 Configuration Configuration of the CC Link system is done in the PLC Logic It is essential that this configuration matches the Dip Switch settings of the FEC CC Link slave FEC is considered a Remote Device in the PLC configuration The number of Occupied Stations set in the PLC must also match the set tings in the AFC User Console set up Note The last 16 output addresses are used by the CC Link communica
166. lation Resistance MOTOR SIZE Pins J K PinsK L Pins L J M80 More than 50 mega ohms at 500 VDC M50 Page 8 5 Chapter 8 Maintenance and Inspection 8 2 4Transmission Disassembly and Inspection e The planetary gear transmissions used in the FUSION System s tool assemblies are de signed to withstand the forces exerted upon them by high production requirements of modern assembly plants e The total cycle count of the tool assembly is stored on the Tool Preamplifier and can be re trieved using the FUSION User Console Software This count can be used for diagnostic and maintenance purposes Only FEC can reset this counter e prolong the life of the transmission assembly the components must be inspected and greased at regular intervals e FEC INC recommends performing this procedure initially after equipment has been in use for one year or 500 000 cycles whichever is reached first e When the initial maintenance is performed the condition of the transmission assembly should be analyzed to determine future maintenance requirements Systems operating under more severe conditions Full scale torque in high temperatures may require maintenance every 250 000 cycles while other systems may only require maintenance every one million cycles 1 REMOVE TRANSMISSION FROM TOOL ASSEMBLY Separate the transmission from the motor by disassembling tool assembly drive end See Tool Assembly Manual Note Care must be t
167. lay Controller automatically checks that replacement tool is the same type 8 3 3 Replace homerun cable 1 Verify all System power is off 2 Disconnect the damaged cable s from the nutrunner tool and the Controller unit and replace with the spare cable s Align keyways on both ends and fully twist connectors into the locked position Note Wave Washer Part WAV 25036 can be used to tighten the tool side twist lock connector if desired The washer must be split and inserted by threading the washer underneath the twist lock rollers Page 8 8 FUSION Operations Manual Chapter 9 Troubleshooting Rev 3 Chapter 9 Troubleshooting Page 9 1 Chapter 9 Troubleshooting 9 1 Abnormal Conditions When an abnormal condition is detected by the system the affected spindle stops and lights in the DATA display For ease of troubleshooting the nature of the abnormal the sys tem provides an abnormal code in the PARM display and an abnormal sub code in the COUNT D NO display Note ABNORMALS are not to be confused with fastening REJECTS Abnormal s signify a failure of a system process or self check during the fastening cycle e Abnormal code display When an Abnormal condition occurs the display mode will automatically change to the STATUS mode If the display is not in the STATUS mode depress the MODE button until a blinking A appears in the WORK display area A code number appears at t
168. ld stall during operation Data No 74 Accept Batch Count Setting Range 0 99 Used to set the number of accepts for WORK ACCEPT Setting 0 disables function Data No 80 CW Stop Angle Pistol Pulse Function Deg Setting Range 0 200 Used to set the swing stop angle in the CW direction This is the angle the pistol will swing up to be fore shutting off Setting 180 disables function Data No 81 CW Swing Pause Angle Pistol Pulse Function Deg Setting Range 0 200 Used to set the swing Pause angle in the CW direction Data No 82 CW Swing Stop Servo Lock Time Pistol Pulse Function msec Setting Range 0 500 Used to set the swing stop servo lock time in the CW direction Data No 83 CW CCW Motor Resume Time Pistol Pulse Function msec Setting Range 0 500 Used to set the motor resume time in the CW direction Data No 86 CCW Stop Angle Pistol Pulse Function Deg Setting Range 0 200 Used to set the swing stop angle in the CW direction This is the angle the pistol will swing up to be fore shutting off Setting 180 disables function Data No 87 CCW Swing Pause Angle Pistol Pulse Function Deg Setting Range 0 200 Used to set the swing Pause angle in the CW direction Data No 88 Angle Head Torque Variation 95 Setting Range 0 500 0 4 disables funct
169. leted the first step all units simultaneously start the second step SYNC COMMON Spindle SYNC signals are connected in series from one spindle to the next Fig 4 13 Sync Connector CN6 Sync Connector PIN DESCRIPTION 1 Sync Signal BV TTL 2 Not Used 3 Sync Common 0v 4 Frame Ground FG Page 4 34 FEC FUSION Operations Manual Chapter 4 System Setup and Wiring Rev 3 4 14 Options Ethernet card An optional Ethernet card is available for AFC Programming Monitoring software connec tion as well as 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 v
170. lip stick friction Incorrect parameter set up Increased joint compression Reduced joint friction Excessive yield of fastener EIER EP CIMIT High initial prevailing torque Incorrect parameter set up Reject condition caused by another monitor item reject Torque Peak Torque High Limit Final Torque High Limit Peak Torque Low Limit Final Torque Low Limit Crossover Torque Snug Torque 1 Torque Threshold Torque Speed Change Torque Angle Time Standard Angle 19 Time Final Time FIG 6 2 2b Final Torque Monitor Angle Control Page 6 15 Chapter 6 Fastening Instructions 6 2 3 Angle Monitoring Angle Monitoring commences upon reaching the preset SNUG TORQUE value and continues until completion of the fastening process e n Angle Control method the Angle High and Low Limits are set based upon the engineering specification for that specific fastener ANGLE CONTROL REJECT TYPE CAUSES ANGLE HIGH LIMIT Incorrect parameter set up ANGLE LOW LIMIT Reject condition caused by another monitor item reject Torque Angle Low Limit Angle High Limit Peak Torque High Limit Final Torque High Limit Peak Torque Low Limit Final Torque Low Limit Crossover Torque Snug Torque J z hae 1 Torque Speed Change Torque boni diee ix Angle Time Standard Angle 1 Time
171. ller malfunctions RECOVERY 1 Check that the tool has no signs of an external force being applied to it No heavy impact has occurred with the tool assembly 2 Verify that the cable or controller is not located near any high voltage transient power sources Relocate as required and reinitialize 3 Exchange tool cable tool and or controller with known working units Reinitialize the sys tem after each exchange and make note of any change in the location of the abnormal 4 Replace the defective component Page 9 3 Chapter 9 Troubleshooting 9 2 3 9 2 4 9 2 5 9 2 6 Code 1 2 TORQUE TRANSDUCER ZERO CHECK ERROR Zero level voltage loaded to memory from tool EEPROM during initialization does not match the actual zero level during a self check with the self check function DISABLED This abnormal is caused from 1 When the tool transducer is sensing excessive torque due to pressure or vibration during the fastening cycle start 2 If the controller or the transducer cable is located in an electric or magnetic noise field 3 When the torque transducer Tool cable or the controller malfunctions RECOVERY 1 Check that the tool has no external force applied to it 2 Verify the tool mounting bolts are tight and nothing is cause excessive vibration to the tool 3 Verify that the cable or controller is not located near any high voltage transient power sources Relocate as required and attempt again the fastening
172. llowing inspections verify that the system is disabled prior to touching any moveable components 8 2 1 Torque Transducer The system can perform a transducer check before each fastening cycle comparing the val ues from the torque transducer zero and calibration to the data stored in the system memory The system is maintenance free however it can be manually checked as follows 1 Be sure that the nutrunner is in the READY mode powered up and not running 2 Check that the torque display shows 0 when the keyboard display unit RESET key is being pressed 3 At the same time as 2 above check that ABN is not displayed on the Data display 4 Check that the display is showing the full scale torque value when the Controller unit CAL key is being pressed 5 At the same time as 4 above check that ABN is not displayed on the Data display If any of these checks fail internal limits an ABNORMAL will be generated and ABN will display See Chapter 9 for troubleshooting 8 2 2 Resolver Take the following steps to manually inspect the resolver 1 Make sure that the system will not be started by an operator 2 Place the Controller keyboard display unit into the real time display mode Chapter 7 Display has only one digit active in the D NO display This is the default mode when power is applied The D NO display must be set to 3 using the Up Down arrow keys in order to see the angle of rotation on the DATA dis
173. mbol indicates that failure to observe instruction marked amp Warning in with this symbol may result in severe personal injury or death This symbol indicates that failure to observe instruction marked A Caution with this symbol may result in minor personal injury or material damage Caution Even instructions that are marked with may result in severe damage if they are not observed according to conditions Contents marked with the above symbols are very important instructions For your safety follow all instructions and especially those marked with these symbols This instruction manual uses the following additional symbols for instructions that shall be ob served Electric shock Fire Fire Electric shock High Temperature G rores Prohibited Do not disassemble e Safety Precautions Maing Do not remove the motors and gear cases of tools while power is applied The tool output spindle may rotate and cause injury Do not repair disassemble or modify the equipment individual components of the system Failure to observe this instruction may cause injury electric shock fire and malfunction Never operate the equipment where it is exposed to water near a corrosive atmosphere or flammable gases Failure to observe this instruction may cause fire Keep fingers away from the connectors while the equipment is turned ON and for a while af ter the equipment is turned OFF Failure to observe thi
