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ELECTRIC SERVO NUTRUNNER

AFC1500 MULTI SYSTEM

MULTI-2 UNIT HARDWARE MANUAL

SECOND Edition March 2009

51327 Quadrate Drive Phone: (586) 781-2100

Macomb, MI. 48042 Fax: (586) 781-0044

Web: www.fec-usa.com E-mail: sales@fec-usa.com

AFC1500E-HM2-2

Automation Systems

Summary of content (129 pages)

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ELECTRIC SERVO NUTRUNNER AFC1500 MULTI SYSTEM MULTI-2 UNIT HARDWARE MANUAL SECOND Edition March 2009 Automation Systems 51327 Quadrate Drive Macomb, MI. 48042 Web: www.fec-usa.com Phone: (586) 781-2100 Fax: (586) 781-0044 E-mail: sales@fec-usa.
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WARNING All applicable national and local codes must be followed when installing and operating the equipment detailed in this manual. FAILURE TO ABIDE BY THESE CODES AND THE SPECIFICATIONS DESCRIBED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY TO PERSONNEL AND/OR DAMAGE TO THE EQUIPMENT! Any questions regarding the contents of this document or any related matter should be directed to FEC INC. at (586) 781-2100, faxed to (586) 781-0044 or emailed to support@fec-usa.com.
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Revision Revision Date 1 04/2008 Initial Release 2 3/2009 Revision affecting most chapters including minor fixes, revised information and new items – Added Ethernet, Profinet & Toolsnet info. 2.
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Introduction Thank you for purchasing our Electric Servo Nutrunner - AFC1500 System. This instruction manual describes the procedures for installation, wiring, 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”.
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Introduction Warranty Warranty Period FEC Inc. warrants that the equipment manufactured by it and delivered hereunder will be free of defects in material and workmanship for a period of twelve (12) months from the date of placing the equipment in operation, or eighteen (18) months from the date of shipment, or 500,000 machine cycles - whichever shall first occur.
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Safety Precautions Read ead all instructions before operating the equipment in order to use this equipment safely and correctly. Prior to use, read this instruction manual carefully and fully understand the equipments functions, safety precautions and instructions.. Safety precautions in this manual are marked with two symbols [Warning] and [Caution].
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Safety Precautions Warning Never touch rotating devices or any part of the nutrunner tool while it is rotating. Make sure that no part of your body gets near any moving part of the tool. The spindle may rotate unexpectedly, resulting in injury. 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.
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Safety Precautions Transportation / Storage 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°C (Avoid freezing) ◆ Ambient humidity: 5 50% RH or lower (Avoid moisture) ◆ Package: Tight seal ◆ Rust prevention measure: Apply grease or oil on tools. Failure to observe this instruction may cause earth leakage and malfunction.
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Safety Precautions Installation / Wiring Caution Install all tools firmly where they can bear the maximum torque during operation. Failure to observe this instruction may cause injury and malfunction. Install the AXIS Unit firmly inside the control panel using the specified screws. Failure to observe this instruction may cause malfunction. Use the specified tool for the AXIS (SAN) Unit. Failure to observe this instruction may cause fire and malfunction.
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Safety Precautions Operation / Adjustment Caution Never operate the equipment with wet hands or while standing in a wet location. location Failure to observe this instruction may cause electric shock. Keep fingers away from the AXIS (SAN) Unit radiating fin and tool motors while the equipment is turned ON or for a while after the equipment is turned OFF. These parts may become very hot. Failure to observe this instruction may cause burns. Use the equipment under the following conditions.
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Table of Contents Chapter 1: 1.1 1.2 1.3 Outline About this Manual......................................................................................... 1-2 Functions...............................…..……………………………………………… 1-3 Safety Precautions……….....…..………………………………………………. 1-4 Chapter 2: Specifications 2.1 Specifications.........................………………………………………………….. 2-2 2.2 Unit Dimensions……….................................…….…………………………… 2-3 Chapter 3: System Description 3.1 System Block Diagram..
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Table of Contents Chapter 5: Control Interfaces 5.1 Interface Board ……......…….………………………………………………….. 5-2 5.2 Interface Board DIP Switch Setup................…….…………………………… 5-2 5.3 Discrete I/O Interface….........………………………………………………….. 5-3 5.3.1 Sinking Type (NPN)…................………………………………………….. 5-3 5.3.1.1 Discrete Signal Connection (Sinking Type)………………………….. 5-4 5.3.2 Sourcing Type (PNP)..................………………………………………….. 5-5 5.3.2.1 Discrete Signal Connection (Sourcing Type).……………………….. 5-6 5.3.
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Table of Contents 5.11 Ethernet-I/P Interface…........………………………………………………….. 5-55 5.11.1 Component Descriptions...........………………………………………….. 5-56 5.11.2 User Console Software Settings. .……………………………………….. 5-57 5.11.3 Input Signals (Reference Layout).……………………………………….. 5-58 5.11.4 Output Signals (Reference Layout)..…………………………………….. 5-59 5.11.5 PLC Message Transfer Setup Example…..……………………………… 5-61 5.12 Profinet Interface……………………………………………………………….. 5-69 5.12.1 Component Descriptions………………………………………………….. 5-70 5.
