Operating Instruction Booklet. Sequence controller. - Translation of the original instruction en

Transcription

1 013564en Operating Instruction Booklet - Translation of the original instruction - Sequence controller AST A NOTICE ALL DOCUMENTATIONS! Before beginning work this operating instruction booklet and the enclosed safety instructions (no , pink-colored booklet) have to be read through carefully. Always follow the instructions during operation. Give this operating instruction booklet and the appropriate safety instructions to the operator.

2 Contents 1 DEFINITION OF SIGNAL WORDS AND SYMBOLS SAFETY INSTRUCTIONS INTENDED USE SCOPE OF DELIVERY SHORT DESCRIPTION FRONT AND REAR PANEL Front panel of AST Connection panel of AST INTERFACE DESCRIPTION Screwdriver Voltage supply Ethernet Interface Feeder / clearance to start ASSEMBLY INSTRUCTIONS Minimum bending Radius of Screwdriver Cable Information on programming the controller Dimension sheet FUNCTIONING OF THE SEQUENCE CONTROLLER AST OPERATION General Operating via the touch display Control elements Menu structure Description of the menu structure Operation via the web interface Requirements Preparing to use the web interface Description SETTINGS Description of the adjustable parameter Default values SCREWDRIVING STRATEGIES AND COMMANDS Screwdriving Strategy Tighten / loosen to Torque Extended screwdriving to torque Screwdriving - tighten / loosen to angle Friction Value Package (optional) Commands Display values Save values Statistic Waiting time Hold position DIAGNOSIS System test Screwdriver test Speed test Angle test Torque test Screwdriver interface Sequence test

3 13.4 Interface Internal External E/A module DOCUMENTATION Final values Curve representation Statistic MAINTENANCE AND SERVICING Updating the software Main control and touch display Power element Calibrating the touch display Exchanging the battery Spare parts ERROR DISPLAY AND TROUBLESHOOTING System error Error in the screwing sequence TROUBLE SHOOTING REQUIRED ACCESSORIES Power Cable Motor Cable for MICROMAT-E OPTIONAL EQUIPMENT AST5 to PC connecting cable Base Plug connector voltage supply Plug connector clearance to start / PLC Touch-Pen Motor extension cable for MICROMAT -E External I/O module Optional software packages Friction value software package DataLogger GRAPH10 - curve overlapping TECHNICAL DATA GLOSSARY EC DECLARATION OF INCORPORATION SERVICE LOCATIONS AND AUTHORIZED PARTNERS List of figures Figure 1: Front panel of AST Figure 2: Connection panel of AST Figure 3: Connecting diagram for the screw feed device (SFD) Figure 4: Clearance to start connecting diagram Figure 5: Dimension sheet Figure 6: Main screen: Process display Figure 7: Selecting between two options Figure 8: Selecting between several options Figure 9: Numerical block for numerical input Figure 10: Keyboard for text input Figure 11: Menu structure Figure 12: Main menu Figure 13: Process data menu

4 Figure 14: Menu system Figure 15: Screwing sequence Figure 16: Test menu Figure 17: The home page Figure 18: Home page Figure 19: Web interface menu structure Figure 20: Statistic Figure 21: Downloading curve data Figure 22: Screwdriver results Figure 23: Tool data Figure 24: System data Figure 25: Update Figure 26: Activating options Figure 27: General settings Figure 28: General settings - lower part of the page Figure 29: Date / Time Figure 30: Change password...34 Figure 31: Screwing sequence Figure 32: Manuals Figure 33: Additional programs Figure 34: Screwdriving Application to torque Figure 35: Expanded screwdriving to Torque Figure 36: Screwdriving to Angle...43 Figure 37: Loosening on Angle...44 Figure 38: Friction Value Measurement Figure 39: Screwdriving on differential Torque Figure 40: Screwdriving Applications depending on Friction Figure 41: External I/O module Figure 42: DataLogger Figure 43: GRAPH10E List of tables Table 1: Adjustable parameter Table 2: Default values Table 3: Structure of the data set Table 4: System error Table 5: Fault in the screwing sequence Table 6: Troubleshooting

5 1 Definition of signal words and symbols The signal words and symbols used in the technical documentation (safety instructions, operating instruction booklet, etc.) have the following meaning: DANGER Indicates an immediate danger which causes serious injuries or even death if not avoided. WARNING Indicates a threatening danger which can cause serious injuries or even death if not avoided. CAUTION Indicates a danger or unsafe procedure which can cause injuries to a person or material damages if not avoided. NOTICE Indicates a potentially dangerous situation which can cause damage to the product or its surroundings if not avoided. IMPORTANT Indicates tips and other useful information. In each case the symbol used does not replace the safety text. The text must always be read fully. In some cases other symbols will be used with the signal words. 5

6 2 Safety instructions Reading the enclosed safety instruction booklet no (pink-coloured booklet) is essential for working with the equipment. WARNING Fires, electric shocks and other injuries, or damages to components can be caused if the safety guidelines are ignored. WARNING Risk of fatal injury due to electrocution! Disconnect the electric equipment from the power supply before starting any work on the tool (e.g. installation, changing of accessories or machine tools, removal of covers prior to longer downtimes, maintenance works, etc.). Switch off the mains switch and pull out the mains plug! 3 Intended use The sequence controller AST 5 is designed exclusively for fittings in industrial use. And must only be operated with DEPRAG MICROMAT EC screwdrivers (handheld) of the series 320Exx19. The system is especially suitable for application requiring the highest demand of quality, flexibility and documentation. Use beyond its intended use is considered unauthorized and therefore improper. Furthermore, DEPRAG is not liable for damage resulting from the misuse of the instrument; the user alone is liable. The correct use of the instrument includes compliance with all operating, maintenance and repair instructions. IMPORTANT Please contact your DEPRAG Representative, our international service centers or contact DEPRAG SCHULZ GMBH u. CO. directly if you have any questions. Visit our website at 6