174. meter numbers WORK Selection of WORK is for actual Fastening Operational Selection that the Tool will per form while in Run State Arrows are used to select the appropriate Parameter for preset verification and changing while in the Bypass State Alternative WORK input while in Run State available though use of PLC inputs See Section 7 2 5 item 5 for more information on set up selection using the Terminal I O TB1 method for Work Selection Page 7 4 FUSION Operations Manual Chapter 7 System Operations Rev 3a 7 2 Run State Modes The FUSION system has two operational states that are controlled by depressing the MODE and SET Buttons on the front of the Controller simultaneously or by the PLC By pass input The operational modes available in the Run State are identified below Under this condition after Power up the MODE and SET Buttons have not been pressed simul taneously and the BYPASS external signal is not active During the Run State the display mainly shows the results of fastening abnormalities preset values etc 7 2 1 Display indication modes Three modes can be selected while in the Run State by pressing the MODE push button By using the and 7 keys to change the D NO selected the DATA display contents may be varied up or down The displays will remain blank and mode selection will be disabled while the nutrunner is active BUSY If an Abnormal condition occurs t
175. mment Connection Comment NO NO NO WORK SELECT 0 WORK SELECT 1 WORK SELECT 2 WORK SELECT 3 Signal Comment STOP RESET REVERSE START BYPASS SELF CHECK OFF Comment BATCH OK RESET WORK SELECT 4 Page 4 83 Chapter 4 System Setup and Wiring CH No Bit Signal Connection Comment Obit NO ibit NO 2bit NO 3bit NO Abit NO Nods NO 6bit NO 7bit NO Comment Note NC Normal Closed NO Normal Open Example Siemens PLC SFC15 is used 32 bytes are stored from M70 0 SFCIS write Lonsistent Dat 3 to a St andar d DF ave DPUR DAT 18168120 LADDR RET VAL HING 70 0 BYTE 32 4RECORD LADDR Output address set by H W configuration Hexadecimal WORD form RET VAL Memory address when error occurs RECORD Read output signal from PLC Page 4 84 FEC FUSION Operations Manual Chapter 4 System Setup and Wiring Rev 3 Output Signal Specification Output number 32 bytes 256 bits Output map is permanently set Output Map Signal Connection Comment END ACCEPT REJECT Output No 01 Job Cycle Accept WORK SELECT 4 Time 1 Reject Time 2 Reject WORK SELECT 0 WORK SELECT 1 WORK SELECT 2 WORK SELECT 3 REJECT A
176. multiple spindle application 1 Once SPEED CHANGE TORQUE is reached or FREERUN REVOLUTIONS expires the sys tem 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 1 torque rate monitoring section 6 2 3096 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 3PP 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 ET range to go from 1ST TORQUE to STANDARD Torque Standard Torque tbe nete otio ate Crossover Torque ml Wm rx i 1 To
177. mum cable length SILVER Tool Style Cables 01 Model designation One cable connects to the torque trans Each cable should be labeled with a specific spindle or iden tification number and should be connected to the corresponding controller and tool Cable tie points should be loose enough Cable tie points that are too tight cause a Turn off all controller power before attempting to connect or disconnect any motor cables or tool damage may occur 100 must be free from Electrical Noise FEC Part Cable Description Length FEB 1309 M5 Main Cable Straight Female Plug 5 meter FEB 1309 M10 Main Cable Straight Female Plug 10 meter FEB 1309 M15 Main Cable Straight Female Plug 15 meter FEB 1311 M5 Main Cable 90 Degree Female Plug 5 meter FEB 1311 M10 Main Cable 90 Degree Female Plug 10 meter FEB 1311 M15 Main Cable 90 Degree Female Plug 15 meter FEB 1310 M1 Extension Cable Straight Female Plug 1 meter FEB 1310 M2 Extension Cable Straight Female Plug 2 meter FEB 1310 M3 Extension Cable Straight Female Plug 3 meter FEB 1310 M5 Extension Cable Straight Female Plug 5 meter FEB 1310 M10 Extension Cable Straight Female Plug 10 meter FEB 1312 M1 Extension Cable 90 Degree Female Plug 1 meter FEB 1312 M2 Extension Cable 90 Degree Female Plug 2 meter FEB 1312 M3 Extension Cable 90 Degree Female Plug 3 meter FEB 1312 M5 Extension Cable 90 Degree Female Plug 5 meter FEB 1312 M10 Extensio
178. n Abnormal is output Speed Freerun Revolutions Freerun Initial Time Torque Inhibit Revolutions Slow Down Initial Torque 1 Fina Fig 6 6 9 Torque Inhibit Function WARNING The Torque Inhibit Rev setting should be set as low as possible for the intended application to avoid ignoring torque readings as the fastener approaches the seating point If the fastener seats and the system is still in Torque Inhibit mode possible fastener part and or system damage may occur Page 6 27 Chapter 6 Fastening Instructions Blank Page Page 6 28 FUSION Operations Manual Chapter 7 System Operations Rev 3a Chapter 7 System Operations Page 7 1 Chapter 7 System Operations 7 1 FUSION Display and Programming unit operation The FUSION system can be programmed and monitored using the AFC Software package or through use of the keypad and LED display on the front panel While the AFC software of fers an easy to use Windows based software especially for multiples of spindles the keypad and display offer an economical alternative FUSION POWER FIG 7 1 Operational controls and indicators 7 1 1 Manual Fastening controls e START The Start switch for the FUSION Controller is located on the Handheld tool This Trigger switch initiates the fastening cycle When partially depressed the tool will run in a slow start speed until the trigger
179. n Cable 90 Degree Female Plug 10 meter Wave Washer Part WAV 25036 can be used to tighten the tool side twist lock connector washer must be split and inserted by threading the washer underneath the twist lock rollers GOLD Tool Style Cables 10 model designation FEC Part Cable Description Length C15 F7 M05 Main Cable Straight Female Plug 5 meter C15 F7 M10 Main Cable Straight Female Plug 10 meter C15 F7 M15 Main Cable Straight Female Plug 15 meter C15 EF7 M05 Extension Cable Straight Female Plug 5 meter C15 EF7 M10 Extension Cable Straight Female Plug 10 meter C15 EF7 M15 Extension Cable Straight Female Plug 15 meter The Page 4 29 Chapter 4 System Setup and Wiring 4 11 1 Cable Installation Guidelines Improper installation of cables can reduce cable life expectancy drastically The following guide lines should be used when installing cables The cables must be prepared for installation without twists bends or kinks Upon unpack ing 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 sh
180. ne setting number See example above Sequence Function Enable x1xx xOxx Sequence Function Disable x1xx Sequence Function Enable Auto Reject Upon non Completion x2xx F W Ver 5 10 or later xOxx No Output until Sequence is completed x2xx REJECT Output if Sequence stops before completion Add numbers to determine setting number Ex Sequence Function Enabled x1xx Reject Output if Sequence stops before completion x2xx 0300 Note you can only ENABLE either the Batch or the Sequence function at one time START signal must be maintained during sequence if START is lost during sequence fas tening stops Fastening will start from beginning upon next start Page 7 27 Chapter 7 System Operations Data No 91 Sequence Stage 1 Data No 92 Sequence Stage 2 Data No 93 Sequence Stage 3 Parameter Count or Dwell Data No 94 Sequence Stage 4 Parameter Count or Dwell Parameter Count or Dwell Data No 95 Sequence Stage 5 mE Count or Dwell Parameter Count or Dwell Data No 96 Sequence Stage 6 Parameter Count or Dwell Data No 97 Sequence Stage 7 Parameter Count or Dwell Data No 98 Sequence Stage 8 Parameter Count or Dwell Setting range Parameter 0 32 Count or Dwell 0 99 BATCH SEQUENCE PROGRAM EXAMPLES Batch Function There are 4 data digits used for each step which specifies the parameter number and number of acce
181. ng methods re ferred to as Torque Control and Angle Control methods Each control method can be per formed in 1 to 3 incremental steps which will successively secure the fastener to the speci fied torque or angle values NOTE All setting recommendations are based upon common fastening applications Applications that experience high Prevailing torque excessive joint compression or other unique characteristics must be set with these characteristics in mind 6 1 1 Torque Control Method In Torque Control method fastening is performed based upon attaining a desired torque val ue within one to three incremental steps while monitoring the degrees of rotation Angle of the fastener and time Additional monitor items limits can be set to enhance the systems ability to determine if the fastener was properly secured Section 6 2 One Step Fastening One step fastening will be used primarily for joints which have no requirement to synchronize with another spindle during the final stage of the rundown Examples Pipe Plugs Spark Plugs single spindle applications Once SPEED CHANGE TORQUE is reached or FREERUN REVOLUTIONS expires the sys tem 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 TORQ
182. ng the Fieldbus Configuration checkbox Cycle power after download File Extension Information Item Extension Parameter PAR Fieldbus setting FCF Page 4 45 Chapter 4 System Setup and Wiring Profibus 1 0 Size Setting The SETUP tab allows you to set the size of the I O Once the size of I O is set you must DOWNLOAD the setting to the Fusion Controller See above 1 FIELDBUS CONFIGURATION PROFIBUS GENERAL SETUP SET AS DEFAULT 10 SETUP INPUT DATA LENGTH 16 BYTES 128 BIT INPUTS OUTPUT DATA LENGTH f 8 BYTES 64 BIT OUTPUTS mM Y eDefault set up Input data length 16bytes 128bits Output data length 8bytes 64bits e Available I O setup Input data length 1byte 8bits 32bytes 256bits Output data length 1byte 8bits 32bytes 256bits Page 4 46 FUSION Operations Manual Chapter 4 System Setup and Wiring Rev 3 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 architec ture enabling device connection at various locations in the field network can have up to 240 n