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Blank Page xiv
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Chapter 1: Outline
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Chapter 1: Outline 1.1 AFC1500 Multi-2 Unit Hardware Manual (Rev. 2) About this Multi-2 Unit Manual This manual details the configuration, specifications and the operation of the AFC1500 Multi-2 Unit. The following table outlines the contents of each chapter. Title Chapter Contents 1 Outline Basic characteristics and requirements of the AFC1500 Multi-2 Unit. 2 Specifications General specifications of the AFC1500 Multi-2 Unit.
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AFC1500 Multi-2 Unit Hardware Manual (Rev. 2) Chapter 1: Outline 1.2 Functions The Multi-2 Unit is a complimentary controller device to enhance the AFC1500 SAN Unit capabilities by providing the communication and the sequence control features required by larger or more sophisticated multi spindle applications.
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Chapter 1: Outline AFC1500 Multi-2 Unit Hardware Manual (Rev. 2) 1.3 Safety Precautions To ensure the most effective and extended use of all equipment, adhere to the following precautions: Wiring • Use only the specified cables for all system connections. • Do not use a high voltage circuit as a frame ground (FG). Also, the frame ground should be separate from the power ground. The use of a grounding rod located as close as possible to the enclosure housing the AFC1500 Multi-2 Unit is preferable.
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Chapter 2: Specifications
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Chapter 2: Specifications AFC1500 Multi-2 Unit Hardware Manual (Rev.2) 2.1 Specifications Power Supply Voltage Power Consumption In rush current CPU Data Communication Control Interfaces 100 to 220 VAC±15%, 1-phase, 50/60 Hz.
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AFC1500 Multi-2 Unit Hardware Manual (Rev.2) Chapter 2: Specifications 2.2 Unit Dimensions Mounting: Top (1) place Bottom (2) places Weight: 1.4 kg #8-32 screw #8-32 screw Note: Unit Dimensions are the same whether a Multi 2 unit (as shown), or a Multi 2E (Ethernet) version.
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Chapter 2: Specifications AFC1500 Multi-2 Unit Hardware Manual (Rev.
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Chapter 3: System Description
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Chapter 3: System Description AFC1500 Multi-2 Unit Hardware Manual (Rev.2) 3.1 System Block Diagram The diagram below shows how the AFC1500 Multi-2 Unit can be connected to a single unit or combined in a multiple spindle configuration. The use of a Multi-2 Unit provides one set of PLC I/O for controlling multiple spindle fastening operations.
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AFC1500 Multi-2 Unit Hardware Manual (Rev.2) Chapter 3: System Description 3.2 Unit Description AFC MULTI – 2 Standard Version The standard version of the Multi-2 unit includes both an RS232 port (PC Port) and Ethernet port (Ethernet U/C Port) for communicating to a computer running the AFC User Console Software.
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Chapter 3: System Description AFC1500 Multi-2 Unit Hardware Manual (Rev.2) Multi-2 Unit Panel Description Power On LED Indicates when power is applied to the Multi-2 Unit. Busy LED Lights when the unit is performing a self check, return, fastening operation or is downloading/uploading data to the AFC User Console software package. Accept LED Lights if a fastening cycle or a self check test falls within acceptable parameters.
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Chapter 4: Installation & Wiring
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Chapter 4: Installation & Wiring AFC1500 Multi-2 Unit Hardware Manual (Rev. 2) 4.3 Input Power Connection An auto sensing power supply allows for input power in the range of 100 ~ 220VAC single phase, 50/60 hertz. Adequate circuit protection must be provided. Recommended conductor size should be a minimum of #18AWG. Wiring Chart Pin 4 3 2 1 4 3 2 1 Description 100 ~ 220VAC +/-15% 100 ~ 220VAC +/-15% No Connection ** Frame Ground Mating Connector Manufacture: Housing Part No.: Contact Part No.
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Chapter 4: Installation & Wiring AFC1500 Multi-2 Unit Hardware Manual (Rev. 2) 4.5 User Console Ethernet Connection The “User Console Ethernet” port is a dedicated TCP/IP ethernet port for communicating with the AFC User Console Software in a Windows® based PC. Similar to the serial RS232 (PC) port dedicated for the AFC Software connection, this port allows connection in an ethernet environment vs. using the standard serial port connection in previous versions of the Multi Unit.
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Chapter 4: Installation & Wiring AFC1500 Multi-2 Unit Hardware Manual (Rev. 2) 4.5.1 Optional Ethernet Port – Data Communication As an option, an additional ethernet port is available for sending fastening resultant data over an ethernet TCP/IP connection. This port can be configured using a standard web browser for communication to Atlas Copco Toolsnet networks, FEC NET or custom protocols. Additionally, once configured, the AFC User console software can also communicate over this port.
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AFC1500 Multi-2 Unit Hardware Manual (Rev. 2) Chapter 4: Installation & Wiring 4.6 Serial Communication Ports The Multi-2 Unit has three usable serial RS232C and one RS422 communication ports. All of the serial port settings and data format are fully configurable with the AFC User Console software. When the optional “E” ethernet version is used, the PC & DATA-OUT2 ports are removed.
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Chapter 4: Installation & Wiring 4.6.1 AFC1500 Multi-2 Unit Hardware Manual (Rev. 2) PC Port The “PC” port is for communicating with the AFC User Console Software PC. The connecting cable is a standard RS232 Null-Modem cable and can be purchased through FEC (Part #FEB-1301) or any cable supplier that carries standard 9-Pin Null Modem cables.
