MICRO E-HS-2.1 ELECTRIC SERVO MICRO NUTRUNNER OPERATION INSTRUCTION MANUAL FEC MICRO NR 2nd Edition Rev.
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) 580-2622, faxed to (586) 580-2620 or emailed to support@fec-usa.com.
Revision History Revision date Manual No. 2009/06/10 First Edition 2012/02 2012/12 Content of revision Original manual release Second Edition Revised per latest Japanese translations Added selection for X-Y curve in SD Memory 2.
Introduction Thank you for purchasing our Electric Micro Nutrunner 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”.
Introduction Warranty Warranty Period The standard warranty period is one year from the date of purchase or one year from delivery to the designated End User (not to exceed 18 Months). Actual terms are order specific. Provision of warranty If your product proves to be defective, although it has been used properly in accordance with this instruction manual, during the period of warranty, this product will be repaired free of charge.
Safety Precautions Read 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]. 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.
Safety Precautions Warning 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.
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: 50% RH or lower (Avoid moisture) ◆Package: Tight seal ◆Rust prevention measure: Keep dry and ship with humidity control devices (desiccant).
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 controller Unit firmly inside the control panel using the specified screws. Failure to observe this instruction may cause malfunction. Use the specified tool for the controller Unit. Failure to observe this instruction may cause fire and malfunction.
Safety Precautions Operation / Adjustment Caution Never operate the equipment with wet hands. Failure to observe this instruction may cause electric shock. Use the equipment under the following conditions.
Table of Contents Page 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 SAN Unit Specifications 2.4 Capability. 2.4.1 Nutrunner Tool Specification Table Chapter 3: System Description 3.1 System Block Diagram 3.1.1 System Block Diagram Description 3.2 Micro-NR MNR UNIT Front panel 3.2.1 MNR Front Panel Switches and Connectors 3.2.2 MNR Status LED 3.
Chapter 5: Power Up and Initial Checks 5.1 Before Powering On 5.2 Initial Data Setting Chapter 6: Fastening Instructions 6.1 Fastening Control 6.1.1 Torque / Angle Method – Target Torque Control 6.1.2 Torque / Angle Method – Target Angle Control 6.2 Speed Functions 6.3 Reverse Functions 6.4 Special Functions 6.4.1 One Pulse Reverse Function 6.4.2 Rundown Revolution Limits 6.4.3 Torque Inhibit Function Chapter 7: System Operations 7.1 MNR Display and Programming operation. 7.1.
Chapter 9: Troubleshooting 9-1 9.1 Abnormal Conditions. 9.2 Torque Transducer Origin Error, Cal Check Error. 9.2.1 Code 1-0 Torque transducer / Zero Voltage error. 9.2.2 Code 1-1 Torque transducer / Cal Voltage error. 9.2.3 Code 1-2 Torque transducer / Zero check error. 9.2.4 Code 1-3 Torque transducer / Cal self-check error. 9.2.5 Code 1-4 Torque transducer / Started on Zero condition error. 9.2.6 Code 1-5 Torque transducer / Started on Cal condition error 9.2.
FEC Micro Nutrunner Operations Manual Chapter 1: Outline (Rev.
Chapter 1: Outline 1.1 About This operations manual This manual details the configuration, components, specifications, and the operation of the MNR8 Micro Nutrunner Fastening System. The following table outlines the contents of each chapter: Chapter Item Contents Chapter 1 Outline Basic characteristics and requirements of the MICRO NUTRUNNER System. Chapter 2 Specifications General specifications of the MICRO NUTRUNNER System.
FEC Micro Nutrunner Operations Manual Chapter 1: Outline (Rev. 2: 02/12) 1.2 Features { The MICRO NR Fastening System is a culmination of over thirty years of electric fastening expertise integrated with the latest miniature electronic technology. For small screw applications (M2 – M3), the MICRO NR provides a highly accurate, transducerized fastening system with fully programmable set-up. The system is designed with modular construction in mind keeping maintenance and spare parts to a minimum.
Chapter 1: Outline 1.3 Functions { Fastening function. The following fastening control methods can be selected for either clockwise (CW) or counterclockwise (CCW) operation: P Torque / Angle Control The fastening control method of the system is a combination of both Torque Control and Angle Control. Setting both a torque target torque and an angle target torque allows the system to target whichever setting would be reached first.
FEC Micro Nutrunner Operations Manual 1.4 Chapter 1: Outline (Rev. 2: 02/12) System requirements To ensure the most effective and extended use of all equipment, adhere to the following specifications: { Tool Installation Tools must be installed in the proper positions and with adequate bolts. Use the supplied bolts to prevent the tool from loosening due to vibration.