183. ng the Polled option When setting the De viceNet 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 be low screen shots of this configuration using RSNetworx Strobed Change of State Cyclic Input Size EH Bytes c C r Input Size Bytes Polled Output Size Bytes Input Size 16 Bytes Heartbeat Rate msec Output Size Bytes Poll Rate Every Scan z Cancel Restore O Sizes Termination Termination of the DeviceNet network requires a terminating resistor at each end of the net work These resistors should have a value of 121 ohms Page 4 53 Chapter 4 System Setup and Wiring DeviceNet Interface Connections PinNo Signal WireColor Black CAN L Drain Shield See Termination CANH 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 us ing the DIP switches on the front of the module These switches must be set before power is on and cannot be changed during opera tion Baud Rate Settings Baud Rate SW2 125 250 Mac ID Settings MacID SW 3 use SW 4 SW 5 SW 6 SW 7 SW 8 LSB Lu um om desee oe io Sta
184. ng the radius e The cables must be secured with strain relief at both ends In exceptional cases the ca bles 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 e Under no circumstances should excess cable be put into a Flexible Cable Track 4 11 4 Considerations for Cable Trays amp Ladders e Cable drop out panels should be used where cables enter and exit a tray or ladder sys tem Sharp bends need to be avoided whenever possible e Cables should be secured at both entry and exit points of a tray or ladder e 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 e f 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
185. ning abnormalities preset values etc During the Bypass State the controller displays and allows setting of all available parame ter presets WORK Parameter number Abnormal number indicator 2 digits Display for the parameter number of the last fastening Also displays an abnormal code dur ing an abnormal condition When the CAL switch is pressed E is shown if the FULL SCALE preset value is missing or a wrong tool is connected Refer to Chapter 9 Page 7 3 Chapter 7 System Operations Abnormal A9 Display Parameter No 1 Cal E Fault Calibration not set after pressing CAL switch or tool number mis match FIG 7 1 3 Fastening Displays 7 1 4 Fastening Presetting Result Display Controls e MODE button Used to change modes while in the Run state Refer to 7 2 Used to move the cursor while in the Bypass program state Refer to 7 3 e SET button Used to enter the data in edit mode and to confirm data setting change e MODE and SET buttons Depressed simultaneously Switches unit between Run state and Bypass program State e f and J Cursor key Vertical arrows Used to scroll through available data preset items D NO Used to change display data values DATA Used as YES NO acknowledge for Tool type and Torque unit changes and for confirmation of the Parameter copy function Fig 7 3 6 e gt and Cursor key Horizontal arrows Used to scroll through available 16 para
186. nits Reinitialize the system after each exchange and make note of any change in the location of the ab normal 3 Replace the defective component Code 1 0 TORQUE TRANSDUCER ZERO VOLTAGE ERROR Zero level does not match master level read from tool EEPROM during power on initializa tion This abnormal is caused from 1 When the tool transducer is sensing excessive torque due to pressure on the tool body 2 If the controller or the transducer cable is located in an electric or magnetic noise field 3 When the torque transducer Tool cable or the controller malfunctions RECOVERY 1 Check that the tool has no signs of an external force being applied to it No heavy impact has occurred with the tool assembly 2 Verify that the cable or controller is not located near any high voltage transient power sources Relocate as required and reinitialize 3 Exchange tool cable tool and or controller with known working units Reinitialize the sys tem after each exchange and make note of any change in the location of the abnormal 4 Replace the defective component Code 1 1 TORQUE TRANSDUCER CAL VOLTAGE ERROR Calibration voltage error during power on initialization This abnormal is caused from 1 When the tool transducer is sensing excessive torque due to pressure on the tool body 2 If the controller or the transducer cable is located in an electric or magnetic noise field 3 When the torque transducer Tool cable or the contro
187. nted 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 e 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 e 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 GROUNDING of the controller is REQUIRED Perform Class 3 grounding Make sure the controllers power cable ground pin is connected to a proper ground e Conirol 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
188. ntry example made in Siemens Reception circuit of the STL form Message Communication PLC Receive declaration Fusion PLC 90 5 M30 0 S END M30 0 L witteiteo0a W OB CALL RDREC DB52 M30 0 Read a Process Data Record REG END 10 6it7FB INDEX 4096 480 VALID M90 4 BUSY M30 5 ERROR M30 7 Pier 300 0 BYTE 480 M30 0 R END 30 5 The detailed explanation looks at programming manual or system function block manuals of the PLC and please refer to the PLC maker for any questions REQREQ 1 Transfer data record use 1 by transmission start and make it 0 by the completion of Transmission ID Set the Fusion unit slave module address assigned by the hardware configuration INDEX Data record number set to 4096 MLEN Set message block length preset value is 480 at the time of factory shipment RECORD Target area for the fetched data record In the example it is 480 bytes from M300 0 VALID New data record was received and valid BUSYBUSY 1 The read process is not yet terminated ERRORERROR 1 A read error has occurred STATUS Call ID bytes 2 and 3 or error code Please read PLC manual LEN Length of the fetched data record information Page 4 89 Chapter 4 System Setup and Wiring 4 15 7 Message Output Format Resultant fastening data can be output to the PLC via the Fieldbus connection after the end of
189. o 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 self protection circuit e Controller Processor 32 bit RISC Reduced Instruction Set CPU e Parameter Firmware Storage Flash ROM e Fastening Data Storage More than 10 000 cycles stored in flash e Fastening Method Torque and Angle 1 3 step fastening e Torque Rate Calculation 3 ranges e Data communications 1 RS232 Front Panel Input output Programming and Data collection 1 RS232 Rear Panel Output Printer or data collection device T A MON Front Panel Output analog Torque and Angle analysis Discrete I O Rear panel Control and PLC interface Real Time Clock Connection Optional Ethernet Programming amp Data collection Eliminates RS232 Front Panel Port Optional Fieldbus Input Output Control and PLC interface 1 1 1 1 1 Page 2 4 FEC FUSION Operations Manual Chapter 2 Specifications Rev 3 2 4 Capability Fastening Accuracy Torque Torque resolution Torque Display Resolution Angle Resolution Angle Display Resolution Torque transducer accuracy Linearity of torque transducer From 1 4 to full scale torque 3 sigma scatter less than 6 From 1 2 to full scale torque 3 sigma scatter less than 596 Accuracy improvements available with application specific
190. observe this instruction may cause injury o e 0 Safety Precautions Transportation Storage A Caution Transport the equipment properly according to its weight Failure to observe this instruction may cause injury and malfunction The conditions when transporting the equipment by ship is as below Ambient temperature 5 C 55 Avoid freezing Ambient humidity 50 RH or lower Avoid moisture Package Tight seal Rust prevention measure Apply light oil on steel portion of tools Failure to observe this instruction may cause earth leakage and malfunction Do not transport tools by grasping cables Failure to observe this instruction may cause injury and malfunction The equipment shall be stored under the following conditions Ambient temperature 5 C 55 Avoid freezing Ambient humidity 90 RH or lower Avoid moisture Atmosphere Indoors Avoid direct sunlight No corrosive gases or flammable gases No oil mist dust water salt iron powder Avoid direct vibration or shocks Failure to observe this instruction may cause a ground fault and malfunction E A A 9 e Safety Precautions Installation Wiring A Caution Install or provide torque reaction for all tools where they can bear the maximum torque during operation Failure to observe this instruction may cause injury and malfunction Make sure controller is
191. odes with valid rack addresses of 0 59 Its maximum communication baud rate is 230K baud with two other settings of 115K amp 57 6K baud Rack addressing amp baud rate is selectable using the baud address selection DIP switch Module status LED s provide network diagnostics Maximum FEC data is 32 inputs amp 32 outputs 1 4 Rack 1 2 3 4 amp Full rack configura tion 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 1 0 inter face see the AnyBus DT reference found at the end of this chapter or go to the HMS web site www hms se Further AB Remote I O information can be found through Allen Bradley s website www ab com onlo 1 BAUD ADDRESS SETTING 8 LED ABE INDICATION TERMINATION SWITCH ON lt 1 LJ BLUE REMOTE 1 O CONNECTOR 2 SHIELD 3 CLEAR Allen Bradley Remote I O interface Board Page 4 47 Chapter 4 System Setup and Wiring 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 inter face board Specifications AB Remote I O Specifications 0 59 Distance 57 6k
192. of cable hung between trolleys e 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 e One trolley should be fixed to the runway rail to eliminate tugging on or stretching of ca bles 4 11 3 Considerations for Flexible Cable Tracks e 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 e There should be an all around minimum clearance between cables of 1096 of the cable s diameter e 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 gt 1 2 x Track Inner Height then no separation is necessary o If Cable 1 Diameter Cable 2 Diameter lt 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 e The cable weight should be symmetrically distributed along the width of the track e Cables must be able to move freely alo