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AFC1500 Multi-2 Unit Hardware Manual (Rev. 2) 4.6.2 Chapter 4: Installation & Wiring DISPLAY Port “DISPLAY” port is currently not used in the US Market. RS-422 Pin Layout (Male) 1 2 3 4 5 6 7 8 9 4.6.3 TX+ TXRX+ RXGND Not Used Not Used Not Used Not Used Front View DATA-OUT (1) Port “DATA-OUT(1)” is an output port for ASCII fastening data communication to external devices. Information concerning available data and data format is shown in the following sections.
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Chapter 4: Installation & Wiring 4.6.3.1 AFC1500 Multi-2 Unit Hardware Manual (Rev. 2) Available Output Data (From DATA-OUT 1 Port) The Multi-2 Unit is capable of outputting the fastening results data in an ASCII format to a serial printer or other serial peripheral devices. The data is sent from the Multi-2 Unit’s RS232C “DATA OUT - 1” port. The output data string format as well as port configuration can be configured using the AFC User Console Software.
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AFC1500 Multi-2 Unit Hardware Manual (Rev. 2) Chapter 4: Installation & Wiring 4.6.3.2 Output Data Format (From DATA-OUT 1 Port) The example below shows the format of the DATA-OUT (1) port connected to a printer. Actual data output format may vary depending on the configuration and set-up of this port using the AFC User Console Software. The data field is selectable from as little as one output field to all available data (see previous table for available data fields).
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Chapter 4: Installation & Wiring 4.6.4 AFC1500 Multi-2 Unit Hardware Manual (Rev. 2) DATA-OUT 2 Port “DATA-OUT2” port is currently not used. RS-232 Pin Layout (Male) 1 2 3 4 5 6 7 8 9 DCD RXD TXD DTR GND DSR RTS CTS Not Used Front View Note: This port is removed when using the Ethernet Version (Optional Unit 4.6.5 E Version) Multi DATA-IN Port The “DATA-IN” port is for inputting ASCII data to the fastening system for marriage to the fastening data.
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Chapter 4: Installation & Wiring AFC1500 Multi-2 Unit Hardware Manual (Rev. 2) 4.7 PLC Input/Output (I/O) Interface The Multi-2 Unit is able to operate under different Input/Output control structures through use of a modular I/O interface board installed in the unit. Besides standard discrete “hardwired” interface signals, the introduction of “Open” architecture communication networks known as “Fieldbus” made it necessary for the direct interfacing to these networks.
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Chapter 4: Installation & Wiring AFC1500 Multi-2 Unit Hardware Manual (Rev. 2) 4.7.2 Input Signals The list below contains a description of the Input signals available on the I/O interface. Further input mapping can be found in the individual interface information (See Chapter 5). Signal Contact Emergency Stop N.C. Reset N.O. Reverse N.O. Start N.O. Sequence Select Sequence Select Sequence Select Sequence Select 0 1 2 3 N.O. N.O. N.O. N.O. Cycle Count Up N.O. Cycle Count Clear N.O.
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Chapter 4: Installation & Wiring AFC1500 Multi-2 Unit Hardware Manual (Rev. 2) (Continued) [Table 1 – Sequence Selection] Sequence Select 3 Sequence Select 2 Sequence Select 1 Sequence Select 0 Selected Sequence No. OFF OFF OFF OFF OFF OFF OFF OFF ON ON ON ON ON ON ON ON OFF OFF OFF OFF ON ON ON ON OFF OFF OFF OFF ON ON ON ON OFF OFF ON ON OFF OFF ON ON OFF OFF ON ON OFF OFF ON ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 4.7.
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Chapter 4: Installation & Wiring Out Port 1 Out Port 2 Out Port 3 Out Port 4 Out Port 5 Out Port 6 Out Port 7 Out Port 8 AFC1500 Multi-2 Unit Hardware Manual (Rev. 2) These signals will output when the fastening sequence reaches a step that has a [PLC OUTPUT] instruction inserted. Used to provide sequence operation status to external PLC’s and/or control outputs for slide motion, lights, & buzzers, etc without the use of a PLC.
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AFC1500 Multi-2 Unit Hardware Manual (Rev. 2) Chapter 4: Installation & Wiring (Output Signals – Continued) In addition to the main Multi unit output signals, individual spindles that are connected to the Multi unit report status signals to the Multi Unit. These signals are available on a “per spindle” basis and can be used or programmed using the AFC User Console software.
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Chapter 4: Installation & Wiring AFC1500 Multi-2 Unit Hardware Manual (Rev. 2) 4.7.
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Chapter 4: Installation & Wiring AFC1500 Multi-2 Unit Hardware Manual (Rev. 2) 4.7.5 External DIP Switch FRONT (Located on bottom of unit) DIP SWITCH (Factory Setting) No. 4 3 2 1 OFF Not Used Not Used ON Angle resolution: 0.1 Angle resolution: 1 EXT. I/O ENABLE EXT. I/O DISABLE Switch 1: I/O Enable / Disable Test Mode If Switch No.
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Chapter 4: Installation & Wiring AFC1500 Multi-2 Unit Hardware Manual (Rev.
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Chapter 5: Control Interfaces
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Chapter 5: Control Interfaces 5.1 AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) I/O Interface Board The Multi-2 unit interface board provides the interface between real world control signals and the AFC1500 Fastening system I/O. Since there are many different I/O control structures in the industry today, the Multi-2 unit has the ability to adapt to these through use of the I/O interface board.