Chapter 1: Outline { Static Electricity MICRO NR System construction incorporates many 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. { Cleaning Do not use any organic solvents, such as thinner, to clean an MNR unit or a tool. The solvent could melt the surface paint, or penetrate inside and cause damage.
FEC Micro Nutrunner Operations Manual Chapter 2: Specifications (Rev.
Chapter 2: Specifications 2.1 Main Specifications { Power Supply Voltage P 100~240 VAC, Single Phase, 50/60 Hz (24VDC Output) { Operating Power Requirements P 180Watt { Installation Requirement P NEMA 12 enclosure (minimum). { Range of Operation P Duty cycle below 60% (reference Section 2.
FEC Micro Nutrunner Operations Manual 2.3 Chapter 2: Specifications (Rev. 2: 02/12) MNR Unit Specifications UNIT TYPE UAN-8 TOOL MOTOR TYPE MFT-080M10 TOOL MAX. TORQUE 0.8 Nm (7.08 in lb)) TOOL MAX. SPEED 1100RPM OVERALL TOOL WEIGHT 605gram MNR INPUT POWER SUPPLY 100 – 240VAC Single Phase 150watt max.
Chapter 2: Specifications 2.4.1 Micro Tool Specification Table TOOL TYPE MFT-080M10 SERVO TYPE MNR-8 NM FULL SCALE TORQUE KGM KGCM FTLB INLB SPEED RPM MAX MIN 0.8 0.08 7.08 1100 8.0 .59 1 CONVERSION GUIDE: 1 KGM = 100 KGCM = 9.8 NM = 7.2 FTLB = 86.7 INLB Tool Assembly Model Number Breakdown Example: MFT-080M10 MFT: MICRO NR Series Tool 080: .
FEC Micro Nutrunner Operations Manual Chapter 3: System Description (Rev 2: 02/12) Chapter 3: System Description Page 3-1
Chapter 3: System Description 3.1 System Block Diagram 3.1.1 System Block Diagram Description { Spindle programming / monitoring is accomplished through either a detachable Laptop PC or an embedded HMI PC, running the MNR User Console software package. { A keypad/display on each MNR Unit can be used to monitor the individual spindle status. { Discrete 24 VDC (Sinking or Sourcing) I/O on the MNR unit provides direct communications with the PLC for limited individual spindle control.
FEC Micro Nutrunner Operations Manual 3.2 Chapter 3: System Description (Rev 2: 02/12) MNR UNIT Front panel 3.2.
Chapter 3: System Description 3.2.2 MNR Status LED Located on the front of each MNR Unit is a status indicator LED which allows viewing from either the front panel or from the side panel below the Keyboard / Display unit. Multiple system status modes are displayed from this “shared status” LED. START REV. CAL SW2 RESET SW3 CN1 DATA SW1 PARM. MEMORY CARD D-NO. MODE RS232C DATA USB MON SET SAN3-DP2 STATUS STATUS CN2 SHARED STATUS LED Fig.
FEC Micro Nutrunner Operations Manual 3.3 Chapter 3: System Description (Rev 2: 02/12) MNR Keyboard-Display unit description The display unit incorporates programming and monitor functions display into the MNR controller. It comes standard within the MNR unit. Programming of parameters can be accomplished using the programming keys as well as displaying the fastening result data from the LED display.
Chapter 3: System Description 3.3.2 RS232C Communication Protocol Communication protocol from the RS232C port is as follows; Speed: Parity: Data Bits: Stop Bit: 38400bps NONE 8 Bit 2 Bit 3.3.3 Front Display RS232C Communication Format The data output from the RS232C port is a formatted ASCII output. This can be connected to a serial printer, computer or other peripheral device. 78 bytes of data is output per fastening. The data format is described in the table below. Byte 1 Desc.
FEC Micro Nutrunner Operations Manual Chapter 3: System Description (Rev 2: 02/12) 3.3.4 RS232C Data Format Description The table below describes the data convention output from the RS232C serial port on the front display. Non-data bytes will be occupied by the hex character 20H. Data Name Byte # Data Format Cycle Count 1~4 0000-9999 Spindle Number 7~8 01 Parameter Number 12 ~ 13 1–8 Maximum 8 parameters Peak Torque 16 ~20 0.
Chapter 3: System Description 3.3.5 Cable Connection to Front Display 9-Pin to 25-Pin cable example 1. Connection using DTR signal D-Sub 9-Pin Socket MNR RS232C TD RD CTS GND Cable Drawing D-Sub 25-Pin Pin 3 ------------------------------------------------- 3 RD 2 8 ------------------------------------------------- 20 DTR 5 ------------------------------------------------- 7 GND Serial device 2.