7 4 Scope of Delivery Check that the shipment is complete and that there have been no damages in transit. Quantity Designation Part no. 1 AST5 Sequence controller A 1 Power unit Operating instruction booklet en 1 Quick-Start instructions of AST5 with 320E Safety Instruction Short Description The sequence controller AST5 is a sequence controller with integrated performance electronics to operate DEPRAG MICROMAT EC screwdrivers (handheld) of the series 320Exx19. It has a E/A interface and an Ethernet connection. The sequence controller AST5 can be operated via the web interface as well as via the touch display. The web interface and the display on the touch display are available in several languages to select from. 100 different screwing programs can be created. For this, several screwing samples and commands are available. The screwing applications can be analyzed and evaluated using the statistic and curve representations. Extensive diagnosis possibilities help detect possible faults in the screw driving sequence, at the screwdriver or at the controller. 7

8 6 Front and rear panel 6.1 Front panel of AST5 Figure 1: Front panel of AST5 6.2 Connection panel of AST5 Main switch GX4: Screwdriver connection GX1: Power supply connection (voltage supply) GX3: Ethernet GX2: SFD connection / clearance to start Figure 2: Connection panel of AST5 8

9 7 Interface description 7.1 Screwdriver Designation: GX4 Plug connector: SUB-D 15-pole (bushing) 7.2 Voltage supply Designation: GX1 Plug connector: Circular plug-in connector 3-pole Also see 19.3 Plugconnector Voltage Supply PIN Designation 1 24V 2 n.c. 3 GND 7.3 Ethernet Designation: Plug connector: GX3 Bushing RJ45 9

10 7.4 Interface Feeder / clearance to start Designation: GX2 Plug connector: Circular plug-in connector 7-pole Also see 19.4 Plug connector clearance to start / SFD PIN Designation 1 Reload 24V 2 Signal reload 3 24V 4 GND 5 Clearance to start signal 6 Clearance to start GND 7 n.c. When using the internal 24V supply of the AST5 AST5 Reload 24V 1 Signal reload 2 24V 3 GND 4 Clearance to start signal 5 Clearance to start GND 6 n.c V Galvanized insulation yes Signal GND Screw feed device Figure 3: Connecting diagram for the screw feed device (SFD) 10

11 When using the internal 24V supply of the AST5 Reload 24V 1 Signal reload 2 AST5 24V 3 GND 4 Clearance to start signal 5 Clearance to start GND 6 n.c. 7 24V (PC) Clearance to start signal When supplying the 24V supply externally Reload 24V 1 Signal reload 2 AST5 24V 3 GND 4 Clearance to start signal 5 Clearance to start GND 6 n.c. 7 Clearance to start signal 24 V (DC) GND Figure 4: Clearance to start connecting diagram 11

12 8 Assembly instructions WARNING Risk of fatal injury due to electrocution! Disconnect the electric equipment from the power supply before starting any work on the tool (e.g. installation, changing of accessories or machine tools, removal of covers prior to longer downtimes, maintenance works, etc.). Switch off the mains switch and pull out the mains plug! For the initial start-up proceed as indicated in the brief instructions "Quick-Start Instructions for the operation of the sequence controller AST5 with 320E... screwdriver" CAUTION Injuries from electricity or damages on the device Prior to connecting to the power, compare the layout design of the sequence controller AST5 with the in-house power supply (also refer to 20 Technical data) Connect the screwdriver (to the GX4 interface) and screw on the retaining screw tightly. Connect the screw feed machines / clearance to release signal, if screw feed machine is present (GX2 interface). Connect the sequence controller AST5 to the power supply (GX1 interface). Watch for the white marking. Plug the power cable into the power socket. Switch on the sequence controller AST5 using the main switch. More information about the interface assignment can be found under 6.2 Connection panel of AST5 and 7 Interface description. Read the Operating Instruction /Safety Guidelines. Please read and heed the enclosed operating instructions for the individual actuators and sensors. 12

13 8.1 Minimum bending Radius of Screwdriver Cable ATTENTION Non-observance will cause damage to the screwdriver cable! Observe minimum bending radius of screwdriver cable. At constant motion: Minimum bending radius 90 mm At singular motion: Minimum bending radius 45 mm Please make sure that there is no mechanical load on the cables during operation. To assure best possible contact, the connections of the cable to the sequence controller and the screwdriver must be solid. 8.2 Information on programming the controller The sequence controller AST is already pre-configured in its delivery status. A functioning screw assembly program is already available for the enclosed EC screwdriver. The screw assembly programs and settings must however be adjusted to the present application case. Default settings and parameter changes of the screw assembly programs can be done directly on the sequence controller AST5, refer to 10.2 Operation via the integrated touch display. The web interface must be used to modify or create new screw assembly programs refer to 10.3 Operation viathe web interface. The default programs screwing at torque, screwing at an angle of tilt and loosening at angle of tilt, can be created and parametrized at the sequence controller AST5. 13

14 8.3 Dimension sheet Figure 5: Dimension sheet 14

15 9 Functioning of the sequence controller AST5 When manually screwing, the start of a screwing application occurs depending on screw type via contact pressure or via the start button. The program indicated in the program selection menu or in the web interface under settings default settings is started. If the program switching (button or switching lever) is actuated, then program 100 is always being started. After switching on the sequence controller AST5 the main screen will appear. Figure 6: Main screen: Process display The number and name of the active program is displayed on the upper line. To quickly switch programs tab on this line. The program selection page is displayed and you are now able to select the next desired program. IMPORTANT The fast program switching is available if the setting "Direct program selection" is active. In the second line the date, time and duration of the last screwing application is displayed. In the status area the last screwing application is displayed. The status field will be green if the screwing application was fault-free. The status field will be red if the screwing application was ended with a fault. In this case a help text is shown that indicates the fault description. To display this text tab on the input field with the fault message. The results of the last screwing application is displayed in the step, moment and angle area. In the bottom line is the menu button (also refer to Description of the menus) and the button to reload a screw when using a screw feeder. 15