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AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) 5.3 Chapter 5: Control Interfaces Discrete I/O Interface The Discrete I/O Interface is commonly used for hardwire direct connect PLC applications. Two types of Discrete I/O interfaces are available: 24VDC Sinking Type and 24VDC Sourcing Type. The standard discrete I/O interface is the Sinking Type interface. 5.3.1 Sinking Type (NPN) The Sinking Type I/O interface is standard with discrete I/O Multi Units. It connects to 24VDC True Low type (NPN) PLC cards.
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Chapter 5: Control Interfaces 5.3.1.1 AFC1500 Multi-2 Unit Hardware Manual (Rev2.
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AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) 5.3.2 Chapter 5: Control Interfaces Sourcing Type (PNP) The Sourcing Type I/O interface is optional with discrete I/O Multi Units. It connects to 24VDC True High type (PNP) PLC cards.
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Chapter 5: Control Interfaces 5.3.2.1 AFC1500 Multi-2 Unit Hardware Manual (Rev2.
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AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) 5.3.3 Chapter 5: Control Interfaces Input Signals (PLC-IN) Connector The Input Signals are provided on the PLC IN connector. Inputs are assigned in the order as shown in the table below and cannot be changed. Pins designated as “Not Used” have no input assigned to them. NOTE: When using Discrete I/O, “Bypass Spindle” input signals assigned to the PLC IN connector can only be used for up to 10 individual Spindles (from the Multi-2 Unit).
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Chapter 5: Control Interfaces 5.3.4 AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) Ouput Signals (PLC-OUT) Connector The Multi-2 Unit is capable of providing over 570 Output signals to indicate the status of the Multi-2 Unit and of all the AFC1500 SAN Controllers connected to it (up to 31 controllers). These signals are user configurable using the AFC User Console Software and may be programmed on any designated pin.
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AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) 5.3.4.1 Chapter 5: Control Interfaces Ouput Data Banks When working with the Discrete I/O interface, the output signals are programmed into “Banks” of 32 output signals in up to 8 output “Banks” (Max. 256 outputs). If the required output signals from the Multi-2 Unit exceed 32 signals, then Bank 2 can be programmed with additional signals. If over 64 signals are required, Bank 3 can be programmed and so on.
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Chapter 5: Control Interfaces 5.3.5 AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) Standard I/O Cable – Wire Color Code The table below shows the color code of the standard FEC Discrete I/O cable used for I/O connectors PLC IN and PLC OUT. (FEC Cable Assemblies #FEB -1271 (PLC IN Cable), #FEB-1272 (PLC OUT Cable)) Pin No.
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Chapter 5: Control Interfaces AFC1500 Multi-2 2 Unit Hardware Manual (Rev2.1) Interbus S® Interface 5.4 InterBus S from Phoenix Contact is a an open-ring based, distributed device I/O network. I/O data is transmitted in frames that provide simultaneous and predictable updates to all devices in the network. This interface board (S - version) has up to 512 bytes of assigned input data and 512 bytes of assigned output data* (64bytes default).
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Chapter 5: Control Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) InterBus Specifications Baud Rate Nodes Distance Cable Packet Size Communication Type 500K or 2M bits/sec.
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Chapter 5: Control Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) 5.4.1 Component Descriptions Fieldbus Interface Connectors Bus IN 6 1 9 5 (9 pin male D-sub) Bus OUT 9 5 6 1 (9 pin female D-sub) Pin No. Housing 1 2 3 4 5 6 7 8 9 Pin No.
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Chapter 5: Control Interfaces 5.4.2 AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) AFC User Console Software Settings The Anybus board is set up by sending a Fieldbus Configuration File (*.fcf) containing initialization messages from the Multi-2 Unit to the board during power up. This string of data initializes different characteristics required for the board to communicate over the Interbus S network. In this string are messages which set the length of I/O data as well as other messages.
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Chapter 5: Control Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) 5.4.3 Input Signals Mapping (CH1 ~ CH16) Inputs are assigned in the order as shown in the table below and cannot be changed. Bits designated as “Unused” have no input assigned to them. NOTE: If Interbus S TOOLSNET version is used – Input/Output Signal layout is different than shown. See 5.12 for TOOLSNET I/O Layout CH. No. Input CH. No.01 CH. No. Input CH. No.
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Chapter 5: Control Interfaces 5.4.4 AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) Ouput Signals (CH1 ~ CH16) The Multi-2 Unit is capable of providing over 570 Output signals to indicate the status of the Multi-2 Unit and of all the AFC1500 SAN Controllers connected to it (up to 31 controllers). CH. No. Output CH. No.01 Output CH. No.02 Output CH. No.
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Chapter 5: Control Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) 5.5 DeviceNet® Interface The DeviceNet communication interface allows slave connection to an industrial DeviceNet network. DeviceNet allows industrial devices to be controlled over an open network architecture enabling device connection at various locations in the field. This “fieldbus” technology reduces hard wiring/cabling & provides ease of installation.
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Chapter 5: Control Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2.
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Chapter 5: Control Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) 5.5.1 Component Descriptions Fieldbus Interface Connections Pin No. 1 2 3 4 5 Signal VCAN_L Drain/Shield CAN_H V+ Wire Color Black Blue See “Termination” White Red Termination Termination of the fieldbus requires a terminating resistor at each end of the fieldbus. These resistors should have a value of 121 ohms. Configuration Switches On a DeviceNet network, each node must be assigned its own unique Mac ID.