FEC Micro Nutrunner Operations Manual 3.4 Chapter 3: System Description (Rev 2: 02/12) Nutrunner (Tool) Unit Bit Holder – ¼” Torque Transducer Transmission Motor / Resolver Cable Connector FIG. 3-5a Micro Nutrunner (Tool) Unit components { RESOLVER P Provides feedback for speed regulation to Servo Amplifier. P Provides angular rotation monitoring capability to fastening operation. { MOTOR P Totally enclosed DC permanent magnet motor. { TRANSMISSION P Durable Planetary gear transmission.
Chapter 3: System Description [Blank Page] Page 3-10
FEC Micro Nutrunner Operations Manual Chapter 4: Chapter 4: System Setup and Wiring (Rev. 2.
Chapter 4: System Setup and Wiring 4.1 Component Dimensions The specifications for all of the Micro NR standard system equipment is outlined in this Chapter to aid in determining space, mounting and wiring requirements. 4 4.1.1 MNR Controller Unit Dimensions START REV. CAL RESET DATA PARM. D-NO. MODE DATA 162 SET 4 SAN3-DP2 150 RS232C 15 50 80 4.5 15 4.5 30 10.4 53.8 (60) FIG. 4-1-1 MNR Controller Unit Dimensions Note: Dimensions shown in millimeters.
FEC Micro Nutrunner Operations Manual Chapter 4: System Setup and Wiring (Rev. 2.1: 12/12) 4.1.2 Tool Tool dimensions and mounting specifications are critical in determining the design of the tool mounting plate. Provide adequate clearance to ensure that 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 system or possible damage to the tool assembly.
Chapter 4: System Setup and Wiring 4.2 Power Requirements and Connections 4.2.1 MNR Unit WARNING: Follow Lockout/Tagout and other safety precautions when connecting and/or disconnecting cabling, wiring, and equipment. POWER MP CP 0V 1 2 3 MOTOR U V W FG 1 2 3 4 Mating Connectors: Manufacturer: Phoenix Contact Power Model #: MSTB 2, 5/3-STF-5.08 Motor Model #: MSTB 2, 5/4-STF-5.08 Type: Screw Terminal Type Fig.
FEC Micro Nutrunner Operations Manual Chapter 4: Circuit Protection Controller MNR-8 System Setup and Wiring DESCRIPTION IDEC #NRC210L-5A-AA or Equivalent * * Specify delay operation type. Noise Filter Controller MNR-8 DESCRIPTION TDK #ZRWT2205-ME (250V, 5A) or Equivalent Motor Cable Length Limitation Controller MNR-8 Cable Length 3 Meter Maximum Page 4-5 (Rev. 2.
Chapter 4: System Setup and Wiring 4.3 Wiring PLC I/O The MNR I/O can accommodate both active true low (sinking NPN) or active true high (sourcing PNP) interface devices depending on the wiring configuration. (See PLC Wiring Example 4.4.3) Outputs Max: 30V Inputs Max: 30V 50mA 7mA STATUS CN2 T/D RESOLVER PLC PLC Connector Manufacturer: Hirose Connector Model #: DF1E-14S-2.5C Terminal Model#: DF1B-2428SC As viewed from the front of the MNR Unit. FIG.
FEC Micro NR Operations Manual Chapter 4: System Setup and Wiring (Rev2.1: 12/12) 4.3.1 Explanation of SAN Unit I/O PLC Pin # INPUT SIGNALS 1 SIGNAL TYPE SIGNAL NAME INPUT COMMON DESCRIPTION Input signal common. Connection to either +12 ~ 24 VDC or OVDC common required. (Reference PLC wiring example) Reset Input 2 INPUT RESET When active (on), this signal will clear all fastening data and discrete outputs. A Zero Check of the torque transducer will be completed.
Chapter 4: System Setup and Wiring PLC Pin # OUTPUT SIGNALS 8 9 10 11 12 13 SIGNAL SIGNAL TYPE NAME DESCRIPTION Output when the fastening result is a REJECT. Indicates that the spindle has failed the fastening limits. This output remains active unOUTPUT REJECT til the START signal or RESET signal is input. Output when the fastening result is a ACCEPT. Indicates that the spindle is within the fastening limits.
FEC Micro NR Operations Manual Chapter 4: System Setup and Wiring (Rev2.1: 12/12) 4.3.3 PLC Wiring Example This diagram represents standard I/O connections. The I/O can be connected to either a NPN (Sinking) or PNP (Sourcing) PLC I/O card. See below for wiring examples of both. NPN (Sinking) Connection reference FIG. 4-3-3-a PLC Wiring Example (Sinking) To ensure correct operation of MNR output circuits, do not connect to an input device with high Input resistance.
Chapter 4: System Setup and Wiring PNP (Sourcing) Connection reference FIG. 4-3-3-b PLC Wiring Example (Sourcing) To ensure correct operation of MNR output circuits, do not connect to an input device with high Input resistance.
