Chapter 4: System Setup and Wiring User Console Version A3.
Chapter 4: System Setup and Wiring 4.1 User Console Version A3.53 Design and Build Procedure Review Chapters 1 and 2 prior to designing a System. If the requirements and specifications in these two (2) Chapters are not addressed, there is a chance of degraded System performance. WARNING: FOLLOW LOCKOUT/TAGOUT AND OTHER SAFETY PRECAUTIONS WHEN CONNECTING AND DISCONNECTING CABLING, WIRING, AND EQUIPMENT. No Items .
Chapter 4: System Setup and Wiring 4.2 User Console Version A3.53 Component Dimensions The specifications for all of the FEC INC. standard AFC1200 System equipment is outlined in this Chapter to aid in determining enclosure requirements. The dimensions for the System monitor (VGA CRT) are based upon a current standard which is subject to variation with advancements in technology. 4.2.1 Monitor (VGA CRT) Dimensions FIG.
Chapter 4: System Setup and Wiring User Console Version A3.53 4.2.2 Main Controller Unit Dimensions FIG. 4-2-2 Main Controller Unit Dimensions Due to communication cable connections, the Main Unit must be mounted in a location that will provide a minimum of 50 mm clearance surrounding the Unit. Cable connections on the front of the Unit require 100 mm of clearance. 4.2.3 Axis Controller Unit Dimensions FIG.
Chapter 4: System Setup and Wiring 4.3 User Console Version A3.53 Unit Arrangement FIG. 4-3 Unit Arrangement Figure 4-3 provides a reference for the layout of the AFC1200 System components. The Units may be mounted in any desired configuration as long as the minimum spacing requirements not neglected. Maximum cable length for the communication bus ribbon cable is 48 inches.
Chapter 4: System Setup and Wiring 4.4 User Console Version A3.53 Nutrunner (Tool) Dimensions Tool dimensions and mounting specifications are critical in determining the design of the powerhead that will house the tool assemblies. Caution must be taken to ensure that the tool assemblies do not come in contact with any other assembly. Failure to provide adequate clearance may result in inaccuracies in the monitoring capability of the system or possibly damage to the tool assembly.
Chapter 4: System Setup and Wiring User Console Version A3.53 4.4.2 Offset Tool A B C E D 60 F W G Q O V P øJ L øK H øM øI R 4-TAP U N FIG. 4-4-2 Offset Tool DFTTYPE 101M1-O1 201M1-O 401M1-O 401M2-O 601M3-O 801M3-O 132M3-O 152M3-O 202M3-O 302M3-O 502M4-O TORQUE SPEED (kgm) (rpm) A B C D E F G H I J K 1 2 4 4 500 500 250 500 406 406 428 456 376 376 398 416 30 30 30 40 236 236 258 269 140 140 140 147 5 5 5 5 12 12 12 16 5 5 5 8 3.5 3.5 3.5 4.
Chapter 4: System Setup and Wiring 4.5 User Console Version A3.53 Wiring Diagrams WARNING: Follow Lockout/Tagout and other safety precautions when connecting and/or disconnecting cabling, wiring, and equipment. 110 VAC PROGRAMMABLE VGA CRT (MONITOR) LOGIC CONTROLLER (PLC) SOURCE VOLTAGE CB 200~230 VAC MAIN UNIT COMMUNICATION BUS RIBBON CABLE CB AXIS UNIT NO. 1 TOOL 1 AXIS UNIT NO. 2 TOOL 2 AXIS UNIT NO. n TOOL n HOMERUN CABLES (3) FIG.
Chapter 4: System Setup and Wiring 4.6 User Console Version A3.53 Power Requirements and Connections WARNING: Follow Lockout/Tagout and other safety precautions when connecting and/or disconnecting cabling, wiring, and equipment. 4.6.1 Monitor (VGA CRT) Power Requirements and Connections PIN NUMBER DESCRIPTION 1 FRAME GROUND 2 110/230VAC AUTOSENSE 50/60Hz 3 110/230VAC AUTOSENSE 50/60Hz CAUTION: VOLTAGE MAY VARY DEPENDENT UPON WHICH CRT MODEL IS USED WITH THE SYSTEM.