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Chapter 5: Control Interfaces 5.5.2 AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) User Console Software Settings The Anybus board is set up by sending a Fieldbus Configuration File (*.fcf) containing initialization messages from the Multi-2 Unit to the board during power up. This string of data initializes different characteristics required for the board to communicate over the DeviceNet network. In this string are messages which set the length of I/O data as well as other messages.
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Chapter 5: Control Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) 5.5.3 Input Signals (CH1 ~ CH16) Inputs are assigned in the order as shown in the table below and cannot be changed. Bits designated as “Not Used” have no input assigned to them. Operation Note: The first 16 bits of I/O are used by DeviceNet communication. The first input must be set “ON” to enable communication. NOTE: If Devicenet TOOLSNET version is used – Input/Output Signal layout is different than shown. See 5.
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Chapter 5: Control Interfaces 5.5.4 AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) Ouput Signals (CH1 ~ CH16) The Multi-2 Unit is capable of providing over 570 Output signals to indicate the status of the Multi-2 Unit and of all the AFC1500 SAN Controllers connected to it (up to 31 controllers). CH. No. Output CH. No.01 Output CH. No.02 Output CH. No.
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Chapter 5: Control Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) 5.6 Profibus® Interface The Profibus-DP communication interface allows slave connection to an industrial Profibus network. Profibus-DP allows industrial devices to be controlled over an open network architecture enabling device connection at various locations in the field. This “Fieldbus” technology reduces hardwiring/cabling & provides ease of installation.
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Chapter 5: Control Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) Profibus Specifications Speed Nodes Distance Cable Communications Type Protocol Version Maximum Cyclic I/O Size Data transmission 9.6K - 12M baud - auto selected 126 Note: Node 126 is reserved for commissioning purposes only 200m max. at 1.5Mbit/s extendable with repeaters. Shielded Copper Twisted Pair or fiber optic Master/Slave - EIA RS485 Ver. 1.10 244bytes In, 244 bytes out max. 416 total bytes max.
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Chapter 5: Control Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) 5.6.1 Component Descriptions Fieldbus Interface Connection 9 5 6 1 (9 pin female D-sub) Pin No. 1 2 3 4 5 6 7 8 9 Housing Signal N.C. N.C. B- Line RTS GND Bus +5V Bus N.C. A- Line N.C. Shield Description Positive RxD/TxD according to RS485 Spec. Request to send Isolated GND from RS 485 side Isolated +5V from RS 485 side Negative RxD/TxD according to RS485 Spec.
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Chapter 5: Control Interfaces 5.6.2 AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) User Console Software Settings The Anybus board is set up by sending a Fieldbus Configuration File (*.fcf) containing initialization messages from the Multi-2 Unit to the board during power up. This string of data initializes different characteristics required for the board to communicate over the Profibus network. In this string are messages which set the length of I/O data as well as other messages.
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Chapter 5: Control Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) 5.6.3 Input Signals (Word 01 ~ Word 16) Inputs are assigned in the order as shown in the table below and cannot be changed. Bits designated as “Unused” have no input assigned to them. NOTE: If Profibus TOOLSNET version is used – Input/Output Signal layout is different than shown. See 5.12 for TOOLSNET I/O Layout CH. No. Input Word No.01 CH. No. Input Word No.
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Chapter 5: Control Interfaces 5.6.4 AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) Ouput Signals (Word 01 ~ Word 16) The Multi-2 Unit is capable of providing over 570 Output signals to indicate the status of the Multi-2 Unit and of all the AFC1500 SAN Controllers connected to it (up to 31 controllers). See Section 4.7.3 for available output signals. Word No. Output Word No.01 Output Word No.02 Output Word No.
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Chapter 5: Control Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) 5.7 Modbus Plus® Interface Modbus Plus is a local area network system designed for industrial control and monitoring applications developed by Modicon Inc. The network enables programmable controllers, host computers and other devices to communicate throughout the plant. Modbus Plus is normally used in industrial automation to transfer fast data (up to 1Mbit/sec.
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Chapter 5: Control Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) Modbus Plus Specifications Baud Rate Max. Nodes Max. Distance Max. Bus Cable Length Cable Communication Type 1M bits/sec.
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Chapter 5: Control Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) 5.7.1 Component Descriptions Fieldbus Interface Connector 9 5 6 1 (9 pin female D-sub) Pin No.
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Chapter 5: Control Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) Status LEDs LED 1 2 ERROR 4 1 3 2 3 MBP Active 4 MBP Init Status Description - Not Used Red Communication is not OK. Green flashing every 160ms; on 80ms; off 80ms Green flashing at 1 second intervals Green - 2 flashes, on 160ms then off 480ms. Green - 3 flashes, on 160ms, off 240ms then off 1.6sec. Green - 4 flashes, on 160ms, off 240ms then off 1.2sec. Green Node working normal, receiving and passing token.
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AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) 5.7.2 Chapter 5: Control Interfaces User Console Software Settings The Anybus board is set up by sending a Fieldbus Configuration File (*.fcf) containing initialization messages from the Multi-2 Unit to the board during power up. This string of data initializes different characteristics required for the board to communicate over the Modbus Plus network. In this string are messages which set the length of I/O data as well as other messages.
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Chapter 5: Control Interfaces 5.7.3 AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) Input Signals (Word 01 ~ Word 16) Inputs are assigned in the order as shown in the table below and cannot be changed. Bits designated as “Unused” have no input assigned to them. Since Modbus Plus sends I/O signals 8 bits at a time, and trying to use the data as a word, all bits and bytes are transferred backwards. Word No. Input Word No.01 Word No. Input Word No.