16 10 Operation 10.1 General The sequence controller AST5 can be programmed via the web interface as well as directly via the touch display. Both operating MMIs provide different possibilities. The web interface offers a larger surface and better possibilities for displaying. Therefore several points that take up several pages in the control menu are compiled here on one page. Screwing sequences can be easily prepared using the web interface. You are able to create multi-level screwing programs and and add commands for the result display and the documentation. Standard programs that are parametrized matching to the connected EC screwdriver can be created directly on the sequence controller AST. Test functions can not be performed via the web interface since the movement of the EC screwdriver can only be started via the touch display Operating via the touch display The sequence controller AST5 is equipped with a TFT touch display. The operation is done directly via the touch surface of the display Control elements Buttons The touch display has different operating areas: Display fields Display fields can be recognized by the pointed corners. They only have a display function. Input fields Input fields can be recognized by the rounded corners. Buttons Keys are buttons that can be used to access and control the menu, for example. Switches Switches are used, for example, in the interface tests to switch the outputs on and off Selecting between two options If only two options are available for selection, e.g. active or inactive, then the selected option is displayed in a key. To switch to another option, tab on the key. 16

17 Figure 7: Selecting between two options Selecting between several options All options are displayed in their own buttons, if several options are available for selection, e.g. the language, the program selection, the torque unit. The option that has been selected is highlighted in blue. Figure 8: Selecting between several options 17

18 Text and numerical input Numerical inputs are required, for example, for the selection of a sequence, specification of the screwing time, setting of date and time and much more. If you tab on a numerical input field then the numerical block is opened via which the numerics can be entered. Depending on the type of input required, numbers with decimals and internal decimal places are also a possibility. A text input is required, for example, for the program name. Tab the text input field and a keyboard will be displayed. Here, letters, numbers, hyphens and space characters can be entered. A text that is already in the text input field can also be displayed in the display field of the keyboard. Figure 9: Numerical block for numerical input Figure 10: Keyboard for text input Tab the key to delete the last character. Complete the input by tabbing the key accepted.. The keyboard closes and the value entered is Tab the key, to close the keyboard and keep the original value. IMPORTANT If the maximum amount of characters is reached, then it is no longer possible to enter any further characters. 18

19 Menu structure Process Data Statistics Graphic System System Data Screwdriver Data Setup Screwdriving Sequence Test System Test Screwdriver Test Speed Test Angle Test Torque Test Interface Screwdriver Sequence Test Figure 11: Menu structure Interface 19

20 Description of the menu structure Figure 12: Main menu All submenus in which values can be changed or that will lead to an interruption of the automatic operation can be protected by a password. These are: System settings (open without password: a change is not possible, only a display of the parameter is provided) Screwing sequence (open without password: a change is not possible, only a display of the parameter is provided) Test (can not be opened without a password) If the password is set to 0000, then all menus are released! The password can be changed in settings. IMPORTANT The setting at time of delivery are: Password: 0000 IMPORTANT The selection of the following sub-menus leads to an interrupt of the automatic operation: System settings Screwing sequence Test By providing a password, please ensure that only authorized persons can perform changes. 20

21 Process data menu Figure 13: Process data menu The process data menu provides the possibility to receive information about the screwing processes. The statistics for the individual programs can be displayed via the menu item statistic. The requirement for this is that the screwing program contains the command 'Statistic' after the respective screwing level (also refer to 14.3 Statistic). In the curve representation menu item the graphic of the last screwing application is displayed System menu Figure 14: Menu system The system menu contains all information about the complete system as well as system settings. In the system data menu all information for the sequence controller AST5 is displayed, in the tool data menu all information for the screwdriver are displayed. If the correct password is entered then the default settings for the sequence controller AST5 can be set in the settings menu (also refer to 11 Settings). 21

22 If you did not enter a password then only the set values are displayed. Changes are not possible Screwing sequence menu Figure 15: Screwing sequence If the correct password is entered then the prepared programs can be adjusted in the screwing sequence menu via the web interface (also refer to 12 Screwing samples and commands). Parameter changes can only be performed at the sequence controller AST5. If you would like to insert further steps or options such as angle monitoring, then you must do this via the angle monitoring (also refer to Screwing sequence). It is possible for you to create a standard program, if there is no program available. For this, tap the "standard program" button. Select the desired screwing program and confirm your selection by tabbing the "Accept" button. The desired program is created by the sequence controller AST5. If you did not enter a password then only the set values are displayed. Changes are not possible. 22

23 Test menu Figure 16: Test menu The test menu offer different tests for the sequence controller AST5 as well as for the EC screwdriver (also refer to 13 Diagnosis). The system test shows the current status of the sequence controller AST5. Different tests for the EC screwdriver an be performed in the tool test menu. These are torque, angle and rotation test, as well as a test of the E/A interface of the screwdriver. The sequence test provides the possibility to process the individual screwing programs step-by-step. For example, to limit problems during parametrization. The interface test provides the possibility to test the interfaces of the sequence controller AST5. 23