FEC Micro NR Operations Manual 4.4 Chapter 4: System Setup and Wiring (Rev2.1: 12/12) Signal Timing Chart A. Basic Control Signals FIG. 4-4 Basic Control Signals { Because the RESET input clears all fastening data, discrete outputs and communication buffers, it should be activated only to clear a System Abnormal or to perform a required Zero Check. The System will automatically reset with each fastening and a manual RESET activation between cycles could result in data loss.
Chapter 4: System Setup and Wiring 4.5 USB Communication Port Communication to a PC and accompanying software is done through the mini USB port. Connection from your PC USB port and this Mini USB port can be done with a standard USB Mini cable. The Micro NR software will allow programming and monitoring of the Micro NR system.
FEC Micro NR Operations Manual 4.6 Chapter 4: System Setup and Wiring (Rev2.1: 12/12) MNR Unit DIP Switch setting. The MNR Unit has three DIP switches used for configuration setting. located on the front of the MNR unit. SW2 SW1, SW2 & SW3 are SW3 CN2 SW1 SW1 Orientation (See below for setting) SW2 Orientation (Not Used – Set all OFF) FIG.
Chapter 4: System Setup and Wiring 4.6.1 MNR Unit DIP SW1 Settings { Switch 1 – START Signal Type .
FEC Micro NR Operations Manual 4.7 Chapter 4: System Setup and Wiring (Rev2.1: 12/12) Tool Connection { Tools are connected to the MNR controller using one cable (Cable supplied standard with each spindle). One cable contains the motor, resolver and torque transducer signal cables. Cable should be securely tightened to the motor to insure complete connection. { If cable ties are required, cable ties should be loose enough to allow the cable to move, but yet hold it in place.
Chapter 4: System Setup and Wiring 4.7.1 Cable Installation Guidelines Improper installation of cables can reduce cable life expectancy drastically. The following guidelines should be used when installing cables. The cables must be prepared for installation without twists, bends or kinks. Upon unpacking the cables, any tie wraps used in shipping should be removed.
FEC Micro NR Operations Manual 4.7.2 Chapter 4: System Setup and Wiring (Rev2.1: 12/12) Considerations for Cable Trolleys 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. Restraint cords should be used in between cable trolleys to limit movement and reduce the stress on cables as they are extended.
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FEC Micro Nutrunner Operations Manual Chapter 5: Chapter 5: Power Up and Initial Checks (Rev.
Chapter 5: Power Up and Initial Checks 5.1 Before Powering On WARNING: Follow Lockout/Tagout 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 3.1 System Block Diagram and Section 4.5 Wiring Diagram. WARNING: Damage may occur if the 24 VDC and 0 VDC Commons are improperly connected. 1. Verify San Unit DIP switch settings (4.10) P 2.
FEC Micro Nutrunner Operations Manual 5.2 Chapter 5: Power Up and Initial Checks (Rev. 2: 02/12) 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 required 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 system will not run until this data is correctly set-up.
Chapter 5: Power Up and Initial Checks [Blank Page] Page 5-4
FEC Micro Nutrunner Operations Manual Chapter 6: Chapter 6: Fastening Instructions (Rev.
Chapter 6: Fastening Instructions 6.1 Fastening Control. The Micro NR is presentable from two different fastening methods, by parameter setting Torque Control or Angle Control methods. (Based on parameter setting) 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 / Angle Method - Target Torque Control.
FEC Micro Nutrunner Operations Manual Chapter 6: Fastening Instructions (Rev.
Chapter 6: Fastening Instructions 6.1.2 Torque / Angle Method - Target Angle Control. Fastening is performed based upon attaining a desired Angle value, while monitoring the Torque of the fastener and time. Additional monitor items (limits) can be set to enhance the system’s ability to determine if the fastener was properly secured (Section 6.2). { Fastening explanation 1. After start signal command the system runs INITIAL SPEED until INITIAL TIME expires. 2.
FEC Micro Nutrunner Operations Manual Chapter 6: Fastening Instructions (Rev. 2: 02/12) Torque 12: Peak torque High Toque High 13: Standard Torque 11: Peak Torque low 16: Snug Torque 14: Speed Change Torque Angle/Time 20: Angle low limit 22: Standard Angle 21: Angle High limit 42: Final time High limit 68: Rundown revolution low limit 69: Rundown revolution high limit FIG.
Chapter 6: Fastening Instructions 6.2 Speed Functions The Micro NR 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 and controlling the applied torque during all stages. Special conditions that affect these operations will be identified in the appropriate section. 1. Fastening Initial stage to seating process: a.
FEC Micro Nutrunner Operations Manual Chapter 6: Fastening Instructions (Rev. 2: 02/12) The graphic below describes the ideal relationship between torque and speed. Typically for high motor durability, high speed (FREERUN speed) should slow to SLOWDOWN SPEED before the fastener seats. Final TORQUE SPEED should not exceed 50 RPM.