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Chapter 5: Control Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) 5.7.4 Ouput Signals (Word 01 ~ Word 16) The Multi-2 Unit is capable of providing over 570 Output signals to indicate the status of the Multi-2 Unit and of all the AFC1500 SAN Controllers connected to it (up to 31 controllers). See Section 4.7.3 for available output signals. Since Modbus Plus sends I/O signals 8 bits at a time, and trying to use the data as a word, all bits and bytes are transferred backwards. Word No.
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Chapter 5: Control Interfaces 5.8 AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) CC-Link® Interface (Version 1) The Mitsubishi CC-Link communication interface allows slave connection to an industrial Mitsubishi CCLink network. FEC has a partner license with Mitsubishi for the AFC1500 system for connection on the CC-Link network. Mitsubishi CC-Link allows industrial devices to be controlled over an open network architecture enabling device connection at various locations in the field.
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AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) Chapter 5: Control Interfaces CC-Link Specifications Speed Stations Distance Cable Communications Type Transmission Format Maximum Cyclic I/O Size I/O Configuration* 156K - 10M baud - selectable 64 Max. 1200m max. at 156K baud / 50m max. at 10Mbit/s Shielded Copper Twisted Pair Mitsubishi BA1SJ61-(m) m=Meters Belden 8102 or equivalent Master/Slave - EIA RS485 HDLC Standard 128 inputs, 128 outputs max.
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Chapter 5: Control Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) 5.8.1 Component Descriptions Fieldbus Interface Connection Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 DA DB DG SHIELD FG See “Termination” Communication Line Communication Line Digital Ground Connect cable shield Field Ground Mating Connector: Allows in-line “series” connection Manufacturer Model Name ：Phoenix Contact ：TMSTBP 2.5/5-ST-5.08 *Connector is attached.
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Chapter 5: Control Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) Number of Occupied Stations (SW3) Occupied Stations setting determines the number of 32 bit station buffer memory locations that will be allocated for this station in the Master buffer memory. This sets the number of total I/O available for the station. Each memory bit has a designated input AND output buffer. So a setting of (1) 32 station actually allocates 32 input & 32 output locations for a total of 64 total points.
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Chapter 5: Control Interfaces 5.8.2 AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) Input Signals Inputs are assigned in the order as shown in the table below and cannot be changed. Bits designated as “Unused” have no input assigned to them.
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Chapter 5: Control Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) 5.8.4 Output Signals The Multi-2 Unit is capable of providing over 570 Output signals to indicate the status of the Multi-2 Unit and of all the AFC1500 SAN Controllers connected to it (up to 31 controllers). See Section 4.7.3 for available output signals.
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Chapter 5: Control Interfaces 5.9 AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) CC-Link® Interface (Version 2) FEC integrates the CC-Link board (Version 2 setting) manufactured by HMS Fieldbus Systems AB into the Multi-2 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.
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AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) Chapter 5: Control Interfaces CC-Link Specifications Speed Stations Distance Cable Communications Type Transmission Format Maximum Cyclic I/O Size I/O Configuration* 156K - 10M baud - selectable 64 Max. 1200m max. at 156K baud / 50m max. at 10Mbit/s Shielded Copper Twisted Pair Mitsubishi BA1SJ61-(m) m=Meters Belden 8102 or equivalent Master/Slave - EIA RS485 HDLC Standard 896 inputs, 896 outputs max.
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Chapter 5: Control Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) 5.9.1 Component Descriptions Fieldbus Interface Connection Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 DA DB DG SHIELD FG Communication Line Communication Line Digital Ground Connect cable shield Field Ground See “Termination” Mating Connector: Allows in-line “series” connection Manufacturer Model Name ：Phoenix Contact ：TMSTBP 2.5/5-ST-5.08 *Connector is attached.
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AFC1500 Multi-2 Unit Hardware Manual (Rev2.
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Chapter 5: Control Interfaces 5.9.2 AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) User Console Software Settings The Anybus board is set up by sending a Fieldbus Configuration File (*.fcf) containing initialization messages from the Multi-2 Unit to the board during power up. This string of data initializes different characteristics required for the board to communicate over the CC-Link network. In this string are messages which set the length of I/O data as well as other messages.
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Chapter 5: Control Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) 5.9.3 Input Signals Inputs are assigned in the order as shown in the table below and cannot be changed. Bits designated as “Unused” have no input assigned to them.
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Chapter 5: Control Interfaces 5.9.4 AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) Ouput Signals The Multi-2 Unit is capable of providing over 570 Output signals to indicate the status of the Multi-2 Unit and of all the AFC1500 SAN Controllers connected to it (up to 31 controllers). See Section 4.7.3 for available output signals.
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Chapter 5: Control Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) 5.10 Allen-Bradley Remote I/O Interface 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.
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Chapter 5: Control Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) AB Remote I/O Specifications Speed Rack Addresses Nodes Rack Configuration supported* Distance Cable Communications Type 57.6, 115, 230K baud - Selectable 0-59 up to 240 1/4 racks 1/4, 1/2 (Default), 3/4, Full 57.6k - 3048 meter 115K - 1524 meter 230K - 762 meter 78 ohm Twinax Belden #9463 or equivalent Master/Slave *Rack Config. set by AFC User Console software. Contact FEC for other setting.
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Chapter 5: Control Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) 5.10.1 Component Descriptions Fieldbus Interface Connection Pin No. 1 2 3 Color Blue Clear Shield Description COM Line Ground COM Line Termination Termination of the RIO network requires a terminating resistor at each end of the network. A termination switch is provided on the front of the interface board. Set the switch to “ON”, if termination is required.