193. on based upon completing a step of the process and then calculat ing the rate for the full duration of that step The chart below identifies the different areas that torque rate can be calculated Each Torque Rate is calculated by dividing the change in torque during the specific period by the change in angle Example 25Nm 100deg 0 25 Nm Deg rate NOTE Setting any of the Torque Rate START POINTS above the FASTENING END TORQUE will eliminate the torque rate calculation for that stage Torque Rate Calculation Areas Typical for 1 or 2 step CROSSOVER TORQUE set above FASTENING END TORQUE Refer to Fig 6 2 4a STAGE START POINT STOP POINT 1ST TORQUE RATE THRESHOLD TORQUE 1ST TORQUE 2ND TORQUE RATE 2ND RATE START TORQUE FASTENING END Torque Rate Calculation Areas Typical for 3 step however can be used on 1 or 2 step Refer to Fig 6 2 4b STAGE START POINT STOP POINT 1ST TORQUE RATE THRESHOLD TORQUE 1ST TORQUE 2ND TORQUE RATE 2ND RATE START TORQUE CROSSOVER TORQUE 3RD TORQUE RATE CROSSOVER TORQUE FASTENING END In the case that Torque Rate Stop Points are not set incrementally larger from THRESHOLD to 2ND RATE START TORQUE and then to CROSSOVER TORQUE the rate calculation will be performed at the next successive available stop point prior to fastening end 2ND TORQUE RATE 2ND RATE START STAGE START POINT AVAILABLE STOP POINTS 1ST TORQUE
194. orque Nm Kgm Setting range 0 10 Cal torque 1 0 Start point for 2 Torque rate monitoring Crossover is the end Torque 18 CROS mE SP X 33 Rate 2 High Limit ES 32 Rate 2 Low Limit Angle If 2nd Torque Rate monitoring is not required 1 2 Rate Start Torque should be set the same or higher than 10 Calibration Torque Data No 26 2ND Rate Start Angle deg NOT USED as standard function Setting range 0 9999 degrees Start point for 2 d Torque rate monitoring CROS Torque Angle is the end Torque 33 Rate 2 High Limit TOW 32 Rate 2 Low Limit i Angle Page 7 21 Chapter 7 System Operations Data No 20 Low Angle deg Data No 21 High Angle deg Setting range 0 9999 Sets the High and Low limits for Fastening Judgment Angle as measured from 16 SNUG Torque to Fastening End If the High limit is reached the fastening operation will stop even if the operation is not complete Data No 22 Standard Angle deg Setting range 0 9999 Sets the target Angle value for fastening as measured from 16 SNUG Torque This is only available when 00 Fastening Mode is Angle Mode Data No 25 Correction Angle deg Setting range 0 99 Compensation value for when the Final Angle value of the equipment does not match the value read from an external master device
195. orrect fcf file After the file has been selected click download to send the file data to the Anybus board Biss CONFIGURATION T GEMERAL SETUP CONFIGURATION RLE BROWSE fius ETHERNET 1P COMBMUNCATION yep we UPLOAD bow OAD Page 4 61 Chapter 4 System Setup and Wiring If no file exists or if the settings need to be changed after the Bus Type has been se lected click on the Setup Tab e am I SET AS WETWORK SETUP ARE 53 192 163 J SUMT MASK 55 255 255 0 E 4 DU AULT GATEWAY 192 353 IO SETUP PUT DATA LENGTH QU EN PLII 16 BYTES 129 TET IMPUT S VATA LEMCTI IPLE gt Fulton 5 04 eT OUTPUTS w BOUT usi PLC MESSAGE BLOCK t xo BYTES MESSAGE BLOCK 2 BYTES In NETWORK SETUP input all of the IP settings required by the host PLC In I O SETUP select the Input Data Length and Output Data Length as required by you ap plication Data lengths MUST MATCH the PLC s same 1 O length setup otherwise con nection will not be possible The Ethernet I P interface also has the ability to transfer resultant fastening data using the message data Transfer CIP function The MESSAGE INPUT Fusion to PLC de fault is MORES MESSAGE OUTPUT is currently not used PLC Setting The setup procedure of Rockwell Automation RXLogix5000 V15 02 00 and Allen Bradley CompactLogix L32E is de
196. ot rotate freely after reassembling the tool then disassemble the tool again to isolate and correct the cause Page 8 6 FUSION Operations Manual Chapter 8 Maintenance and Inspection Rev 3 8 3 Replacements WARNING DO NOT CONNECT OR DISCONNECT CABLES OR OTHER SYSTEM COMPONENTS WITH POWER APPLIED FOLLOW LOCKOUT TAGOUT AND OTHER APPLICABLE SAFETY PRECAUTIONS WHEN CONNECTING OR DISCONNECTING CABLING WIRING AND EQUIPMENT figured with the same Hardware and the same Firmware version as the unit being replaced Controller Unit displays the Firmware Version number when WORK 00 D NO 01 is select ed Version will show in the Data Display ie 1 02 ae NOTE When replacing the FUSION System Controller unit ensure that the new unit is con 8 3 1 Controller Unit Replacement No Partial Replacement All tools operate from one model of Controller HFC EC 16 When one Controller unit is be ing replaced with another it is important to verify that the new unit is set up identical to the unit being removed 1 Verify the controller power is off Ensure all cables connected to the controller are clearly marked for ease of reconnection 2 Disconnect all cables from the rear amp front if applicable of the unit If wires are connected to the I O terminal the controller and to avoid removing all the I O wires you may simply disassemble the terminal block from the controller using the top and bottom screws holding the
197. play 3 If the socket of the tool is turned in the clockwise direction the angle indication should in crease 4 Verify that the angle rotated matches the indicated angle in the data display 8 2 3 Motor If doubts about the condition of the motor exist the windings can be manually checked with a Ohm meter To check the motor measure the winding s resistance and the isolation re sistance 1 Power down the system 2 Disconnect the motor connector from the tool assembly 3 Measure the resistance between windings Refer to Fig 8 2 3 Page 8 4 FUSION Operations Manual Chapter 8 Maintenance and Inspection Rev 3 e 4 Measure the isolation resistance between each pair and the frame Insulation resistance Using a megohmmeter 500 VDC 50 Mohms or more test the insula tion resistance between the motor windings and the motor case The values should register in excess of 50 Mohms for each winding FIG 8 2 3 Motor Inspection Motor Winding Resistance MOTOR SIZE Pins A M PinsM L PinsL A M80 5 00 5 00 5 00 50 7 80 7 80 7 8 Tolerance 1096 Resolver Winding Resistance MOTOR SIZE Pins C D Pins P R PinsV S M80 20 30 0 65 75 65 750 M50 20 30 0 65 75 65 750 Resolver windings should not be Open or zero ohms Insu
198. point for judgment Example When 16 SNUG Torque is 10Nm 22 Standard Angle is 90 Torque Judgment torque 16 SNUG 10Nm Angle 90 22 Standard Angle All values related to Angles are referenced from 16 SNUG Torque Data No 17 Threshold Torque Nm Kgm Setting range 0 10 Calibration torque x 1 0 Start point for 1 Torque Rate monitoring Torque 5d eT ee eee 31 Rate 1 High Limit 4 30 Rate 1 Low Limit 17 Threshold M M H Angle If 1 Torque Rate monitoring is not required 17 Threshold Torque should be set the same or higher than 10 Calibration Torque Page 7 19 Chapter 7 System Operations Data No 18 CROS Torque Nm Kgm Setting range 0 10 Calibration torque x 1 0 2nd stop synchronization point for multiple step fastening operations End point for 2nd torque rate calculation 1E 2 Rate Start Torque is beginning Start point for 3 Torque Rate calculation Fastening End is the stop point Torque 13 Standard Rcs 35 Rate 3 High Limit 34Rate 3 Low Limit RS CROS CC eet er Angle If 3rd Torque Rate monitoring is not required 18 CROS Torque should be set the same or higher than 10 Calibration Torque Data No 24 CROS Angle deg NOT USED as standard function Setting range 0 999
199. pts required in order to go to the next step The fastening must be within the parame ter limits Accepts to be counted WORK ACCEPT signal turns on after each step is com plete Both the Green ACCEPT LED on the controller and tool flash upon the step completion 0 2 0 4 L Number of accepts to complete step Parameter Number to be used for step Batch Data Number Data Operation Step 90 0010 Activate Batch Program 1 91 0103 Fasten 3 times using Parameter 1 2 92 0204 Fasten 4 times using Parameter 2 3 93 0701 Fasten 1 time using Parameter 7 4 94 0000 End 0000 Ends Batch 5 95 0000 6 96 0000 7 97 0000 8 98 0000 Page 7 28 FUSION Operations Manual Chapter 7 System Operations Rev 3a Sequence Function There are 4 data digits used for each step which specifies the parameter number and dwell time after the step is complete 0 1 0 5 L Dwell Time to be used after step Parameter Number to be used in step Sequence Data Number Data Operation Step 90 0300 Activate Sequence Program with Reject if not complete 1 91 0105 Run Parameter 1 and dwell 0 5 second after 2 92 0203 Run Parameter 2 and dwell 0 3 second after 3 93 0300 Run Parameter 3 4 94 0000 End 0000 Ends Sequence 5 95 0000 6 96 0000 7 97 0000 8 98 0000 Parameter Number Operation 1 Fasten to 10 Nm 2 Turn CCW for 360 degrees by angle method 3 Fas
200. pulse function Set D No 81 to 1 D No 82 to 0 and D No 84 to 3 Caution This function may reduce fastening accuracy Page 7 24 FUSION Operations Manual Chapter 7 System Operations Rev 3a Data No 50 Initial Speed rpm Setting range Tool s minimum rpm Tool s maximum rpm Sets the speed at which the tool will begin operations Slower speeds are used to aid in fastener engagement Data No 51 Freerun Speed rpm Setting range 1 Tool s maximum rpm Sets the high speed rundown value used to drive a fastener to seating Shifts to 52 Slow Down Speed when 14 Speed Change Torque is sensed Data No 52 Slow Down Speed rpm Setting range 1 Tool s maximum rpm Sets the speed used to draw the fastener down to 15 1 Torque or 23 1 Angle When 15 1 Torque or 23 15 Angle is sensed the operation will switch to b3 Torque Speed Data No 53 Torque Speed rpm Setting range 1 Tool s maximum rpm Sets the speed during final fastening operations Slower torque speed results in better fastening accuracy Data No 54 Reverse Speed 1 rpm Setting range 1 Tool s maximum rpm Reverse 1 operates when the manual reverse input is selected TB1 Terminal or when the tool reverse switch is activated and the start trigger depressed Data No 55 Recovery Pulse Speed rpm Setting range Tool s minimum rpm Tool s maximum rpm Se