24 10.3 Operation via the web interface Requirements Hardware The web interface operates on any common PC or Notebook with a network card or a WLAN card Software The web interface can be used with any common operating system, such as MS Windows, Linux, OS X... and it also functions with any common browser. So far, it has only been successfully tested with Firefox, Internet Explorer, Konqueror and Opera Connection to the sequence controller AST5 The PC on which the web interface is operating can either be connected with the sequence controller AST5 or via a common network. Cross cables as well as uncrossed cables can be used for the direct connection; the sequence controller AST5 recognizes them automatically and adjusts the connection respectively Preparing to use the web interface In order to use the web interface, the sequence controller AST5 as well as the browser must be set in a manner that a TCP/Ip connection between both can be established and the data exchange released Setting the sequence controller AST5 A set IP address must be set at the sequence controller AST5 (also refer to System menu and brief description "Quick-Start Instructions for the Operation of Sequence controlö AST5"). They must be issued by the administrator of the local network. At the time of delivery the following values are preset: IP Address: Subnetwork mask Gateway: Setting the browsers/operating systems The browser must have free access to the sequence controller AST5, meaning; the IP address of the sequence controller AST5 must be reachable. the HTTP protocol must not be deactivated a possible proxy for the IP address of the sequence controller AST5 (or local addresses general) must be deactivated. Furthermore, the browser cookies must accept the sequence controller AST5 and javascript must be activated. In case of doubts contact your responsible EDV representative. 24

25 Description Start To access the web interface, enter the IP address of the sequence controller AST5 (also refer to System menu) into the address bar of the browser and press the enter key (e.g. " The browser connects to the sequence controller AST5 and loads the home page. Figure 17: The home page If you intend to perform changes, enter the password. The standard password at the time of delivery is "0000". If you only want to view data, without changing them, you will not need a password and leave the input fields empty. Click the login button or press the enter key. Subsequently the home page is displayed. 25

26 Figure 18: Home page The home page shows the versions of the main control, the power element and the screwdriver logistics. On the left side is the main menu, which is used to access the individual pages of the web interface. If you enter a valid password then all pages are accessible. Otherwise, the pages on which changes can be made are hidden. 26

27 The menu structure The menu has the following structure: Start Page Process Data Statistics Graphic Final Values System Tool Data System Data Update Extensions Setup General Settings Time New password Screwdriving Sequence Extra Manuals Figure 19: Web interface menu structure Additional Programs 27

28 Process data The process menu data is for the display of the screwing sequences, the statistics, the screwing curves and the screwdriver results. Changes are not possible in this menu item Statistic Figure 20: Statistic Here, the statistics for all programs are displayed. You can select the program for which the statistic should be displayed. This is done by clicking the respective button. (Also refer to 14.3 Statistic) IMPORTANT Statistic values are only saved and analyzed if the "statistic" command in the screwing sequence is open. 28

29 Curve representation Figure 21: Downloading curve data This page provides the possibility to load the data of the last screwing application as a data from the sequence controller AST5. In principle, all screwing applications are recorded. The record will be available until the sequence controller AST5 is switched off or a new screw connection is established. It is furthermore possible to download, free of charge, the viewing program GRAPH10(E) for the binary curve data. If you click the blue note on the "Viewer for the display of binary data" then you will first receive a detailed description of the installation of the GRAPH10 viewer. At the end of the description you will find information to load the program onto your PC. (Also refer to 14.2 Curve representation) Screwdriver results The end values of the screwing of the last seven days can be downloaded as CSV data (refer to 14.1 Final values). 29

30 Figure 22: Screwdriver results System information The system information menu is for the display of tool and system data. Changes are not possible in this menu item Tool data On this page the important data of the connected screwdriver are displayed. Figure 23: Tool data Changes to the tool data are not possible. 30

31 System data This page shows the fixed data as well as the network settings for the sequence controller AST5. Figure 24: System data Update New software kan be uploaded on the controller in the menu Update. See also 15.1 Updating the software Figure 25: Update 31

32 Extensions On this page you are able to activate options of the AST5. Figure 26: Activating options Different options are available, at extra cost, for the sequence controller AST5 (also refer to 19 Optional Equipment). To activate these options please contact the DEPRAG sales department or your DEPRAG dealer. In order to be able to perform the activation, some information is required which must be contained in your order: Activation key of the respective option Serial number of the controller The activation key can be found to the right, next to the respective option. The key can either be directly copied and inserted in an or saved by clicking the file. You will receive a license file for the activation, which contains the respective activation key. The activation key can be entered directly on the bottom of the page or by clicking the button "load key". As an alternative, the license data can be also directly loaded. To do this, click on the button "search..." and select the respective file. Click "load license data". One the activation key is loaded, the option is displayed as released and can now be used. 32

33 Setup The setting menu is intended for the display and modification of the general settings, setting of date and time as well as setting a password for the sequence controller AST General settings Here it is possible to perform most settings for the sequence controller AST5. Figure 27: General settings A description of the individual parameters can be found in Chapter 11 Settings. Click "accept" to transfer the settings to the sequence controller AST5. Click "Reset" to redo your changes. Click "Set Default Values" to restore the default values (delivery status). In the lower part of the page you can save your settings in order to transfer them to other sequence controllers Type AST5, or to reload later. Figure 28: General settings - lower part of the page After clicking the "Back up copy" button, a dialog is opened in which you can set the name and location of the back up file. In order to transfer back up copy to the sequence controller AST5 you must enter the file name and path in the lower input field and click "load back up copy". Alternatively you can select the file by clicking the "Search.." button next to the input field. 33

34 Time Here, you can enter the date and time of the sequence controller AST5. Figure 29: Date / Time Password On this page you can set the password for the access to the sequence controller AST5. Figure 30: Change password The password is only valid for changes to the settings of the sequence controller AST5, not for the complete access. 34

35 Screwing sequence On this page you are able to create and modify screwing sequences. Changes are only possible if you have entered a password on login. Figure 31: Screwing sequence You are able to create up to 100 programs. It is easy to detect what programs already exist, they are highlighted in Grey on the respective button. If you like to process a program or create a new program, click the button with the corresponding program number. On the first registry card you can select program 1 to 20. For programs 21 to 100 click first on the matching registry card and subsequently select the desired program. General parameter: There are three parameter for each program, which affect the complete program: Program title: Any designation with a character length limit of 16 characters. The title is intended for easier labeling of the program and has no effect on the screwing sequence. The program name must not contain any special characters. Reversal of rotation direction: Determines if another main rotational direction applies for this program in the general settings. If for example the rotational direction is set to the right, the program will screw to the left if the reversal of rotation is switched on. Reload signal: Determines when the reload signal is given to the feed screwdrivers. OK and NOT OK values: After each screwing application the reload signal is issued. Only on OK: The reload signal is only issued after an OK screwing application. No signal: The control provides no reload signal. 35