Chapter 6: Fastening Instructions 6.3 Reverse Function The Micro NR System is capable of reverse operations using the manual reverse input on the MNR unit front panel or via the PLC input. 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. Time/Revolutions 54: Reverse Speed RPM FIG.
FEC Micro Nutrunner Operations Manual 6.4 Chapter 6: Fastening Instructions (Rev. 2: 02/12) Special Functions 6.4.1 One Pulse Reverse Function One Pulse Reverse is used in applications where socket to fastener tolerances allow the fastener to “stick” or lock into the socket during fastening operations.
Chapter 6: Fastening Instructions 6.4.2 Rundown Revolution Limits Rundown Revolution high and low limits can be set to identify fasteners that may be too long or too short for normal operations or for a redundant check for bolts that reach torque but are not seated. This is especially the case where different length fasteners are used and placed by hand. The number of rundown revolutions until fastening end is monitored and judged.
FEC Micro Nutrunner Operations Manual 6.4.3 Chapter 6: Fastening Instructions (Rev. 2: 02/12) 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.
Chapter 6: Fastening Instructions [Blank Page] Page 6-12
FEC Micro Nutrunner Operations Manual Chapter 7: System Operations (Rev. 2.
Chapter 7: System Operations 7.1 MNR Display and Programming operation. REVERSE Button CAL Button RESET START Button Button ＲＳ-２３２Ｃ Connecter ＤＡＴＡ display (4digit) ＰＡＲＭ display (2digit) Ｄ－ＮＯ display (2digit) DATA ↑Button チ MODE Button DATA ↓Button SET Button FIG. 7-1 Operational controls and indicators 7.1.1 Manual Fastening controls for Display Programming Unit. wSTART This push button initiates the fastening cycle.
FEC Micro Nutrunner Operations Manual Chapter 7: System Operations (Rev. 2.1: 12/12) 7.1.2 Fastening Preset / Result displays. w[D-NO] Data number indicator (2 digits). Indicates the Display mode and data type (number) ・No digit: Status Display mode ・One digit: Real Time Display mode ・Two digits: Parameter Display mode ・Digit on the left : Fastening Result Display mode When an Abnormal occurs the abnormal Sub Code will be displayed here. w[DATA] Data value indicator (4 digits).
Chapter 7: System Operations 7.2 Display indication modes. Five modes can be selected by pressing the MODE push-button. By using the [] and [] keys to change the D-NO selected, the DATA display contents for parameters 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, the display will automatically change to the Abnormal (Abn) display mode displaying the abnormal code and sub-code.
FEC Micro Nutrunner Operations Manual Chapter 7: System Operations (Rev. 2.1: 12/12) 7.2.1 STATUS display Non-fastening Status display Various types of non-Fastening Results STATUS can be displayed. 1) When the STOP signal is activated (signal goes low): The DATA display will indicate when the STOP signal has halted the MNR Unit as shown in the figure. 2) When an ABNORMAL condition occurs the [PARM] display will show a flashing "A" character followed by a number that represents the Abnormal number code.
Chapter 7: System Operations 5) At the end of the fastening cycle the results will be displayed. ■ Fastening Accepted ■ Fastening Rejected 6) If a memory card is installed for saving cycle data, the status of the card will be displayed alternatively between the fastening cycle results display or ready display. ■ Memory card writing ■ Memory card Full ■ Memory card space warning 7) When the system is communicating with the User Console computer (Upload, Download, etc.), the following will be displayed.
FEC Micro Nutrunner Operations Manual Chapter 7: System Operations (Rev. 2.1: 12/12) Fastening Status display The following example values are displayed during fastening operations using Parameter No.
Chapter 7: System Operations 7.2.2 Real Time Display mode. While in the Real Time Display mode, you can choose the desired type of data by pressing the [] and [] keys. The indicator will display the following data in the [DATA] area and [PAR] / [D-NO] display area. PRESS or PRESS Torque value: The real-time torque value from the torque transducer is displayed in the [DATA] area.
FEC Micro Nutrunner Operations Manual Chapter 7: System Operations (Rev. 2.1: 12/12) Motor Lock Function When [SET] is pressed during the Torque/Angle display, the motor is locked for up to one minute allowing the spindle to be checked with a torque wrench while displaying the reaction torque. Press RESET to unlock the Motor before one minute has expired. WARNING: Do not repeat this procedure repetitively or the motor will overheat.
Chapter 7: System Operations 7.2.3 Fastening Results Display Mode. In Fastening Results Display mode, when [D-NO] shows _0 ~ ), data can be obtained by pressing the [] and [] keys to scroll the [D-NO] until the desired DATA item is displayed.