201. que Control method the Final Torque High and Low Torque limits are only selectable when Torque Recovery is enabled and are typically set based upon the engineering specification for that specific fastener TORQUE CONTROL TORQUE RECOVERY ENABLED REJECT TYPE CAUSES FINAL TORQUE HIGH LIMIT Excessive chatter of the torque signal due to slip stick friction Incorrect parameter set up FINAL TORQUE LOW LIMIT Reject condition caused by another monitor item reject Torque Recovery Pulse Time Torque Peak Torque High Limit Final Torque High Limit Standard Torque Final Torque Low Limit Crossover Torque Snug Torque 1 Torque Threshold Torque Speed Change Torque P 1 4 Time Only I 1 Time Final Time FIG 6 2 2a Final Torque Monitor Torque Control W Torque Recovery Page 6 14 FEC Fusion Operations Manual Chapter 6 Fastening Instructions Rev 3 e For Angle Control operations the Torque value may reach a peak value and then drop to a lower value as the fastener is stretched beyond the point of yielding Final Torque High and Low Limits are either set by the engineering specification for that specific fastener or by determining the acceptable limits from a study of known good and bad assemblies ANGLE CONTROL REJECT TYPE CAUSES Reduced joint compression FINAL TORQUE HIGH LIMIT Increased joint friction Excessive chatter of the torque signal due to s
202. r Zero Level Self Check Error 9 5 9 3 Torque Over 9 6 9 3 1 Code 2 1 Torque Over Abnormal Torque Inhibit High Limit 9 6 9 3 2 Code 2 2 Torque Over Abnormal Angel Head Variation 9 6 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 square T 9 12 9 9 7 Code 8 11 Servo Amplifier error Resolver Signal Error 9 12 9 9 8 Code 8 14 Servo Amplifier error Motor Control Circuit Error 9 13 9 9 9 Code 8 15 Servo Amplifier error Power On Error
203. r unit as a self protection feature If a Controller unit does become disabled turn the power off for five 5 minutes before making another attempt to power up Page 4 9 Chapter 4 System Setup and Wiring 4 7 Wiring PLC I O All interface devices must accommodate active true low logic for correct operation with the STANDARD FUSION CONTROLLER Unit DC inputs and outputs I O Optional PNP active true high is available Four output relay contacts are provided for isolated connection to an external controller Optional Fieldbus interfaces are available Outputs are rated at 12 24 VDC 200mA When activated open collector sinking outputs normally high pull the input device signal low 0 VDC Inputs are normally high and activated when pulled low 0 VDC The opposite is true with the optional PNP version controller TB1 I O is enabled even if a Fieldbus interface is installed Both I O will be active Once wired the TB1 terminal block can be quick disconnected from the Controller by loosen ing the captive screws located at the top and bottom of the terminal strip for quick change over to a new controller without disconnecting the terminal wires CAUTION 69 The PLC I O wiring must be routed minimum of 300 mm away from any transient high volt age sources Cable length must not exceed 50 feet NPN VERSION SHOWN
204. requirement to synchronize with another spindle during the final stage of the rundown Angle control commences at SNUG TORQUE All angle values are referenced from this point 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 ANGLE The system will fasten to the 1ST TORQUE ANGLE value during the specified 1ST TIME 1ST TORQUE ANGLE must be reached within the 1ST TIME limits or a reject will occur Upon reaching 1ST TORQUE ANGLE 1ST TIME ends and FINAL TIME begins 1ST TORQUE ANGLE is the shift point to TORQUE SPEED and the synchronization point prior to com mencing the next step See 4 13 for Sync info The system will fasten to STANDARD ANGLE using TORQUE SPEED during FINAL TIME STANDARD ANGLE must be reached within the FINAL TIME limits or a reject will occur NOTE When performing multiple step Angle control fastening the rotation Angle should be performed as one continuous operation There should be no intermediate stop synchronization points once Snug Torque has been sensed and rotation angle is being controlled Under special conditions multiple steps can be performed using in termediate Torque or Angle stop synchronization points FUNCTION RECOMMENDATION COMMENT SPEED CHANGE TORQUE 30 of SNUG TORQUE THRESHOLD TORQUE Start point of 1 torque rate monitoring section 6 2 8096 of S
205. rk Select 3 0 17 Stop 1 18 Reset 2 19 Reverse 2 3 20 Start 4 21 Bypass 5 22 Disable Self check 6 23 7 24 02 0 25 1 26 2 27 3 3 28 4 29 Batch OK Reset 5 30 Work Select 4 6 31 7 32 Input Word 03 04 have no signals assigned and are not shown Page 4 42 FEC FUSION Operations Manual Chapter 4 System Setup and Wiring Rev 3 Output Signals From Fusion to PLC 8 Words 16 Bytes 128 Bits Word Byte Bit No Signal Description Comment 0 1 End 1 2 Accept 2 3 Reject 3 4 CY E 5 6 Job Cycle Accepted Total Accept for Sequence Function 6 7 01 0 9 Work Select 4 Selected echo 1 10 2 11 Time 1 Reject 1 3 12 Time 2 Reject 4 13 Work Select Bit 0 Selected echo 5 14 Work Select Bit 1 Selected echo 6 15 Work Select Bit 2 Selected echo 7 16 Work Select Bit 3 Selected echo 0 17 Reject 1 18 Accept 2 19 Abnormal 2 3 20 Ready 4 21 Busy 5 22 Torque High Reject 6 23 Torque Low Reject 02 7 24 Bypass 0 25 Angle High Reject 1 26 Angle Low Reject 2 27 Rate High Reject 3 3 28 Rate1 Low Reject 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 Outputs Fas
206. rmals 9 3 1 Code 2 1 TORQUE OVER ABNORMAL TORQUE INHIBIT HIGH LIMIT High torque was detected during the Torque Inhibit Function which was greater than the Torque Inhibit high limit parameter The cause of this abnormal is 1 Torque Inhibit High Limit parameter set too low for application 2 Initial starting torque is too high for size of tool If limit is set at full scale torque 3 Excessive binding of output shaft or driver during Torque Inhibit RECOVERY 1 Raise Torque Inhibit Limit 2 Check that the tool has no external force applied to it 3 Verify that torque required is not more than tool capability 4 Verify that nothing is binding on the output shaft of the tool while it begins it s cycle 9 3 2 Code 2 2 TORQUE OVER ABNORMAL ANGLE HEAD TORQUE VARIATION High Torque irregularity over the set limit of D No 88 was detected with the in the Angle Head of the tool The cause of this abnormal is 1 Possible degradation of the Angle Head gears 2 Initial starting torque is too high for size of tool If limit is set at full scale torque 3 Excessive binding of output shaft or driver during Torque Inhibit RECOVERY 1 Adjust Angle Head Variation limit D No 88 between 0 100 2 Replace tool with known good tool if OK the Angle Head of the tool removed may be ex periencing wear of the internal gears 3 Verify that torque required is not more than tool capability 4 A highly fluctuating fastening
207. rmware update is now complete Note This connector is for FEC use only and it is not recommended for use other than CN 8 onnaoooonooooonanaooonaoo BOTTOM OF CONTROLLER FIG 4 12 CN8 location CONTROLLER unit bottom view Page 4 33 Chapter 4 System Setup and Wiring 413 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 opera tion using individual Fusion controllers the SYNC terminals must be wired between all affect ed spindles The SYNC signals are Bi directional signals for synchronized fastening 5V TTL signal 1 Atthe 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 comp
208. roller unit is in Status display mode when no digits are displayed STATUS display indicates if an abnormal condition occurs or if an emergency stop has halted the system Page 7 5 Chapter 7 System Operations 7 2 2 Real time display indication mode D NO One digit While the mode is in Real time display mode COUNT D NO displays 0 8 You can choose the desired type of data by pressing the 4 and 7 keys to change the COUNT D NO data number The indicator will display the following data in the DATA area for the selected D No The display will remain showing the parameter number The Controller will be in Real time display mode immediately after powering up the unit Once a fastening cycle has been performed the Controller will switch to Fastening results display mode Real time display mode can be selected at any time while in the RUN state by pressing the MODE push button Button operation during the real time mode is in dicated in Fig 7 2 2 T z o DATA Torque value Torque voltage Peak Torque maximum hold Rotated Angle Thermal Overload Value 0 100 Current Sensor Value Start Trigger Level 127 255 Reverse Button Level 127 255 8 FEC specific data Torque value The real time torque value from the torque transducer is displayed LJ Lg 2 1 Torque voltage The real time torque signal volt
209. roper gear ratio if different than 1 1 or ANGLE count could be wrong 7 Torque Curve Storage setup WORK 0 D No 08 Standard setting 0000 Version V5 17 or later SET UP RANGE 0000 3999 Setup torque curve storage as below 3999 Number of ACCEPT 0 Maximum savable number Set 999 if ALL are required Number of Torque Curve data 0 100 1 200 2 400 3 600 Maximum savable number 105 70 42 30 Example When 1 200 is chosen and the judgment of 35 of the 70 savable fastening s were REJECT then only 35 Accepted torque curves will be saved When setting 999 as the number savable ACCEPT 70 Accepted torque curves will be saved The stored data is updated by the latest data when it reaches the upper limit X Data is cleared when power is turned off and or changing the setup Curve SAVE can be set up per each parameter number WORK 1 32 D No 06 Data No 6 Enable Disable Save Page 7 13 Chapter 7 System Operations 8 Tool Type Data number entry WORK 0 D No 20 The tool number is entered into WORK 0 D No 20 and must be set correctly to match the attached tool or an abnormal will result Tool Type Error Enter the Tool Number which corresponds to the tool being connected to the CONTROLLER Unit Note When using the AFC software to program the controller this tool number is automati cally set to the tool chosen in the software set up aS od Max RPM Min RPM Max Rate weight Nm rpm rpm Nm d