Chapter 4: System Setup and Wiring User Console Version A3.53 4.6.3 Axis Unit Power Requirements and Connections WARNING: Follow Lockout/Tagout and other safety precautions when connecting or disconnecting cabling, wiring, and equipment. PIN NUMBER DESCRIPTION A 200~230 VAC + 10%, 50/60Hz, 3-Phase B 200~230 VAC + 10%, 50/60Hz, 3-Phase C 200~230 VAC + 10%, 50/60Hz, 3-Phase D FRAME GROUND Fig.
Chapter 4: System Setup and Wiring User Console Version A3.53 4.6.4. Calculating Circuit Protection WARNING: Follow Lockout/Tagout and other safety precautions when connecting and/or disconnecting cabling, wiring, and equipment. RATED VALUES FOR CALCULATING CIRCUIT PROTECTION TOOL TYPE MOTOR WATTAGE # OF SPINDLES PER 1 KVA KVA PER SPINDLE DFT-101M1-S1/O1 60 8 SPINDLES .125 KVA DFT-201M1-S/O 60 8 SPINDLES .125 KVA DFT-401M1-S/O 60 8 SPINDLES .125 KVA DFT-401M2-S/O 100 5 SPINDLES .
Chapter 4: System Setup and Wiring User Console Version A3.53 4.6.5 Power Distribution Reference Drawing WARNING: Follow Lockout/Tagout and other safety precautions when connecting and disconnecting cabling, wiring, and equipment. The following drawing is provided as a reference for the design and connection of power to the AFC1200 System. Refer to the preceding Sections of this manual to determine the correct transformer and fuse requirements for each specific application. FIG.
Chapter 4: System Setup and Wiring 4.7 User Console Version A3.53 Wiring PLC I/O All interface devices must accommodate active true low logic for correct operation with AFC1200 inputs and outputs (I/O). Outputs are rated at 12~24 VDC, 200mA. When activated, open collector sink outputs (normally high) pull the input device signal low (0 VDC). Inputs are sourced (normally high) and activated when pulled low (0 VDC).
Chapter 4: System Setup and Wiring User Console Version A3.53 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 requires a pulse of 200~500 milliseconds if the Machine Configuration screen is set up for AUTOMATIC Start input. If the Machine Configuration screen is set up for DEADMAN (hand-held operations) input, the Start input must be maintained "on" for the entire cycle.
Chapter 4: System Setup and Wiring Pin # 13 14 15 16 SIGNAL NAME INPUT PORT 1 INPUT PORT 2 INPUT PORT 3 INPUT PORT 4 17 18 19 20 21 22 BYPASS HEAD A BYPASS HEAD B BYPASS HEAD C BYPASS HEAD D BANK SELECT 0 BANK SELECT 1 23 24 25 26 27 28 29 30 31 32 33 34 BANK DATA 0 BANK DATA 1 BANK DATA 2 BANK DATA 3 BANK DATA 4 BANK DATA 5 BANK DATA 6 BANK DATA 7 OUT COM OUT COM 0 VDC COM 0 VDC COM User Console Version A3.
Chapter 4: System Setup and Wiring User Console Version A3.53 4.7.3 Bank Select Table BANK 1 0 BANK DATA PIN 22 PIN 21 # PINS 23~30 1 OFF OFF NAME OF SIGNAL DESCRIPTION DATA 0 REJECT Output when the fastening result is a REJECT. Indicates one (1) or more spindles has failed fastening limits. This output remains active until the START signal or RESET signal is input. DATA 1 ACCEPT Output when the fastening result is a ACCEPT. Indicates all spindles are within fastening limits.