36 Adding steps to the program: Select an available program step by clicking this step. Subsequently click the screwing sample or the command that you like to insert. If you click "insert in front", if the screw program or command should be inserted in front of the currently selected program step or click "insert behind", if the screwing sample or the command should be inserted behind the currently selected program step. IMPORTANT If the screwing program is still empty, then the screwing sample or command are always inserted as first parameter step. View/process a program step: Select an available program step by clicking this step. The parameter of this step are displayed. A new value can be directly entered in the input field next to the parameter. Save program: Click the "accept" button, which can be found below the last program step in order to save the program step and the parameter. Copy program: If you want to save an available program under another program number, select the new program number from the list field next to the "accept as" button. The "accept as" button can be found below the last program step. Subsequently click on "accept as" in order to save the program under a new number. Existing programs can be saved on the "general" registry card and saved programs can be repaired and all programs can be deleted. After clicking the "Back up copy" button, a window is opened in which you can set the name and location of the back up file. In order repair saved programs, enter the file name and path in the input field and click "load back up copy". Alternatively you can select the file by clicking the "Search.." button next to the input field. 36

37 Extra Manuals On this page you can transfer and read all available manuals for the sequence controller AST5. If your browser has a pdf plug in, then you can read the manuals directly in the browser. Figure 32: Manuals Additional Programs On this page you can download all programs which are available for the controller AST5. Usage of the software is partly liable to pay costs. Please consider the notes regarding the activation in the respective programs. 37

38 Figure 33: Additional programs 38

39 11 Settings 11.1 Description of the adjustable parameter Parameter IP Address Network mask Gateway Baud rate Language Torque unit Main direction of rotation Program selection Abort delay Clearance for start Rotation speed decrease Direct program selection Description The IP address via which the AST5 can be reached in the network. It indicates the network segment in which the sequence controller AST5 is located. The IP address of the gateway for the network segment in which the sequence controller AST5 is located. You are able to adjust whether the Ethernet connection with 10 Mbits/s should process or if it should automatically adjust to the network. The language that should be displayed in the web interface as well as also the operating interface of the sequence controller AST5. The torque unit that is used for display and settings of torque values. Available units are: N m N cm ft lb. in lb. kg m kg cm The main direction of rotation indicates what direction is defined as screwing application. The main direction right means that all screwing samples will operate rotating to the right, all screw samples to release with rotate to the left. The number of screwing sequences that must be performed during the start of the screwdriver. The set abort delay prevents that a screwing process is evaluated as aborted, if the start signal of the screwdriver separates, but is present again within the set time. This is especially important in connection with a screw feeder device to prevent errors during the pushing through of the screw through the mouth piece. If the clearance to start is active then a screwing application can be started, if 24v are available at the start release input (also refer to 7.4 Interface Feeder / clearance to start). This can be required in connection with a position stand. If the rotation speed decrease is active then the torque screwing levels, that do not have torque transfer occurring, will automatically lower the rotation speeds when 80% of the target torque is reached. This provides a higher cut-out accuracy. If the direct program selection is active, the program selection can be accessed at the sequence controller AST5 directly via the input field for the program name in the process display. 39

40 Type of program selection Amount of rows Signal sound Password Date / Time External E/A module IP Address IP port Status Table 1: Adjustable parameter The program selection at the sequence controller AST5 can either be done via the program number or via the program name. If the program selection is activated via name, then it is possible to set as to how many programs per page should be displayed. determines under which conditions the signal sound is released at the end of the screwing process. The menus of the controller in which changes can be performed can be password protected. The password can be in a range of 0000 to 9999 and must be four-digit. If 0000 is set as a password then all menus at the controller are freely accessible. In delivery state the password is set to Setting for the internal true clock of the controller. External input/output module to expand the functionality. Device address for communication Communication interface Device state 11.2 Default values The default values can be adjusted as follows: at the control in the system menu settings on the general page to "set default values" click the "Set Default Values" button in the web interface in the setting menu General Settings Parameter Value Language English Unit for torque N cm Main direction of rotation right Password 0000 Clearance for start inactive Abort delay 0 Baud rate auto Rotation speed decrease active Signal sound never Type of program selection number only Amount of lines for the program selection with 5 name Program selection (pre-set program) 1 Direct program selection active Statistic: Limits for CP/CPK value +/- 15% Table 2: Default values 40

41 12 Screwdriving Strategies and Commands 12.1 Screwdriving Strategy Tighten / loosen to Torque The screwdriving strategy tighten / loosen to torque is a tightening / loosening process with stop control via parameter torque. Angle monitoring is possible as an option. Strategy Description: Figure 34: Screwdriving Application to torque Strategy description: At the start of the screwdriving sequence cycle time monitoring is started. Cyclic torque measurements are performed. If the angle measurement option is active then angle measurements are performed additionally starting at the preselected torque threshold. Shut-off criteria: The screwdriving process is ended once the: Target torque is achieved the maximum screwdriving time (monitoring time) is exceeded the maximum angle of rotation is reached (only for angle monitoring) Analysis: OK evaluation: The screwdriving sequence is considered OK (fault free), if the shut off is achieved via torque and the torque value is within the preset limits. With optional Angle monitoring active the angle value must also be within the preset limits. Not OK analysis: The screwdriving sequence is evaluated as Not OK (faulty) if the final torque value is outside the preset limits or the maximum screwdriving time has been exceeded. If angle monitoring is active the screwdriving sequence is evaluated as Not OK, if the angle value is outside the preset upper and lower limits. 41