210. rque Threshold Torque Speed Change Torque Angle Time I 1t Time Final Time FIG 6 1 1b Torque Control Functions for Two Step Fastening Page 6 4 FEC Fusion Operations Manual Chapter 6 Fastening Instructions Rev 3 Three Step Fastening Three step fastening will be used primarily for joints that have a requirement to synchronize with another spindle during the incremental stages of the rundown to crush compress a gas ket or grommet or for special joint conditioning valve cover oil pan or body assembly for example 1 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 2 Once SPEED CHANGE TORQUE is reached or FREERUN REVOLUTIONS expires the sys tem will switch from FREERUN SPEED to SLOWDOWN SPEED and continue to fasten to 1ST TORQUE 3 Upon reaching 18T 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 CROSSOVER TORQUE synchronize with other spindles and then 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
211. s instruction may cause electric shock Wiring operation and maintenance work shall be conducted by a qualified professional Failure to observe this instruction may cause electric shock and injury Turn OFF the power when conducting wiring operation and maintenance Failure to observe this instruction may cause electric shock and injury Never damage the cables apply excess stress to cables or squeeze the cables Never use damaged cables Failure to observe this instruction may cause electric shock and fire Properly GROUND all Field Ground FG Connections and terminals including the ground pin on the POWER CORD NEVER operate this equipment without the ground pin on the power cord grounded Failure to observe this instruction may cause electric shock In case of an abnormal odor noise or operation error occurrence stop operation immediately and turn OFF the power source Failure to observe this instruction may cause injury and fire Install a Power shutdown device in order to ensure the safety of equipment Failure to observe this instruction may cause injury When equipment is automatically operated install an emergency stop circuit on the outside of equipment in order to stop operation promptly Failure to observe this may cause injury Keep away from the equipment during recovery from a temporary blackout and ensure safety measures are conducted after restarting the equipment The equipment may suddenly restart Failure to
212. s portion of this chapter this system is capable of performing multiple step fastening operations The duration of each of these steps is gov erned by one of two independent watchdog time settings If the step fails to attain the desired result before the completion of the specified time a TIME HIGH reject condition will occur Time Low Limits Low time limit settings for both 1st and Final steps are available for special applications This allows the setting of a low time limit which can be used to detect conditions in which the fas tening reaches a given point before it would have under normal conditions Short bolts short threads blind holes cross threads etc are all conditions which may be detected with this setting Times under the low limit will produce a reject for that fastening 1 Step Fastening Function Start Point Stop Point Time Preset Limits 4ST STEP START 1ST TORQUE 1ST TIME HIGH LOW LIMIT 1ST TORQUE FASTENING END FINAL TIME HIGH LOW LIMIT 1st TORQUE also serves as a shift point to TORQUE SPEED and the monitoring stop point for 15 TORQUE RATE The system does not stop or synchronize at this point 2 Step Fastening Function Start Point Stop Point Time Preset Limits 1ST STEP START 1ST TORQUE 1ST TIME HIGH LOW LIMIT 2ND STEP 1ST TORQUE FASTENING END FINAL TIME HIGH LOW LIMIT 1st TORQUE also serves as a shift point to TORQUE SPEED and the monitoring stop point for
213. s the SET button to proceed with the copy e Press either arrow button to confirm H 3 the change YES or to cancel it NO The display will return to the Setup Mode if no action is taken within 4 sec 1L onds 088 e f YES is displayed press the SET T Fir button again to copy the parameter Fu ti LIC zi FIG 7 3 6 Parameter copy procedure Page 7 36 FUSION Operations Manual Chapter 7 System Operations Rev 3a 7 4 Calibration Adjustment The calibration value is set according to the tool type capacity However depending on the application characteristics or on the prevailing torque generated external to the tool output shaft the value of the applied torque and the torque display by the CONTROLLER unit may mismatch In this case it is possible to adjust the FULL SCALE TORQUE CAL value so the displayed torque matches the installation torque registered by an external torque trans ducer Master The CAL value can be adjusted up to 1096 of the FULL SCALE TORQUE value Example Consider the HF T 025M80 A tool Nominal CAL value 3 5 Kg m Range of adjustment from 2 8 Kg m to 4 2 Kg m The FULL SCALE TORQUE value is read from Parameter 1 16 D No 10 Use the following formula on a collection of at least 10 fastenings when a calibration correc tion is necessary New CAL value Master transducer mean FEC transducer mean x Existing CAL value Note The torque unit Kgm Nm
214. scribed Please inquire to each manufacturer when you use other PLC Note Some PLC manufac turers may not support this Messaging CIP function Connection with HFC EC 16 BUS FEI Configuration right click gt 1769 L32E Ethernet Port Local ENB gt New Module 3 8 Configuration Backplane CompactLogix System fa 0 1769 L32E test de Etnern E New Module 176 8 ETH cae Page 4 62 FEC FUSION Operations Manual Chapter 4 System Setup and Wiring Rev 3 Please select Generic Ethernet Module from among the module list and click OK Select Module gt Description Vendor 1788 EN2DN A 1788 Ethernet to DeviceNet Linking Device Allen Bradl 1788 ENBT A 1788 10 100 Mbps Ethernet Bridge Twisted Pai Allen Bradl 1788 EWEB A 1788 10 100 Mbps Ethernet Bridge w Enhanced Allen Bradl 1794 AENT A 1794 10 100 Mbps Ethernet Adapter Twisted P Allen Bradl Drivelogix5730 10 100 Mbps Ethernet Port on DriveLogix5730 Allen Bradl ETHERNET BRL Generic EtherNet IP CIP Bridge Allen Bradl ETHERNET MO Generic Ethernet Module Allen Bradl EtherNet IP SoftLogix5800 EtherNet IP Allen Bradl PH PSSCENA A Ethernet Adapter Twisted Pair Media Parker Han Drives HMI By Category By Vendor Favorites Module Property General Name Inputs the Station Name IP Address Inputs the same IP address as you configured the Ethernet I P module
215. should be flashing to indicate Reverse Mode has been selected B Press the manual Start switch on the Tool Assembly while the tool is in Reverse Mode 1 Verify that the spindle is turning in the appropriate direction opposite the preset parameter direction 4 Verify operation of manual start A Setthe Tool assembly to Fastening Mode 1 Momentarily depress the Reverse pushbutton switch on the Tool Assembly 2 The Tool Assembly light ring should not be flashing flashing indicates Re verse Mode has been selected B Press the manual Start switch on the Tool Assembly while the tool is in Fastening Mode 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 e 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 e 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 3 Chapter 6 Fastening Instructions Page 6 1 Chapter 6 Fastening Instructions 6 1 Fastening Control The Fusion system is user programmable to select from two different fasteni
216. start input 4 Exchange tool cable tool and or controller with known working units Input the start signal after each exchange and make note of any change in the location of the abnormal 5 Replace the defective component Code 1 3 TORQUE TRANSDUCER CAL SELF CHECK ERROR Calibration level voltage error after a fastening start was attempted This abnormal is caused from 1 When the tool transducer is sensing excessive torque due to pressure or vibration during the fastening cycle start 2 If the controller or the transducer cable is located in an electric or magnetic noise field 3 When the torque transducer Tool cable or the controller malfunctions RECOVERY 1 Check that the tool has no external force applied to it 2 Verify the tool mounting bolts are tight and nothing is cause excessive vibration to the tool 3 Verify that the cable or controller is not located near any high voltage transient power sources Relocate as required and attempt again a fastening start input 4 Exchange tool cable tool and or controller with known working units Input the start input after each exchange and make note of any change in the location of the abnormal 5 Replace the defective component Code 1 4 TORQUE TRANSDUCER STARTED ON ZERO ERROR CONDITION The start signal was input while a Zero voltage abnormal condition existed RECOVERY 1 Interlock the PLC circuit to disable the start signal during an existing abnormal condition
217. struction 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 Any defect due to improper conditions improper circumstances and improper handling Any defect due to modifications or repairs performed by the customer Any defect caused by other equipment Any defect caused by customer failing to meet the equipment s specification 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 Safety Precautions Read all instructions before operating the equipment in order to use this equipment safely and cor rectly Prior to use read this instruction manual carefully and fully understand the equipments func tions safety precautions and instructions Safety precautions in this manual are marked with two symbols Warning and Caution To prevent danger to the user and other persons as well as property damage instructions that must be fully observed are marked with the symbols below This instruction manual uses the following two symbols according to the degree of damage that may be caused when the instruction is not observed This sy
218. t port with the con figured IP address for future easy reference Page 4 36 FEC FUSION Operations Manual Chapter 4 System Setup and Wiring Rev 3 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 need to be made if the desired Ethernet protocol requires selection of work selects by Ether Optional Work Select terminations only gt H net COM 1 RS232C ETHERNET POWER amp AUXILIARY 1357 jo ie V 3 a Z e e of lo c DIAGRAM ROTATED 90 RIBBON CABLE 9 PIN 9 PIN FEMALE MALE 1 1 24V RXD 2 2 TXD ov TXD 3 3 RXD INPUT A DTR 4 4 DSR INPUT B GND 5 5 GND OUTPUT A 6 6 DTR OUTPUT B RTS 7 7 CTS OUTPUT C CTS 8 8 RTS OUTPUT D 9 9 DEGREES I O CABLE 1 2 3 NOT USED 4 NOT USED 5 6 8 A10 B9 B5 A5 B6 A6 24N DC OV WORK SEL O WORK SEL 1 WORK SEL 2 WORK SEL 3 Fig 4 14 2 Ethernet Module Connection Connection to an Ethernet network is done