Chapter 4: System Setup and Wiring BANK SELECT INPUT PLC / MAIN CONTROLLER UNIT BANK DATA BANK 1 0 BANK DATA PIN 22 PIN 21 # PINS 23~30 3 ON OFF DESCRIPTION DATA 3 DATA 4 HEAD A END DATA 5 HEAD B END DATA 6 HEAD C END DATA 7 HEAD D END DATA 0 HEAD A ABN. DATA 1 HEAD B ABN. DATA 2 HEAD C ABN. DATA 3 HEAD D ABN. DATA 4 HEAD A REJ. DATA 5 HEAD B REJ. DATA 6 HEAD C REJ. DATA 7 HEAD D REJ.
Chapter 4: System Setup and Wiring User Console Version A3.53 4.7.4 Explanation of Axis Unit I/O Individual spindle PLC signals connect to each Axis Unit via the PLC connector located on the front of the Axis Unit. CAUTION: The PLC I/O wiring must be routed a minimum of 300 mm away from any transient high voltage sources. Cable length must not exceed 50 feet. FIG.
Chapter 4: System Setup and Wiring 13 ANGLE CW/CCW 14 ANGLE PULSE OUTPUT ANALOG TORQUE OUTPUT 15 16 ANALOG GROUND User Console Version A3.53 Angle CW/CCW Output (Analog output 0 VDC / +5 VDC) High (+5 VDC) = Clockwise Low (0 VDC) = Counterclockwise This signal shows the direction of the tool rotation. Angle Pulse Output (Analog output 0 VDC / +5 VDC) Outputs one pulse per degree. Analog Torque Output (Analog output -4.5 ~ +4.5 VDC) A 0 ~ 2.5 VDC differential signal. Example: Zero = -2.
Chapter 4: System Setup and Wiring User Console Version A3.53 4.7.6 PLC Wiring Sample FIG. 4-7-6 PLC Wiring Sample All AFC1200 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, 200mA. When activated, open collector sink outputs (normally high) pull the input device signal low (0 VDC). Inputs are sourced (normally high) and activated when pulled low (0 VDC).
Chapter 4: System Setup and Wiring User Console Version A3.53 4.7.7 Signal Timing Chart A. Basic Control Signals MAIN UNIT SIGNALS STOP READY RESET START FASTENING FASTENING FASTENING BUSY ACCEPT REJECT ABNORMAL AXIS UNIT SIGNALS AXIS 1 ACCEPT AXIS 1 REJECT AXIS 2 5 0 MSEC BYPASS (INPUT) AXIS 2 BYPASS (OUTPUT) AXIS 2 ACCEPT FIG.
Chapter 4: System Setup and Wiring User Console Version A3.53 B. Fastening Sequence Selection and START signal input (Main Unit) OFF SEQUENCE SELECT 0 ON Selection of SEQUENCE 2 (BANK DATA 7, BANK 1). (PIN 9) OFF SEQUENCE SELECT 1 Reference Section 4.7.2 for SEQUENCE 1~8 selections. (PIN 10) OFF SEQUENCE SELECT 2 (PIN 11) OFF BANK 1 is required to enable SEQUENCE 0~2 outputs. Default setting: BANK SELECT 0 & 1 = OFF Reference Section 4.7.3 for BANK 1~4 settings.
Chapter 4: System Setup and Wiring 4.8 User Console Version A3.53 PLC Reference Drawings This Section provides examples of connections commonly used in PLC / AFC1200 System integration. Two (2) different types of PLC's are addressed here, and this information is for reference only. The actual signal connections required for each application must be determined by reviewing the signal descriptions provided in Section 4.7.
Chapter 4: System Setup and Wiring User Console Version A3.53 4.8.2 Allen Bradley Output Card 1771-OQ16 Axis Unit Connection FIG. 4-8-2 Allen Bradley Output Card 1771-OQ16 Axis Unit Connection NOTE: The +12~24 VDC Common is connected directly to the Axis Unit PLC connector on pin # 6. The 0 VDC Common is connected to Pin # 7, and is shown on the PLC input card sheet for the Axis Unit (FIG. 4-8-4).