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Chapter 5: Control Interfaces 5.10.2 AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) User Console Software Settings The Anybus board is set up by sending a Fieldbus Configuration File (*.fcf) containing initialization messages from the Multi-2 Unit to the board during power up. This string of data initializes different characteristics required for the board to communicate over the Allen-Bradley Remote I/O network. In this string are messages which set the length of I/O data as well as other messages.
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Chapter 5: Control Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) 5.10.3 Input Signals (CH1 ~ CH16) Inputs are assigned in the order as shown in the table below and cannot be changed. Bits designated as “Not Used” have no input assigned to them. CH. No. Input CH. No.01 CH. No. Input CH. No.
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Chapter 5: Control Interfaces 5.10.4 AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) Ouput Signals (CH1 ~ CH16) The Multi-2 Unit is capable of providing over 570 Output signals to indicate the status of the Multi-2 Unit and of all the AFC1500 SAN Controllers connected to it (up to 31 controllers). See Section 4.7.3 for available output signals. CH. No. Output CH. No.01 Output CH. No.02 Output CH. No.
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Chapter 5: Control Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) 5.11 Ethernet-I/P Interface 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 & 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.
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Chapter 5: Control Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) 5.11.1 Component Descriptions Fieldbus Interface Connections Pin Signal Note 1 TD+ 2 TD3 RD+ 4 Normally left unused; to ensure signal integrity, these pins are tied together and terminated to PE via a filter circuitt in the module. 5 6 RD7 Normally left unused; to ensure signal integrity, these pins are tied together and terminated to PE via a filter circuit in the module.
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AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) 5.11.2 Chapter 5: Control Interfaces User Console Software Settings The Anybus board is set up by sending a Fieldbus Configuration File (*.fcf) containing initialization messages from the Multi-2 Unit to the board during power up. This string of data initializes different characteristics required for the board to communicate over the Ethernet-I/P network.
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Chapter 5: Control Interfaces 5.11.3 AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) Input Signals (CH1 ~ CH16) Inputs are assigned in the order as shown in the table below and cannot be changed. Bits designated as “Unused” have no input assigned to them. CH. No. Input CH. No.01 CH. No. Input CH. No.
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Chapter 5: Control Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) 5.11.4 Ouput Signals (CH1 ~ CH16) The Multi-2 Unit is capable of providing over 570 Output signals to indicate the status of the Multi-2 Unit and of all the AFC1500 SAN Controllers connected to it (up to 31 controllers). See Section 4.7.3 for available output signals. CH. No. Output CH. No.01 Output CH. No.02 Output CH. No.
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Chapter 5: Control Interfaces 5.11.5 AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) PLC Message Transfer Setup Example This example procedure is written using Rockwell Automation RXLogix5000 V15.02.00 and AllenBradley Compact Logix L32E. Please contact your PLC manufacturer for specific setup and configuration information. Note: Allen-Bradley Control Logix configures up to 400 bytes per block with a maximum of 5 blocks of data for a total of 2000 bytes. Configuration 1.
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AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) Chapter 5: Control Interfaces Specify the “Name” (FEC AFC1500), “IP address”, and “Connection Parameters” that match the parameters set to the Multi2 unit using the AFC software. Click on the “Connection” tab and set connection setup as below.
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Chapter 5: Control Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) When the MULTI-2 unit is added to the I/O configuration, the data table will be added to the controller tags automatically. AFC1500_2:I Input signals from MULTI-2 unit. (MULTI-2 -> PLC) AFC1500_2:O Output signals to MULTI-2 unit (PLC -> MULTI-2) AFC1500_2:C Message communication data from the MULTI-2 unit (MULTI-2 -> PLC for fastening result data). An additional program/command needs to be added for retrieving the data. 2.
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AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) Chapter 5: Control Interfaces Select the DATA TYPE format (BCD or ASCII). Data from the Multi-2 and Axis (Spindle) must be configured in the table below each tab. The MULTI FORMAT contains the “Header” data (such as Date, Time, Sequence #, Cycle Count, etc. – aka data that comes from the Multi-2 Unit) The AXIS FORMAT contains the actual spindle fastening data (such as Torque, Angle, Time, Rate, etc.
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Chapter 5: Control Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) After the fastening result data has been selected, download the configuration to the MULTI-2 controller. The setup for this configuration is part of the “PLC SIGNAL OUTPUT FORMAT”. PLC Program Read_Tag needs be added to the “Controller Tags” for message transfer This data tag contains the configuration of the message transfer. Each MSG command needs to have its own Read_ tag.
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Chapter 5: Control Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) Property of the MSG command is shown below. (Right Click in MSG command) Message Type Service Type Service Code Class Instance Attribute Destination CIP Generic Get Attribute Single E B0 1 1~5 The controller tag “C” should be selected Note: Each message command can only handle 400 bytes.
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Chapter 5: Control Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) At the communication tab screen, select “Path”. The MULTI-2 controller can be browsed as shown below.
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AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) Chapter 5: Control Interfaces An example of a message transfer program is shown below. This program transfers up to 800 bytes of fastening result data. The first MSG command has “1” as attribute and is sending the data into AFC1500:C memory block. The second MSG command has “2” as attribute and sending the data into another data memory block that would have been manually added when the second Read_tag was added.
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Chapter 5: Control Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2.
