Chapter 4: System Setup and Wiring Chapter 4: System Setup and Wiring 4.1 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.
Chapter 4: System Setup and Wiring 5 Select an Air Handling Unit (as required) Select an Air Handling Unit applicable to the environmental conditions (A/C, Heat Exch, etc.) 2.1 6 Select an adequate PLC PLC must directly connect to the AFC1200 System (24 VDC true low). 4.7 4.8 7 PLC logic design (or review) A PLC logic program can be written using signal descriptions and timing charts provided. 4.7 4.
Chapter 4: System Setup and Wiring 4.2 System Component Dimensions The specifications for all of the FEC INC. standard AFC1200 System equipment are outlined in this Chapter to aid in determining enclosure requirements. The dimensions for the System monitor (CRT) are based upon a current standard which is subject to variation with advancements in technology. 4.2.1 Flat Panel LCD 11.50 AMDG 10.50 FIG.
Chapter 4: System Setup and Wiring 4.2.2 ISA Main Controller Unit FIG. 4-2-2 ISA Main Controller Unit Dimensions When mounted, the ISA Main Unit requires minimum clearances of 50 mm surrounding the Unit and 100 mm at the front of the Unit. These clearances are required for cable connections and heat dissipation. 4.2.3 Axis Controller Unit FIG.
Chapter 4: System Setup and Wiring Component Arrangement REV FNL ISA-MAIN CONTROLLER PARM /ABN REJECT ACCEPT PARM /ABN ACCEPT NORMAL PROGRAM SENSOR BYPASS (RED) ENCODER DSP 2 SPDL SENSOR ENCODER TORQUE LOW ANGLE (ORANGE) 1ST RATE HIGH BYPASS (RED) 3RD RATE 2ND RATE SENSOR (RED) 1ST (ORANGE) FNL (RED) TIME NORMAL MOTOR HIGH 3RD RATE IN BYPASS 1ST (ORANGE) FNL (RED) TIME NORMAL MOTOR REJECT ACCEPT ABNORMAL (ORANGE) 2ND RATE IN BYPASS 1ST (ORANGE) FNL (RED) TIME
Chapter 4: System Setup and Wiring 4.4 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 4.4.2 Offset Tool A B C E D 60° F W G r.S T O Q V P øJ øK L H øM øI R N 4-TAP U FIG. 4-4-2 Offset Tool DFTTYPE TORQUE (kgm) SPEED (rpm) A B C D E F G H I J K 101M1-O1 201M1-O 401M1-O 401M2-O 601M3-O 801M3-O 132M3-O 152M3-O 202M3-O 302M3-O 502M4-O 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 P Plate must be blanchard ground (to ensure sides are adequately flat and parallel) FLAT PANEL LCD 110 VAC PLC SOURCE VOLTAGE 200~230 VAC CB AFC-1200K/B SYSTEM ISA-MAIN CONTROLLER AFC1200 ACCEPT POWER 7 8 9 HLP 4 5 6 DEL 1 2 3 SEL 0 . + - . REJECT CRT BU SY CHECK CH2 RS232C AXIS-DISPLAY 3 4 2 5 1 6 7 K/B FDD RUN KEYPAD PROGRAM AXIS-DISPLAY MANUAL RESET START REV DSP1 DSP2 1 PT Q. F.
Chapter 4: System Setup and Wiring to a thickness of 15.88 mm (.625 inch) .05 mm (.002 inch). P Both sides of all bores must be chamfered 1.6 mm (.063 inch) x 45 degrees. P Tools must be mounted 1.6 mm (.
Chapter 4: System Setup and Wiring 4.5 Wiring Diagrams WARNING: Follow Lockout/Tagout and other safety precautions when connecting and/or disconnecting cabling, wiring and equipment. FIG. 4-5 Wiring Diagram A basic layout of System component interconnection is presented in Figure 4-5. Detailed reference drawings can be found throughout this Chapter and also in Appendix A.
Chapter 4: System Setup and Wiring 4.6 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 (Flat Panel LCD Screen) PIN NUMBER DESCRIPTION 1 FRAME GROUND 2 110 VAC 50/60 Hz 3 110 VAC 50/60 Hz CAUTION: VOLTAGE MAY VARY BASED ON WHICH CRT MODEL IS USED. REFER TO THE OWNER'S MANUAL FOR MONITOR SPECIFICATIONS. 2 1 3 FIG. 4-6-1 Flat Panel LCD Screen 4.6.
Chapter 4: System Setup and Wiring 4.6.3 Axis Controller Unit WARNING: Follow Lockout/Tagout and other safety precautions when connecting and 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. 4-6-3 Axis Unit Power Connector NOTE: After an Axis Unit is powered down, the power must not be applied again for at least five (5) seconds.
Chapter 4: System Setup and Wiring 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 .2 KVA DFT-601M3-S/O 200 2.
Chapter 4: System Setup and Wiring * Use a fuse or circuit breaker with a rating just above the computed required size.
Chapter 4: System Setup and Wiring 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 generic reference for the design and connection of power to the AFC1200 System. Transformer, fuse and circuit breaker requirements must be computed specifically for each application. FIG.
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 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). CAUTION: The PLC I/O wiring must be routed a minimum of 300 mm away from any transient high voltage sources.