Chapter 4: System Setup and Wiring User Console Version A3.53 4.8.3 Allen Bradley Input Card 1771-IQ16 Main Unit Connection FIG. 4-8-3 Allen Bradley Input Card 1771-IQ16 Main Unit Connection NOTE: The Output Common connections on Pins 31 and 32 are electrically the same signal. These two pins should be connected to the 0 VDC reference for the PLC input card. The Input Common connections on Pins 33 and 34 are electrically the same signal.
Chapter 4: System Setup and Wiring User Console Version A3.53 4.8.4 Allen Bradley Input Card 1771-IQ16 Axis Unit Connection FIG. 4-8-4 Allen Bradley Input Card 1771-IQ16 Axis Unit Connection NOTE: The 0 VDC Common is connected directly to the Axis Unit PLC connector on Pin 7. The +12~24 VDC Common is connected directly to Pin 6, and is shown on the PLC output card sheet for the Axis Unit. (FIG.
Chapter 4: System Setup and Wiring User Console Version A3.53 4.8.5 Modicon Output Card B832-016 Main Unit Connection FIG. 4-8-5 Modicon Output Card B832-016 Main Unit Connection NOTE: When connecting certain PLC output cards to the AFC1200 System, diode terminals are required. This prevents the AFC1200 input circuit from activating the output LED on the PLC card.
Chapter 4: System Setup and Wiring User Console Version A3.53 4.8.6 Modicon Output Card B832-016 Axis Unit Connection FIG. 4-8-6 Modicon Output Card B832-016 Axis Unit Connection NOTES: When connecting certain PLC output cards to the AFC1200 System, diode terminals are required. This prevents the AFC1200 input circuit from activating the output LED on the PLC card. The +12~24 VDC Common is connected directly to the Axis Unit PLC connector on Pin 6.
Chapter 4: System Setup and Wiring User Console Version A3.53 4.8.7 Modicon Input Card B833-016 Main and Axis Unit Connection FIG. 4-8-7 Modicon Input Card B833-016 Main and Axis Unit Connection NOTE: The Output Common connection on Pins 31 and 32 are electrically the same signal. These two pins should be connected to the 0 VDC reference for the PLC input card. The Input Common connection on Pins 33 and 34 are electrically the same signal.
Chapter 4: System Setup and Wiring 4.9 User Console Version A3.53 Nutrunner Setup and Connections 4.9.1 Spindle Number Setup When using the AFC1200 System in a multi-spindle application, Axis Unit / spindle numbers must be setup. These numbers must uniquely identify each Axis Unit in consecutive order, beginning with number one (1). FIG.
Chapter 4: System Setup and Wiring User Console Version A3.53 4.9.2 Ramp-Up Time Setup The ramp-up time dip switches control the duration of the initial tool speed ramp-up. If the duration is too short, the tool starting inertia may be falsely sensed by the System as a torque reading. If the duration is too long, the extended cycle time will result in reduced System efficiency. FIG.
Chapter 4: System Setup and Wiring User Console Version A3.53 4.9.3 Ribbon Cable Connections FIG. 4-9-3 Main Unit to Axis Unit Ribbon Cable Connection Ribbon cables function as a communication bus between the Axis Units and the Main Unit. One cable is connected from the upper right hand side of the Main Controller Unit to the bottom of the nearest mounted Axis Controller Unit. All Axis Units are then connected (daisy-chained) with ribbon cables as shown in Figure 4-9-3.
Chapter 4: System Setup and Wiring User Console Version A3.53 4.9.4 Tool connection { Connect the encoder cable, the motor cable, and the transducer (sensor) cable to the corresponding numbered tool. Ensure that the cable tag numbers match the tool tag numbers. { Attach the preamp to the enclosure frame as shown in the following diagrams. { Ensure that the cable is tied so that there is no undue stress on it when the powerhead moves.
Chapter 4: System Setup and Wiring User Console Version A3.53 Each tool has a preamplifier which must be securely mounted to ensure accurate System performance. Dimensions given below are in millimeters. FIG.