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Chapter 5: Control Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) 5.12 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 & 512 output bits. FEC Inputs match the discrete input layout. FEC Output location is programmed using the AFC User Console Software.
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Chapter 5: Control Interfaces 5.12.1 AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) Component Descriptions Fieldbus Interface Connections Pin Signal Note 1 TD+ 2 TD3 RD+ 4 Normally left unused; to ensure signal integrity, these pins are tied together and terminated to PE via a filter circuit in the module. 5 6 RD7 Normally left unused; to ensure signal integrity, these pins are tied together and terminated to PE via a filter circuit in the module.
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AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) 5.12.2 Chapter 5: Control Interfaces User Console Software Settings The Anybus board is set up by sending a Fieldbus Configuration File (*.fcf) containing initialization messages from the Multi-2 Unit to the board during power up. This string of data initializes different characteristics required for the board to communicate over the Ethernet-I/P network.
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Chapter 5: Control Interfaces 5.12.3 AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) Input Signals (CH1 ~ CH16) Inputs are assigned in the order as shown in the table below and cannot be changed. Bits designated as “Unused” have no input assigned to them. CH. No. Input CH. No.01 CH. No. Input CH. No.
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Chapter 5: Control Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) 5.12.4 Ouput Signals (CH1 ~ CH16) The Multi-2 Unit is capable of providing over 570 Output signals to indicate the status of the Multi-2 Unit and of all the AFC1500 SAN Controllers connected to it (up to 31 controllers). See Section 4.7.3 for available output signals. CH. No. Output CH. No.01 Output CH. No.02 Output CH. No.
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Chapter 5: Control Interfaces 5.13 AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) Input / Output Signal Layout using Toolsnet Version InterBus-S, Devicenet & Profibus interfaces can be configured to be connected to the Atlas Copco Toolsnet Network. If this setting is selected, the I/O signal mapping changes according to the tables below. (If the Toolsnet version is selected during the interface board set-up (5.1), this I/O mapping will be automatically set) 5.13.
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Chapter 5: Control Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) Input Signals Byte No. Byte 0 Byte 1 Byte No. Byte 4 Byte 5 Byte No.
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Chapter 5: Control Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) Input Signals (Toolsnet Version - Continued) Byte No. Byte 12 Byte 13 Byte No. Byte 16 Byte 17 Byte No. Byte 20 Byte 21 Bit Signal Byte No.
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Chapter 5: Control Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) Input Signals (Toolsnet Version - Continued) Byte No. Byte 24 Byte 25 Byte No. Byte 28 Byte 29 Bit Signal Byte No.
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Chapter 5: Control Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) Output Signals (Toolsnet Version) Byte No. Byte 0 Byte 1 Byte No. Byte 4 Byte 5 Bit 0bit 1bit 2bit 3bit 4bit 5bit 6bit 7bit 8bit 9bit 10bit 11bit 12bit 13bit 14bit 15bit Bit 32bit 33bit 34bit 35bit 36bit 37bit 38bit 39bit 40bit 41bit 42bit 43bit 44bit 45bit 46bit 47bit Signal Byte No.
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Chapter 5: Control Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) Output Signals (Toolsnet Version-Continued) Byte No. Byte 8 Byte 9 Byte No. Byte 12 Byte 13 Byte No. Byte 16 Byte 17 Bit Signal Byte No. 64bit 65bit 66bit 67bit 68bit 69bit 70bit 71bit 72bit 73bit 74bit 75bit 76bit 77bit 78bit 79bit Spdl.1 Torque (Item 1 Data) Integer Value Upper Byte Spdl.
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Chapter 5: Control Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) Output Signals (Toolsnet Version-Continued) Byte No. Byte 20 Byte 22 Byte No. Byte 24 Byte 25 Bit Signal Byte No. 160bit 161bit 162bit 163bit 164bit 165bit 166bit 167bit 168bit 169bit 170bit 171bit 172bit 173bit 174bit 175bit Spdl.2 Angle (Item 4 Data) Integer Value Upper Byte Bit Signal 192bit 193bit 194bit 195bit 196bit 197bit 198bit 199bit 200bit 201bit 202bit 203bit 204bit 205bit 206bit 207bit Spdl.
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Chapter 5: Control Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) Output Signals (Toolsnet Version-Continued) VIN Number data from Input signal will be output as echo. Byte No. Byte 104 Byte 105 Byte No. Byte 108 Byte 109 Byte No. Byte 112 Byte 113 Bit Signal Byte No.
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Chapter 5: Control Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) Output Signals (Toolsnet Version-Continued) VIN Number data from Input signal will be output as echo. Byte No. Byte 116 Byte 117 Byte No. Byte 120 Byte 121 Byte No. Byte 124 Byte 125 Bit Signal Byte No.
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Chapter 5: Control Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2.1) Output Signals (Toolsnet Version-Continued) Example output: Torque value 260.5 Nm Byte No. Byte 8 Byte 8/9 value left of decimal Byte 9 Bit Signal 64bit 65bit 66bit 67bit 68bit 69bit 70bit 71bit 72bit 73bit 74bit 75bit 76bit 77bit 78bit 79bit Off Off Off Off Off Off Off On Off Off Off Off Off On Off Off Byte No.
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Chapter 6: Troubleshooting
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Chapter 6: Troubleshooting 6.1 AFC1500 Multi-2 Unit Hardware Manual (Rev. 2) Abnormals The Multi-2 Unit is capable of giving unit fault status to the AFC 1500 User Console in the form of a code number. This number can be read and displayed by the User Console software.