FEC Micro Nutrunner Operations Manual Chapter 7: System Operations (Rev. 2.1: 12/12) 7.2.4 Parameter Display Mode Parameter Display mode displays the preset values programmed in the MNR unit for the fastening operation. The MNR system can store up to 8 different sets of parameters that can be selected by input signals WORK SELECT 0 ~ 2 (see section 4.7.2.). Note: Representation only, not actual data. The data displayed in this section is the DISPLAY only for the Configured Parameters. See Section 7.
Chapter 7: System Operations 「D-NO」 「PARM」 「DATA」 10 01 Calibration Torque (CAL value) 11 01 Peak Low Torque Limit 12 01 Peak High Torque Limit 68 08 Rundown Revolution Low Limit 69 08 Rundown Revolution High Limit ～ [] [] keys Last data of PARAMETER 8 FIG. 7-2-4b Parameter display D-No selection When Parameter Display mode is enabled, the [D-No] display will show 2 digits (10-69) representing the preset data number.
FEC Micro Nutrunner Operations Manual 7.2.5 Chapter 7: System Operations (Rev. 2.1: 12/12) Parameter Data List Item [Unit] Torque [Nm] Angle [deg] Time [sec] Rotation Speed [rpm] Revolutions [rev] Parameter No. Data No.
Chapter 7: System Operations Data No.10 Calibration torque The calibration value is set according to the tool type (capacity). However, depending on the application characteristics or the prevailing torque generated external to the tool output shaft, the value of the applied torque and the torque display by the SAN unit may mismatch.
FEC Micro Nutrunner Operations Manual Chapter 7: System Operations (Rev. 2.1: 12/12) Data No.14 Speed Change Torque [Nm, Kgm...] Setting range: 0 ~ [10: Calibration torque] × 1.0 Set the torque value that switches slow down speed to torque speed.
Chapter 7: System Operations Data No.19 Torque Inhibit Limit [Nm, Kgm...] Setting range: 0 ~ [10: Calibration torque] × 1.1 Limit for ignoring the Torque value sensed during fastening start due to inertia. When the initial Torque exceeds the Torque Inhibit Limit during [61: Torque Inhibit Revolutions] an ABNORMAL will be generated and fastening will end. Data No.1A 1P Reverse Torque [Nm, Kgm...] Setting range: 0 ~ [10: Calibration torque] × 1.
FEC Micro Nutrunner Operations Manual Chapter 7: System Operations (Rev. 2.1: 12/12) Data No.52 Slow Down Speed [rpm] Setting range: 1 ~ Tool’s maximum rpm Sets the speed used to draw the fastener down to [14: Speed Change Torque]. When [14: Speed Change Torque] is sensed the operation will switch to [53: Torque Speed] Data No.53 Torque Speed [rpm] Setting range: 1 ~ Tool’s maximum rpm Sets the speed during final fastening operation. *Slower torque speed results in better fastening accuracy. Data No.
Chapter 7: System Operations 7.3 Parameter Display, Select (setup) and Data Edit Operation All 8 Parameter sets can be setup using the programmer. Press the [MODE] button to select the Parameter Display mode. Use [] and [] keys to select the desired parameter. Downloading via the MNR Software can be accomplished anytime the unit is in the Ready State. This is accomplished by the software, which disables the nutrunner operation during programming.
FEC Micro Nutrunner Operations Manual Chapter 7: System Operations (Rev. 2.1: 12/12) 7.3.2 Data Edit Mode After you have selected the Parameter number and the Data number you would like to edit, press the [SET] button to enter the Data Edit mode. The blinking digit will now appear at the left digit of the [DATA] field. You can move one digit to the right each time you press the [MODE] button.
Chapter 7: System Operations 7.3.3 Parameter Setup Confirmation When the data is changed, the [DATA] display will show "CHNG," and 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 [SET] and [MODE] buttons will have no effect when "NO" appears.
FEC Micro Nutrunner Operations Manual 7.4 Chapter 7: System Operations (Rev. 2.1: 12/12) Torque Unit / RS232C / Memory Card Display Mode Press the [MODE] button to select TORQUE UNIT/RS232C/MEMORY CARD Display mode. STATUS Display mode REAL TIME Display mode RESULT DATA Display mode PARAMETER DATA Display mode TORQUE UNIT/RS232C/MEMORY CARD Display mode Select the desired preset menu by using the [] and [] buttons. (Section 7.4.1) (Section 7.4.2) (Section 7.4.3) (Section 7.4.4) (Section 7.4.
Chapter 7: System Operations 7.4.1 Torque Unit Display / Edit Mode Pressing the [SET] button will initiate the preset edit mode and a blinking data will appear in the [DATA] display. The blinking character can be changed (selected) by using the [] and [] buttons. Note: All parameters will be changed to the selected torque unit. Torque unit selection: Nm Ft lbs Kgm Kgcm Inch lbs Ncm When the Torque Unit parameter is changed, all fastening parameters (01 ~ 08) are cleared.