219. t the All Connect Count 3 for number of connected Remote Device stations 3 Set the refresh device Remote Input X100 Output Y100 at Remote Output RX RY 4 Set the refresh device Remote Register read 01000 at Remote Register RWr 5 Set the refresh device Remote Register write 04000 at Remote Register RWw The allocated set values differ according to the station No of the Controller used 6 Set the station information at Station Information Setting the picture below shows an ex ample for reference Page 4 76 FEC FUSION Operations Manual Chapter 4 System Setup and Wiring Rev 3 Station information Setting example 6 above CC Link station information Module 1 em Expanded Exclusive station Remote station Reserve invalid Intelligent buffer select word _ lt Station type cyclic setting count points station select Send Receive Automatic Ver 2Remote device station v Exclusive station 4 896 points No setting eS ee Ver 2Remote device station Exclusive station 4 896 points v setting I 3 9 Ver 2Remote device station w octuple Exclusive station 4 835 points v No setting Default Check End Cancel Enabling the CC Link connection to the PLC PLC Ladder logic is required to enable the CC Link communication link The logic must address the enable bit Initial Data Processing Request of which the address changes based on the size setting used The l
220. ten to 15 Nm gt ore CN WIRE Y U own new am ec eee man Tum woo Note PARAMETER WORK NUMBER must be selected from PLC prior to having the START signal input The START signal can be input from terminal A2 or the start trigger on the tool The system operates as dead man so the START signal must be held on during operation The system aborts the sequence operation upon any reject during the sequence steps The Accept signal is only output at end of a successful sequence operation The fastening result and the torque curve are only available at the end of sequence The fastening result of each step will be stored into stored data memory Page 7 29 Chapter 7 System Operations 7 2 06 STATUS display Two types of controller STATUS can be displayed either STOP or ABNORMAL 1 When the STOP signal is activated The DATA display will indicate when the STOP signal has halted the FUSION as shown in the figure 2 When an ABNORMAL condition occurs the display will show a flashing A character fol lowed by a number that represents the Abnormal number code The COUNT D NO displays a dash and a number that represents the SERVICE CODE NUMBER or SUB Code The figure below shows a display reporting the Abnormal code 9 and the Sub code number 0 Refer to chapter 9 Page 7 30 FUSION Operations Manual Chapter 7 System Operations Rev 3a
221. tening Torque using bi 1 34 Torque Integer bit 1 nary integer 2 35 Torque Integer bit 2 0 999 max 4 3 36 Torque Integer bit 3 number LEFT of decimal only 4 37 Torque Integer bit 4 Example 5 38 Torque Integer bit 5 Torque Integer bit 2 4 7 Logical 1 6 39 Torque Integer bit 6 148 03 7 40 Torque Integer bit 7 0 41 Torque Integer bit 8 Total Torque including Torque deci 1 42 Torque Integer bit 9 mal word3 148 38 2 43 3 44 5 F4 5 5 46 6 47 7 48 O 49 Torque Decimal bit 0 Outputs Fastening Torque Decimal 1 50 Torque Decimal bit 1 value using binary integer 2 51 Torque Decimal bit 2 0 99 max 6 3 52 Torque Decimal bit 3 number RIGHT of decimal only 4 53 Torque Decimal bit 4 Example 5 54 Torque Decimal bit 5 Torque Decimal bit 1 2 5 Logical 6 55 Torque Decimal bit 6 1 38 7 56 04 0 57 1 58 2 59 3 60 i 4 61 5 62 6 63 7 64 Page 4 43 Chapter 4 System Setup and Wiring Profibus I O Signal Mapping Continued Word Byte Bit No Signal Description Comment 0 65 Angle Integer bit 0 1 66 Angle Integer bit 1 2 67 Angle Integer bit 2 8 3 68 Angle Integer bit 3 4 69 Angle Integer bit 4 utputs Fastening Angle value using 5 70 Angle Integer bit 5 binary integer 6 71 Angle Integer bit 6 0 9999 max 7 72 Angle Integer bit 7 05 O 73 Angle Integer bit
222. ter 6 Fastening Instructions Three Step Fastening Three step fastening will be used primarily for joints that have a requirement to synchronize with another spindle during the incremental stages of the rundown to crush compress a gas ket or grommet or for special joint conditioning valve cover oil pan or body assembly for example Angle control commences at SNUG TORQUE All angle values are referenced from this point 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 ANGLE The system will fasten to the 1ST TORQUE ANGLE value during the specified 1ST TIME 1ST TORQUE ANGLE must be reached within the 1ST TIME limits or a reject will occur Upon reaching 1ST TORQUE ANGLE 1ST TIME ends and FINAL TIME begins 1ST TORQUE ANGLE is the shift point to TORQUE SPEED and the synchronization point prior to com mencing the next step See 4 13 for Sync info The system will fasten to CROSSOVER TORQUE ANGLE synchronize with other spindles and then fasten to STANDARD ANGLE using TORQUE SPEED during FINAL TIME STANDARD ANGLE must be reached within the FINAL TIME limits or a reject will occur NOTE When performing multiple step Angle control fastening the rotation Angle should be performed as one continuous operation There should be no intermediate stop synchronization points once Snug Torque has been sensed and rotation an
223. ter No 01 32 Data No 05 Fastening Option 1 0100 Enables judgment of difference of high and low angle 0000 QL OK SIGNAL LEVEL ON FASTENING END NEXT START 2000 QL OK SIGNAL PULSE ON FASTENING END for 300ms 1000 REDUCE FASTENING REACTION WORK SELECT INPUT WILL RESET TOTAL OK AFTER BATCH COUNT 15 REACHED TOTAL OK Tm COUNT D No C1 C2 C3 C4 C5 C1 WORK ACCEPT T 2 ON T When combining multiple functions add the data numbers in hex Ex 0400 0002 0004 0406 COUNT 5 START OK Data No 06 Fastening Option 2 0000 No Torque Curve Storage enable 1 disable 7 16 FUSION Operations Manual Chapter 7 System Operations Rev 3a Data No 10 Calibration torque The calibration value is set according to the tool type capacity However depending on the applica tion characteristics or the prevailing torque generated external to the tool output shaft the value of the applied torque and the torque display by the Fusion unit may mismatch In this case itis possible to adjust the FULL SCALE TORQUE CAL value so the displayed torque matches the installation torque registered by an external torque transducer Master The CAL value can be adjusted up to 20 of the FULL SCALE TORQUE value Example Consider the HFT 080M80 A tool Nominal CAL value 8 0 Kg m Range of adjustment from 6 2 Kg m to 9 4 Kg m Use
224. the following formula on a collection of at least 10 fastenings when a calibration correc tion is necessary New CAL value Master transducer mean FEC transducer mean x Existing CAL val ue Note The torque unit Kgm Nm Ft Lbs etc must be the same for all terms Do not mix torque units in calculation or errors will result If the new CAL value is out of the adjustable range the Err message will be displayed Example Tool Full Scale value EXISTING CAL is 78 4 Nm STD torque is 49 0 Nm Master transducer mean for 10 piece run is measuring only 47 5 Nm FEC transducer mean for 10 piece run is measuring 49 0 Nm The new CAL value is obtained as follows 47 5 49 0 x 78 4 76 0 The FULL SCALE TORQUE CAL value must be corrected to 76 0 Nm and en tered at PARM 1 16 D NO 10 Data No 11 Peak Torque Low Limit Nm Kgm Data No 12 Peak Torque High Limit Nm Kgm Setting range 0 10 Calibration torque x 1 1 Setting points for the High and Low limits of the Peak Fastening Torque If the High or Low limits are exceeded the operation is rejected Data No 13 Standard Torque Nm Kgm Setting range 0 10 Calibration torque 1 0 Set point of the Fastening Standard Target Torque This function is only available when Torque method is selected for 00 Fastening Mode Page 7 17 Chapter 7 System Operations Data No 14 Speed Change Torque Nm Kgm Sett
225. the following steps occur a The system starts off running at INITIAL SPEED for the period specified by INITIAL TIME This segment is intended to be used for initial fastener engagement b Upon completion of INITIAL TIME the system switches to FREERUN SPEED for the period specified by FREERUN REVOLUTIONS The number of revolutions required to complete INITIAL TIME will be deducted from the number of revolutions run at FREERUN SPEED c Once SPEED CHANGE TORQUE is reached or FREERUN REVOLUTIONS expires the system will switch from FREERUN SPEED to SLOWDOWN SPEED and continue to fasten until 1ST TORQUE ANGLE is attained or the 1ST TIME HIGH LIMIT 1ST time reject is reached SLOW DOWN SPEED is intended to provide a slower more controlled speed to seat the fastener 2 Uponreaching 18T TORQUE ANGLE 1ST TIME ends and FINAL TIME begins 1ST TORQUE ANGLE is the shift point to TORQUE SPEED and the synchronization point prior to commencing the next step See 4 13 for Sync info 3 Fora 2 step fastening the system will fasten to STANDARD TORQUE ANGLE using TORQUE SPEED during FINAL TIME STANDARD TORQUE ANGLE must be reached within the FINAL TIME limits or a reject will occur 4 step fastening the system will fasten to CROSSOVER TORQUE ANGLE synchro nize with other spindles and than fasten to STANDARD TORQUE ANGLE using TORQUE SPEED during FINAL TIME STANDARD TORQUE ANGLE must be reached within the FINAL TIME limits or a reject
226. tion amp cannot be used by the user FEC CC Link Version 2 I O configuration is programmable using the AFC User Console software I O can be set as required by the application according to parameter limits set forth by the CC Link System Profile CSP file The AFC Software allows configuration of the number of Occupied Stations and Extended Cyclic Settings in the Multi Unit Configuration of the CC Link Master MUST match the configuration of the FEC CC Link slave CSP File To simplify network configuration CC Link devices may be associated with a CC Link System Profile also known as a CSP file This file contains a description of the device and can be used by some CC Link system utilities to simplify the configuration process The CSP file associated with the FEC device can be downloaded directly from HMS www hms se 5 9 1 Component Descriptions Page 4 67 Chapter 4 System Setup and Wiring Fieldbus Interface Connection Pin2 DB Communication Line Digital Ground SHIELD Connect cable shield Field Ground Mating Connector Allows in line series connection Manufacturer Phoenix Contact Model Name TMSTBP 2 5 5 ST 5 08 Connector is attached Wiring of the CC Link network should be performed by using the cable listed above in the CC Link Specifications The three twisted conductors should be wired in series to each CC Link device using a terminating resistor at the Master