42 Parameters: The following parameters are used in the screwdriving Sequence: Maximum time until the cut-out torque is reached (monitoring time) Shut-off torque, shut-off torque upper/lower limits RPM Torque holding time Angle measurement: yes / no if angle monitoring is active the following parameters are added: Threshold torque for angle measurement start Angle lower limit / angle upper limit Extended screwdriving to torque The screwdriving strategy Extended screwdriving to torque is a tightening process with shut off at a preset torque value. Angle monitoring is possible as an option. Strategy Description: Figure 35: Expanded screwdriving to Torque Strategy description: At the start of the first screwdriving sequence/step time monitoring is started and the screwdriving process is started with RPM setting 1. Once the torque threshold for step one has been achieved, Sequence step 2 is started and the speed setting is changed to RPM 2. Cyclic torque measurements are performed. If the angle monitoring option is active then angle measurements are performed in addition starting at the preset torque threshold value (sequence step 2). Shut-off criteria: The screwdriving process is ended once the target shut-off torque is achieved the maximum screwdriving time (time monitoring) is expired the maximum angle of rotation is reached (only when angle monitoring is active) Analysis: OK evaluation: The screwdriving sequence is considered OK (fault free), if the shut-off occurs via torque and the torque value is within the preset limits. 42

43 If the Angle monitoring option is active the final angle value must be within the preset limits. Not OK evaluation: The screwdriving sequence is evaluated as Not OK (faulty) if the final torque value is outside the preset limits or the maximum screwdriving time has been exceeded. If angle monitoring is active the screwdriving sequence is evaluated as Not OK, if the angle value is outside the preset limits. Parameter: The following parameters are used in the screwdriving sequence: Maximum time until the shut-off torque is reached (monitoring time) shut-off (target) torque, shut-off torque min/max RPM 1 Threshold torque for RPM 2 (step 2) RPM 2 Torque holding time Angle of rotation: yes / no if angle monitoring is active the following parameters are added. Threshold torque for angle measurement Min/max angle Screwdriving - tighten / loosen to angle The screwdriving Sequence screwdriving application / loosen to angle of rotation is a tightening / loosening process with stop control via angular displacement (angle control). Strategy Description: Figure 36: Screwdriving to Angle 43

44 Figure 37: Loosening on Angle Strategy Description: At the start of the screwdriving sequence time monitoring and angle measurement is started. Cyclic torque measurements are performed. Shut-off criteria: The screwdriving process is ended once the shut-off angle is achieved the maximum screwdriving time (time monitoring) is exceeded the max. torque is reached Analysis: OK evaluation: The screwdriving level is considered OK (fault free), if the screwdriver shut-off occurs via the angle of rotation and the value of the angle measurement is in the preset limits. Furthermore, the torque value must be within the preset limits. Not OK evaluation: The screwdriving sequence is evaluated as Not OK (faulty) if the angle of rotation is outside the preset limits or the screwdriving time has been exceeded. If angle monitoring is active the screwdriving sequence is evaluated as Not OK, if the angle value is outside the preset limits. Parameter: The following parameters are used in the screwdriving sequence: Maximum time until the shut-off angle is achieved (time monitoring) Shut-off angle, shut-off angle upper/lower limits Torque upper/lower limits at target angle RPM Final values: Final torque/maximum torque The resulting torque can be displayed as final torque (torque at end of screwdriving) or the maximum torque (maximum torque achieved during the cycle) in the final values. 44

45 Friction Value Package (optional) Friction Value Measurement The function of the screwdriving Strategy is the tightening of a screw, while considering the friction value prior to screw head contact with the mating surface. The calculated friction value is applied as a factor to the preset torque value. Strategy Description: Figure 38: Friction Value Measurement Shut-off criteria: The measuring process is ended once the end of the measuring range is achieved a calculated (variable) shut-off torque value is determined (based upon the friction value) the maximum screwdriving time (time monitoring) is exceeded Analysis: OK evaluation: The screwdriving sequence is considered OK (fault free), if the shut-off torque value is determined based upon the friction value and the final torque value achieved is within the preset limits. Not OK analysis: The screwdriving sequence is evaluated as Not OK (faulty), if the friction torque in the monitored angle window is outside the preset limits or the determined friction torque value is outside the preset limits. The screwdriving level is also evaluated as Not OK when the maximum time limit is exceeded. 45

46 Parameter: The following parameters are used in the screwing sample: Maximum time Maximum time until the screwing level is aborted Friction measurement angle Input of the angle range in which the friction monitoring should be active. Friction value creation: Mean value/maximum value selectively the maximum value or mean value of the friction value can be used to determine the friction torque. Minimum friction torque Input of a minimum torque that must not be undershot by individual torque values during the friction monitoring. Maximum friction torque Input of a maximum torque that must not be exceeded by individual torque values during the friction monitoring. Minimum friction value Input of the minimum torque that must not be undershot by the friction torque. Maximum friction value Input of the maximum torque that must not be exceeded by the friction torque. The limits of the friction torque can be recorded tighter then the limits of the individual friction values. Torque Input of the rotation speed that should be used for the screwing application Screwdriving with a Differential Torque The function of the differential torque strategy is the addition of a fixed torque value to the friction factor measurement. Strategy Description: Figure 39: Screwdriving on differential Torque 46