FEC Micro Nutrunner Operations Manual Chapter 7: System Operations (Rev. 2.1: 12/12) 7.4.2 RS232C Display / Edit Mode Select RS-232c port either Printer or User-console mode. Depressing the SET button will initiate the preset edit mode and a blinking data will appear in the [DATA] display. The blinking character can be change (select) by using the [] and [] buttons. This operation requiring Data confirmation and Power off and on cycle.
Chapter 7: System Operations 7.4.3 Memory Card Station Name Display / Edit mode After enter [PESET EDIT MODE], the blinking digit will appear at the [DATA ①] field. Use [] and [] buttons to increase or decrease data at blinking digit. Press [MODE] button to move blinking cursor [DATA ①]→ [DATA ②]→[DATA ③]→ [DATA ④] and state change to [PRESET DISPLAY MODE].
FEC Micro Nutrunner Operations Manual Chapter 7: System Operations (Rev. 2.1: 12/12) 7.4.4 Memory Card Data Save Display / Edit mode After enter [PESET EDIT MODE], the blinking data will appear at the [DATA] field. Use [] and [] buttons to select desire preset. The data (Fastening data, Torque signature) will not store on memory card if save is not selected. Not saved on memory card.
Chapter 7: System Operations 7.4.5 Memory Card Data File Update by Size Display / Edit mode After enter [PESET EDIT MODE], the blinking digit will appear at the [DATA ①] field. Use [] and [] buttons to increase or decrease data at blinking digit. Press [MODE] button to move blinking cursor [DATA ①]→[DATA ②]→[DATA ③]→ [DATA ④]and state change to [PRESET DISPLAY MODE].
FEC Micro Nutrunner Operations Manual Chapter 7: System Operations (Rev. 2.1: 12/12) 7.4.6 Memory Card Data File Update by Time Display / Edit mode After entering [PESET EDIT MODE], the blinking digit will appear at the [DATA ①] field. Use [] and [] buttons to increase or decrease data at blinking digit. Press [MODE] button to move blinking cursor [DATA ①]→ [DATA ②]→[DATA ③]→[DATA ④] and state change to [PRESET DISPLAY MODE].
Chapter 7: System Operations 7.4.7 Memory Card Abnormal Display / Edit mode After enter [PESET EDIT MODE], current selection is blinking at [DATA] field. Use [] and [] buttons to select desire mode. Turn MNR controller power OFF and ON after this mode change. Abnormal detect effective [] [] buttons Abnormal detect Invalid Memory card abnormal detection effective: The unit outputs and displays abnormal when an abnormal condition occurs.
FEC Micro Nutrunner Operations Manual Chapter 8: Maintenance and Inspection (Rev.
Chapter 8: System Operations 8.1 Inspection Items A scheduled inspection is recommended to keep the Micro-NR 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.
FEC Micro Nutrunner Operations Manual Chapter 8: Maintenance and Inspection (Rev. 2: 02/12) 8.1.3 MNR Unit Recommended Schedule: Quarterly The MNR Unit requires careful use and handling. Inspect each MNR Unit and ensure the following requirements are met: 1. The environmental conditions are within specifications. 2. There is no moisture, oil, or foreign matter on the unit. 3. The unit is securely mounted, with appropriate clearance on all sides. 4.
Chapter 8: System Operations 8.2 Basic Operational Tests WARNING: Follow Lockout/Tagout and other safety precautions when connecting or disconnecting cabling, wiring and equipment. When performing the following 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 values from the torque transducer (zero and calibration) to the data stored in the system memory.
FEC Micro Nutrunner Operations Manual 8.3 Chapter 8: Maintenance and Inspection (Rev. 2: 02/12) Replacements WARNING: DO NOT CONNECT OR DISCONNECT CABLES OR OTHER SYSTEM COMPONENTS WITH POWER APPLIED. FOLLOW LOCKOUT/TAGOUT AND OTHER APPLICABLE SAFETY PRECAUTIONS. NOTE: When replacing the Micro NR System MNR Unit, ensure that the new unit is configured with the compatible Hardware and Firmware version as the unit being replaced.
Chapter 8: System Operations 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. 1. Verify all System power is off. 2. Ensure that the homerun cable is marked for reconnection, then disconnect it from the tool. 3.
FEC Micro Nutrunner Operations Manual Chapter 9: Troubleshooting (Rev.