227. tool is available in two sizes 15Nm amp 35Nm 49 Note It is recommended when using pistol type tools that the Ergo Smoothing function or other torque reaction devices are used on applications with target torques over 10Nm to re duce operator fatigue or repetitive use injury The FEC Pistol tool incorporates the latest active Ergonomic smoothing technology to re duce operator torque reaction to very low levels This works by using an electric pulsing 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 See Parameter data list 7 2 5 for set up of Ergo Smoothing function Data No 80 89 Tools may be used in horizontal or vertical applications using supplied hanging bracket Pi Tool Cable Balancer Mounting Bracket Mounts Here Clamp area only Fig 4 4 3 P Type Pistol Tool Total A TORQUE Weight Square MODEL TYPE NM ftIb SPEED Kg Lb Drive HFT 015M50 P1 14 7 10 8 1190 rpm 218 1 1 2 2 3 8 HFT 035M80 P1 34 3 25 3 778 rpm 242 1 4 3 1 3 8 NOTE If clamp will be used to support the tool clamp in ONLY the area shown above or damage may occur to tool Cable Balancer Mounting Bracket is included bolts area sho
228. ts the speed during Recovery pulse operation Data No 60 Freerun Revolutions rev Setting range 0 99 9 Sets the number of revolutions the system will run from the beginning of the fastening operation until 51 Freerun Speed is no longer needed Override shifts to 52 Slow Down Speed when 14 Speed Change Torque is sensed Data No 61 Torque Inhibit Revolutions rev Setting range 0 99 9 For operation that require large starting torque Duration for ignoring the Torque value sensed at Fastening start due to inertia When the initial Torque exceeds the 19 Torque Inhibit Limit during 61 Torque Inhibit Revolutions an ABNORMAL will be generated and fastening will end Data No 63 2nd Reverse Revolutions rev Setting range 0 99 9 Just the value which between 1 and 2 Step is set is reversed Data No 64 3rd Reverse Revolutions rev Setting range 0 99 9 Just the value which between 2 and 3 Step is set is reversed Page 7 25 Chapter 7 System Operations Data No 70 Full Scale Current 95 Data No 71 High Current Limit Data No 72 Low Current Limit 95 Data No 73 Fastening Current Limit 95 Setting range 0 120 Used as a redundant check of the fastening process Please contact FEC Inc for assistance No 70 100 No 71 100 No 72 0 No 73 100 Will limit the amount of current allowed during fastening Be careful when settin g too low or tool cou
229. tus LEDs _ LED Description k 1 Reseved Reserved for future use 2 Network Status 3 Module Status 4 Reserved for future use Page 4 54 FEC FUSION Operations Manual Chapter 4 System Setup and Wiring Rev 3 DeviceNet Signal I O Map From Fusion to PLC 8 Words 16 Bytes 128 Bits Data Bit No Signal Description Comment 0 1 End 1 2 Accept 2 3 Reject 3 4 0 F4 5 5 6 Job Cycle Accepted Total Accept for Sequence Function 6 7 7 8 8 9 Work Select Bit4 echo 9 10 10 11 Time 1 Reject 0 11 12 Time 2 Reject 12 13 Work Select Bit O echo 13 14 Work Select Bit 1 echo 14 15 Work Select Bit 2 echo 15 16 Work Select Bit 3 echo 16 17 Reject 17 18 Accept 18 19 Abnormal 0 19 20 Ready 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 0 27 28 Ratet Low Reject 28 29 Rate2 High Reject 29 30 Rate2 Low Reject 30 31 Rate3 High Reject 31 32 Rate3 Low Reject O 33 Torque Integer bit 0 Outputs Fastening Torque using bi 1 34 Torque Integer bit 1 nary integer
230. ust be reached within the 1ST TIME limits or a reject will occur Upon reaching 1ST TORQUE ANGLE 1ST TIME ends and FINAL TIME begins 1ST TORQUE ANGLE is the shift point to TORQUE SPEED The system will fasten to STANDARD ANGLE using TORQUE SPEED during FINAL TIME STANDARD ANGLE must be reached within the FINAL TIME limits or a reject will occur FUNCTION RECOMMENDATION COMMENT SPEED CHANGE TORQUE 30 of SNUG TORQUE THRESHOLD TORQUE Start point of 1 torque rate monitoring section 6 2 1ST TORQUE ANGLE 8096 of SNUG TORQUE Used for RATE TIME settings and TORQUE SPEED initiation SNUG TORQUE Angle Control Start Point CROSSOVER TORQUE ANGLE Start point of torque rate monitoring section 6 2 STANDARD ANGLE Engineered product fastening specification 1ST TIME HIGH LOW LIMIT Acceptance range to reach 1ST TORQUE ANGLE setting FINAL TIME HIGH LOW LIMIT Acceptance range to go from 1ST TORQUE ANGLE to STANDARD ANGLE Page 6 6 FEC Fusion Operations Manual Chapter 6 Fastening Instructions Rev 3 Torque Crossover Torque Snug Torque 1 Torque Speed Change Torque Angle Time Standard Angle is Time 9 Final Time FIG 6 1 2a Angle Control Functions for One Step Fastening Page 6 7 Chapter 6 Fastening Instructions Two Step Fastening Two Step fastening will be used primarily for joints that have a
231. v 3 1 3 Functions e 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 amp three step fastening Torque rate monitoring in up to 3 areas is available in any configuration e Multi Speed Rundown The Initial Freerun Slowdown Torque and Reverse speed set ups provide capability of multi speed fastenings for any application e 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 e 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 e Auto Tool Recognition Smart Tool ID The FUSION tools have an EEPROM in the preamplifier
232. will occur FUNCTION RECOMMENDATION INITIAL TIME Set to a duration which will provide sufficient time for the socket to en gage the fastener Set in seconds INITIAL SPEED Set to the rpm which will allow for easy socket to fastener engagement FREERUN For joints that do not react properly to high speed seating the Freerun REVOLUTIONS revolutions should be set to end prior to the fastener seating FREERUN SPEED Set based upon cycle time requirements This speed is used to run down the bolt quickly SLOW DOWN SPEED First torque fastening speed SET based upon the joint type to allow for a controlled seating LESS THAN 200 RPM TORQUE SPEED Final torque speed to which the nutrunner will shift once 1st TORQUE is reached SET based upon the joint type to allow for a controlled final fastening LESS THAN 50 RPM REVERSE SPEED Speed used to reverse or back out a fastener Typically of full speed Additional reverse functions exist when a MULTI unit is used Page 6 21 Chapter 6 Fastening Instructions The graphic below describes the ideal relationship between torque and speed Typically for high mo tor durability High speed FREERUN speed should slow to SLOWDOWN speed before the fastener seats Final torque speed should not exceed 50 RPM Speed Freerun Revolutions Freerun Speed Initial Time Torque Inhibit Revolutions Slow Down Speed Initial
233. wist type Work Select from Terminal TB1 1811 Comm Speed 9600bps Rev Sw Slide twist type Work Select from Front Panel 1812 Comm Speed 9600bps Rev Switch PB type Work Select from Terminal TB1 1813 Comm Speed 9600bps Rev Switch PB type Work Select from Front Panel Denotes Default setting Note Adding 4 to any Set No above sets the Fastening function in DDK Mode Changing the RS232 data output protocol as listed in 4 8 5 Rear Panel RS232 Alternate Communication Protocol The effect of the Work Select Method Select from Terminal TB1 Note This MUST be configured when using a Fieldbus interface o Work Select must take place from the TB1 Terminal located on the controller backpanel o Batch OK reset input MUST be applied for clearing cycle count Select from Front Panel o Work Select can take place from the Controller front WORK button o Batch OK reset input can be applied for clearing cycle count or cleared automatically at the next START upon Accept NOTE If Fieldbus is installed changing setup to Work Select from Front Panel will disable the Fieldbus board and the Work Select can only be selected from Front Panel Page 7 12 FUSION Operations Manual Chapter 7 System Operations Rev 3a 6 External gear ratio WORK 00 D No 04 Used to enter gear ratio for EXTERNAL gearing 0 3 3 000 Default 1 000 1 1 gear ratio Note If external gearing is used be sure to set the p
234. wn above Optional top cable entry available contact FEC Page 4 7 Chapter 4 System Setup and Wiring 4 5 Connection Diagram A basic layout of System component interconnection is shown in Figure 4 5 Detailed refer ence drawings can be found throughout this Chapter and also in Appendix A WARNING Follow Lockout Tagout and other safety precautions when connecting and or disconnecting cabling wiring and equipment OPTIONAL FIELDBUS INTERFACE PANEL OPTIONA OPTIONAL 5 ETHERNET CARD 18 DATA OUTPUT TOOLSNET QDAS OTHER FIG 4 5 Connection Diagram The Fusion controller can be connected to various external devices for control and monitoring the fastening process The system will operate with no connection to any external devices If control I O is required d
235. ys the preset values programmed in the CONTROLLER unit for fas tening operation When parameter display mode is enabled the COUNT D NO display will show 2 digits 00 73 representing the preset data number The DATA display will show the corresponding preset data value and the parameter display will indicate the parameter number from 0 16 Use the J and 7 keys to change the preset data number D NO If the COUNT D NO display is showing the number 74 of the parameter number 1 pressing the T key will change the COUNT D NO display to the number 00 of the parameter number 2 You can verify the fastening parameters by pressing the J and 1 keys at any time However it is not possible to alter these settings in the Run state Note Representation only not actual data Parameter No 00 System Parameter 00 Torque Unit 01 NR Version 02 Amplifier Version 03 Function Version 04 External Gear Ratio Parameter No 16 Parameter No 15 Parameter No 14 Parameter No 03 Parameter No 02 Parameter No 01 00 Fastening Mode 10 Calibration torque 11 Peak Low Torque 12 Peak High Torque 13 Standard Torque 2 96 Sequence Stage 6 97 Sequence Stage 7 98 Sequence Stage 8 FIG 7 2 4a Parameter number selection Page 7 8 FUSION Operations Manual Chapter 7 System Operations Rev 3a 7 2 5 Parameter Data List amp Explanation

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