Chapter 4: System Setup and Wiring PIN # SIGNAL NAME 1 STOP 2 RESET PLC1 INPUT SIGNALS DESCRIPTION Emergency Stop Input (Normally Closed) This signal must be active (on) for Controller operation. When this signal is inactive (off), all Controller operation ceases, all spindles in motion will stop and all communication ports, inputs and outputs will be disabled. Reset Input (Normally Open) When active (on), this signal will clear all fastening data, discrete outputs and communication buffers.
Chapter 4: System Setup and Wiring PIN # SIGNAL NAME 3 REVERSE 4 START 5 6 RUN / PROGRAM SELF-CHECK 7 OFFSET CHECK 8 CYCLE COUNT 9 10 11 SEQ SELECT 0 SEQ SELECT 1 SEQ SELECT 2 12 SEQ SELECT 3 PLC1 INPUT SIGNALS DESCRIPTION Reverse Spindle Rotation Input (Normally Open) All active spindles will rotate in an opposite direction for as long as this signal is activated (on) and maintained. The Reverse input functions the same as the Reverse pushbutton on the front of the ISA Main Controller Unit.
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 PIN # 23 24 25 26 27 28 29 30 31 32 33 34 SIGNAL NAME 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 PIN # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 PLC1 INPUT SIGNALS DESCRIPTION External Sequence Input
Chapter 4: System Setup and Wiring 4.7.2 Sequence Select Table WARNING: Follow Lockout/Tagout and other safety precautions when connecting and/or disconnecting cabling, wiring and equipment.
Chapter 4: System Setup and Wiring 4.7.
Chapter 4: System Setup and Wiring BANK SELECT INPUT PLC1 BANK DATA 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 exceeded fastening limits. This output remains active until the START signal or RESET signal is input. DATA 1 ACCEPT Output when the fastening result is an ACCEPT. Indicates all spindles are within fastening limits.
Chapter 4: System Setup and Wiring BANK SELECT INPUT PLC1 BANK DATA BANK 1 0 BANK DATA PIN 22 PIN 21 # PINS 23~30 3 ON OFF DATA 0 ON ON DESCRIPTION DATA 2 HEAD A BUSY These four signals will output while their designated spindle(s) are fastening. Reference HEAD B BUSY Section 7.10 Machine Configuration. HEAD C BUSY DATA 3 HEAD D BUSY 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.
Chapter 4: System Setup and Wiring BANK SELECT INPUT PLC2 BANK DATA BANK 1 0 BANK DATA PIN 22 PIN 21 PINS 1~8 # PLC1 1 2 PLC1 PLC2 OFF OFF DATA 8 OFF ON NAME OF SIGNAL DESCRIPTION SEQUENCE 3 Reserved for future use. DATA 9 PROGRAM Reserved for future use. DATA 10 H/W WARNING Reserved for future use. DATA 11 PRN BUSY Reserved for future use.
Chapter 4: System Setup and Wiring 4.7.4 Description 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 Pin # SIGNAL NAME 14 ANGLE PULSE OUTPUT 15 ANALOG TORQUE OUTPUT 16 ANALOG GROUND DESCRIPTION Angle Pulse Output (Analog output 0~5 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 = -2.0 VDC Calibration (full scale) = +0.5 VDC Difference = 2.5 VDC Common for all of the analog outputs. 4.7.
Chapter 4: System Setup and Wiring 4.7.6 PLC Wiring Sample FIG. 4-7-6 PLC Wiring Sample 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 4.7.7 Signal Timing Chart A. Basic Control Signals - ISA Main Unit and Axis Unit ISA 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 BYPASS (INPUT) 50 MSEC AXIS 2 BYPASS (OUTPUT) AXIS 2 ACCEPT FIG.
Chapter 4: System Setup and Wiring B.
Chapter 4: System Setup and Wiring 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 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 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 Pin #6 on the Axis Unit PLC connector. The 0 VDC common is connected to Pin # 7, and is shown in Figure 4-8-4.
Chapter 4: System Setup and Wiring 4.8.3 Allen Bradley Input Card 1771-IQ16 ISA Main Unit Connection FIG. 4-8-3 Allen Bradley Input Card 1771-IQ16 ISA Main Unit Connection Note: Pins 31 and 32 of the ISA Main Unit (0 VDC Out Common) are electrically the same signal, and 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 4.8.4 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 (FIG. 4-8-2) for the Axis Unit.
Chapter 4: System Setup and Wiring 4.8.5 Modicon Output Card B832-016 ISA 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 4.8.6 Modicon Output Card B832-016 Axis Unit Connection FIG. 4-8-6 Modicon Output Card B832-016 Axis 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. The +12~24 VDC Common is connected directly to the Axis Unit PLC connector on Pin 6.
Chapter 4: System Setup and Wiring 4.8.7 Modicon Input Card B833-016 ISA Main and Axis Unit Connection FIG. 4-8-7 Modicon Input Card B833-016 ISA Main and Axis Unit Connection Note: The Output Common connection on Pins 31 and 32 are electrically the same signal. These two (2) 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 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 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 4.9.3 Ribbon Cable Connections FIG. 4-9-3 Ribbon Cable Connection from ISA Main Unit to Axis Unit Ribbon cables function as a communication bus between the Axis Units and the ISA Main Unit. One cable is connected from the front of the ISA 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 4.9.4 Nutrunner (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. { Affix 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 FIG. 4-9-4b Tool Mounting Methods FIG.