47 Shut-off criteria: The screwdriving process is ended once the Preset Shut-off torque value is achieved (variable based upon the addition of the friction value and the fixed differential torque value) A calculated Friction value is achieved the maximum screwdriving time (time monitoring) is exceeded Analysis: OK evaluation: The screwdriving Sequence is considered OK (fault free), if the screwdriver shut-off occurs via the differential torque value and the result is within the preset limits. Not OK analysis: The screwdriving sequence is evaluated as Not OK (faulty) if the differential torque value is outside the preset limits. The screwdriving sequence is evaluated as Not OK (faulty), if the friction torque in the monitored angle window is outside the preset limits The screwdriving level is also evaluated as Not OK when the screwdriving time limit is exceeded. Parameter: The following parameters are used in the Differential strategy: Maximum time Maximum time until the screwdriving sequence step is aborted Differential Torque (fixed value) Input of the differential end torque The actual target torque results from the sum of the torque of the friction sequence step and the differential torque value. Minimum differential torque Lower limit of the differential end torque. The actual torque lower limit results from the sum of the torque of the friction sequence step and the lower limit of the differential moment Maximum differential torque Upper limit of the differential end torque. The actual torque upper limit results from the sum of the torque of the friction sequence step and the upper limit of the differential torque. Screwdriver RPM 1 Input of the rotation speed that should be used for the screw run-down sequence step. Threshold torque value switching to RPM 2 Input of the torque value at which the second rotation speed occurs. The actual threshold torque for the rotation speed decrease results from the sum of the torque of the friction sequence and the differential torque. Screwdriver RPM 2 Input of the rotation speed that should be used for the screw head seating sequence. Torque hold time A holding time can be defined to keep tension applied to the screw joint for a preset time to allow for material elasticity. End value creation: Differential torque / total torque Selectively the end torque can be displayed as difference between the total torque and the torque of the previous level or as total torque in the end values. 47

48 Angle monitoring: yes / no Monitoring of the angle with a window angle if the angle monitoring is switched on, the following parameters are added: Swelling moment Input of the torque from when the angle monitoring should be started (compare point 1 in Figure 39:). Angle upper limit Upper limit of the end angle Angle lower limit Lower limit of the end angle Screwdriving with Friction and Differential Torque The screwdriving Sequence friction dependent screwdriving connects the screwdriving Sequence friction measurement and the screwdriving to differential moment. Strategy Description: Figure 40: Screwdriving Applications depending on Friction Switching off criteria: The screwing process is ended once the cut-out torque is reached a monitoring criteria is reached the maximum screwing time (monitoring time) is expired 48

49 Analysis: OK evaluation: The screwdriving sequence is considered OK (fault free), if the shut-off occurs via torque and the differential value is within the preset limits. If the Angle monitoring option is active the final angle value must be within the preset limits. The screwdriving sequence is considered OK (fault free), if the shut-off occurs via the differential torque calculated from the friction torque and the value of the torque is within the preset limits. Not OK analysis: The screwdriving level is evaluated as Not OK (faulty) if the final torque is outside the preset limits or the determined friction value is outside the indicated limits. If angle monitoring is active the screwdriving sequence is evaluated as Not OK, if the angle of rotation is outside the preset limits. The screwdriving sequence is also evaluated as Not OK when the screwdriving time monitoring is exceeded. Parameter: The following parameters are used in the screwdriving sequence: Maximum time Maximum time until the screwdriving sequence step is aborted Threshold torque for angle monitoring Input of the torque value from where the angle monitoring should start Start angle friction measurement Input of an angle value that should be realized after reaching the threshold torque value, prior to activating the friction value monitoring. Screwdriver RPM 1 Input of the rotation speed that should be used for the first sequence step of the screwdriving application. Friction measurement angle Lower threshold of the angle range in which the friction monitoring should be active. Friction value creation: Mean value/maximum value selectively the maximum value or mean value of the friction value can be used to determine the friction torque. Minimum friction torque Minimum torque limit during the friction monitoring range. Maximum friction torque Maximum torque limit during the friction monitoring range. Minimum friction value Minimum torque limit for the calculated friction torque value (variable) Maximum friction value Maximum torque limit for the calculated friction torque value (variable). Note: The limits of the calculated friction torque can be set to a value that is tighter than the limits of the individual friction values. Threshold torque for the start of screwdriver RPM 2 Input of the differential torque at which screwdriver RPM 2 should start. The actual threshold torque value screwdriver RPM 2 is derived from the calculated friction torque and the differential torque Screwdriver RPM 2 Input of the rotation speed that should be used for the screwdriving application. 49

50 Differential Torque Input of the differential final torque The actual target torque - results from the sum of the determined friction torque and the differential moment o Minimum differential torque Lower limit of the differential final torque. The actual torque lower limit results from the sum of the lower limit of the friction torque and the lower limit of the differential torque. Maximum differential torque Upper limit of the differential final torque. The actual torque upper limit results from the sum of the upper limit of the friction torque and the upper limit of the differential torque. Torque hold time A holding time can be defined to keep tension applied to the screw joint for a preset time to allow for material elasticity. End value creation: Differential torque / total torque Selectively the end torque can be displayed as difference between the total torque and the torque of the previous sequence step or as total torque in the final values. Angle monitoring: yes / no Monitoring of the angle within a torque window if angle monitoring is enabled, the following parameters are added: Threshold torque Input of the torque value from where the angle monitoring should be started (compare point 1 in Figure 39:). Angle upper limit Upper limit of the final angle Angle lower limit Lower limit of the final angle 12.2 Commands Display values Displays the values of the previous screwing level at the touch display. The command can used used as often as you like Save values Saves the values of the previous screwing level into the end value data set. The command can be used as often as you like (also see Screwdriver results). IMPORTANT As a maximum the last three results are saved Statistic Affects the calculation of the statistic of the previous screw level (also see 14.3 Statistic). IMPORTANT The statistic can only be calculated for a screwing level per program. If the 'statistic' command is entered more than once into the program then only the statistic for the last screwing level is calculated, for which the 'statistic' command has been indicated. 50

51 Waiting time Inserts a waiting time into the program. Parameter: Waiting time Hold position Hold the screwdriver tension position. Parameter: Holding time 51