Chapter 9: Troubleshooting 9.1 Abnormal Conditions. When an abnormal condition is detected by the system, the affected spindle stops and shows an “Abn” in the front programming/display. For ease of troubleshooting the nature of the abnormal, the system provides an abnormal code in the [PARM] display and an abnormal sub-code in the [DATA-NO] display. When connected to the MNR User Console Software, the cause of the abnormal is also reported via the Fastening Data Monitor screen. w Abnormal code display.
FEC Micro Nutrunner Operations Manual 9.2 Chapter 9: Troubleshooting (Rev. 2: 02/12) Torque Transducer Origin Error, Cal Check Error. 9.2.1 Code 1-0 TORQUE TRANSDUCER / ZERO VOLTAGE ERROR Zero Level does not match master level read from tool EEPROM 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 tool cable is located in an electrical or magnetic noise field. 3.
Chapter 9: Troubleshooting 9.2.4 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 tool cable is located in an electrical or magnetic noise field. 3. When the torque transducer, tool cable or the controller malfunctions. RECOVERY: 1.
FEC Micro Nutrunner Operations Manual 9.3 Chapter 9: Troubleshooting (Rev. 2: 02/12) Torque Over Abnormals 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.
Chapter 9: Troubleshooting 9.4 Tool EEPROM Errors 9.4.1 Code 3-0 PREAMPLIFIER / TOOL ID CHECKSUM ERROR Communication data checksum error between the Preamplifier and the MNR Unit. Data is not reliable due to data error. This abnormal is caused from; 1. If the controller or the tool cable is located in an electrical or magnetic noise field. 2. When the torque transducer, tool cable or the controller malfunctions. RECOVERY: 1.
FEC Micro Nutrunner Operations Manual 9.5 Chapter 9: Troubleshooting (Rev. 2: 02/12) System Memory / Memory Card Errors 9.5.1 Code 4-1 SYSTEM MEMORY ERROR / FLASH ROM READ ERROR Communications error to internal MNR Flash ROM during READ attempt. This abnormal is caused from; 1. Metal chips and/or debris has migrated inside the MNR Unit through vent holes. 2. Flash ROM IC chip has malfunctioned RECOVERY: 1. Remove MNRN Unit and blow or shake out debris. 2. Replace and return unit to FEC for repair. 9.5.
Chapter 9: Troubleshooting 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 tool cable is damaged or not connected. 2. When the resolver, motor or the controller malfunctions. 3.
FEC Micro Nutrunner Operations Manual 9.7 Chapter 9: Troubleshooting (Rev. 2: 02/12) Servo Type Error 9.7.1 Code 6-0 SERVO TYPE ERROR / SERVO TYPE MISMATCH The MNR Unit model does not match the connected motor type. 1. Verify the servo type tag with the motor type tag. 2. There are multiple types of MNR Units (controllers) available & they must be connected to the correct motor size as shown in the table below.
Chapter 9: Troubleshooting 9.8 Servo Amplifier Error When Servo Amplifier Errors occur and cannot be cleared with a RESET signal, cycle power to the MNR Unit. 9.8.1 Code 8-1 SERVO AMPLIFIER ERROR / SERVO IS OVER HEATED The MNR 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 centigrade) without any air flow. 3.
FEC Micro Nutrunner Operations Manual Chapter 9: Troubleshooting (Rev. 2: 02/12) 9.8.4 Code 8-6 SERVO AMPLIFIER ERROR / INPUT VOLTAGE ABNORMAL The MNR 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 incorrect (24 volts dc) and/or the environment temperature is also close to the limit. 3. The input power wiring is not correct.
Chapter 9: Troubleshooting 9.8.8 Code 8-12 SERVO AMPLIFIER ERROR / AMPLIFIER PARAMETER ERROR An error has occurred in the Amplifier Parameter. RECOVERY: 1. Turn the power off. Wait at least 5 minutes and then turn power back on again. 9.8.9 Code 8-13 SERVO AMPLIFIER ERROR / AMPLIFIER PROGRAM ERROR An error has occurred in the Amplifier Program. RECOVERY: 1. Turn the power off. Wait at least 5 minutes and then turn power back on again. 9.8.
FEC Micro Nutrunner Operations Manual 9.9 Chapter 9: Troubleshooting (Rev. 2: 02/12) Parameter Error 9.9.1 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. 9.9.
Chapter 9: Troubleshooting 9.9.6 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. 9.9.7 Code 9-6 PARAMETER 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.
FEC Micro Nutrunner Operations Manual 9.10 Chapter 9: Troubleshooting (Rev. 2: 02/12) Micro-NR MNR Unit Fastening Faults and Causes REFER TO SECTION “6.2 Monitoring Functions” for detailed descriptions of Fastening Faults and causes related to all monitoring functions. 9.10.1 Accept Conditions An “ACC” (Accept) will be displayed in the DATA area of the front programming/display and the multi-function LED will light “green” for the three following reasons: 1.
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