52 13 Diagnosis In the test menu the inputs and outputs of the screw driving controller AST5, the connected screwdriver and the created programs can be tested System test In the system menu green check marks indicated if the EC screwdriver and the screw driving controller AST5 are active Screwdriver test In test menu Screwing tests can test the rotation speeds, torque, angle as well as the inputs and outputs of the screwdriver Speed test In the submenu rotation speed test you set the rotation speed with which the screwdriver should rotate. For this tab the "target" input field. Subsequently tab the green start arrow. The screwdriver operates and the display field "actual" shows the present rotation speeds. To stop the screwdriver tab the red stop symbol Angle test You are able to check the measured angles in the submenu angle test. For this turn the output side of the screwdriver. In the display field "actual" the angle is displayed (positive = turning to the right and negative = turning to the left. If you tab the "reset' button then the angle value in the display field is set to Torque test In the submenu torque test you set the rotation speed that the screwdriver should reach. For this tab the "target" input field. Subsequently tab the green start arrow. The screwdriver operates and switches off after reaching the set torque. In the display field "actual" the measured torque is displayed. NOTE If you would like to abort the torque test prior to it automatically ending, tab the red stop symbol Screwdriver interface In the submenu interface screwdriver the input and outputs of the screwdriver can be tested. Push the button on your screwdriver and the display for button 1 or button 2 will light up. If you have plugged in a contact pressure start screwdriver (type EGA) then "contact pressure" appears in the touch display as a third input. If you push the screwdriver then the display shows the contact pressure. 52

53 NOTE Not all screwdrivers have two buttons. The outputs are activated by tabbing the button for the outputs OK and Not OK. The OK output corresponds to the green LED on the screwdriver, the output Not OK with the red LED. By tabbing the switch several times, the respective output is switched off again. If the contact pressure is not functioning correctly then it can be readjusted. For this, tap the "adjust" button. IMPORTANT The functionality of the contact pressure adjustment is password protected and can only be performed by authorized persons Sequence test In the test menu sequence test, you can test the available programs step by step. First, select the program you like to test. For this tab either onto the program number and enter the number directly or select the program via the and buttons. The program name appears on the display field. Hold the screwdriver to the screwing location and tab "start" to start the sequence test. The first program step will be processed. If a program step is ended, then the step, torque and angle as well as the result of this level/this program step is displayed. In case of a fault, tab the error message and a help text will be displayed. tab "continue" to process further program steps. Tab "stop" to abort the sequence test. IMPORTANT Only screwing samples are displayed as program steps in the sequence test, commands are skipped. Please also be aware that the display of the program step must therefor not always match the number in the screwing program Interface In the test menu interface input and outputs of the AST5 can be tested Internal After a signal is present at the input, the display lights up for the clearance to start. By tabbing the button for the output reload the display will light up and the output will be activated. By tabbing the switch several times, the respective output is switched off again. 53

54 External E/A module NOTE The interface test for the external E/Z module is only available if the module is registered and released. After one or several signals are present at the input, the display lights up for the program selection. The selection of the programs is binary coded. By tabbing the switch for the OK, Not OK and Ready output the respective display lights up and the output is activated. By tabbing the switch several times, the respective output is switched off again. 54

55 14 Documentation The sequence controller AST5 provides a wide variety of documentation possibilities Final values If the command 'save value' is used on the screwing program, then the screwing results are stored in a CSV data and can be loaded by the controller via the web interface (see also Screwdriver results). The command "save values" can be used as often as you like within the screwing process, however, only the three last values are saved. In case of a fault these values are always saved. IMPORTANT The data is only available if the screwing program has received the command "save final values" or if a faulty screwing application is present. One CSV data per day is saved. The last data of the last seven days is always available. The final values of the screwing application that are older than seven days are overwritten by new final values. The final value data of the last screwing application are also saved in the file "actual.csv". The files are subject to the same limitations as described in chapter 14.2 Curve representation for the curve data. The CSV file is structured as follows: First line: Title bar with caption of the values Following line: results of a screwing application per line Value Description Date Date of screwing application Time Time of screwing application Program number Program used Status Status, also see 16.2 Error in screwing sequence Total duration Total duration of the program Step1 Step number of the first saved step Moment1 Torque of the first saved step Angle1 Angle of tilt of the step of the first saved step Step2 Step number of the second saved step Moment2 Torque of the second saved step Angle2 Angle of tilt of the second saved step Step3 Step number of the third saved step Moment3 Torque of the step of the third saved step Angle3 Angle of tilt of the step of the third saved step Step not OK Step number of the faulty step MomentNotOK Torque of the faulty step AngleNotOK Angle of tilt of the faulty step FC Status Not available for AST5 FC counter Not available for AST5 Torque unit Unit torque Angle unit Angle of rotation unit Table 3: Structure of the data set 55

56 14.2 Curve representation With the sequence controller AST5 each screwing application creates a screwing curve. This can be views or saved in different ways. Display directly at the controller in the process data menu curve representation Download via the web interface in the process data menu curve representation in the following formats: As binary file: The file contains the recorded raw data. The GRAPH10 viewer program is required for viewing or processing. As CSV file: The data is converted into a table separated by commas, meaning the values are represented as text, with commas between the columns and line feed characters between the datasets. This format can be processed and read by table processing programs such as MS Excel or Open Office Calc. It is also possible to analyze with scripts or own programs. There are two limitations for table processing: 1. MS Excel and Open Office Calc can not process more than lines that contain curve data but often more datasets. 2. Both table processes interpret the decimal number depending on language: German version expects a decimal comma, foreign languages a decimal point, the other format is wrongly represented. The AST5 curve data always uses a decimal point, since this is the common format for computer data. For the analysis with the German version of the table processing the commas should therefore be replaced by semi-colons and the decimal point by commas. As shortened CSV file: The amount of datasets is shortened under the process limit of the table processing (65536 lines). For this, several datasets are combined by using the highest value respectively. If the data is shortened to half for example, then the two datasets with the highest rotation speed, the highest torque etc. are compiled to one dataset. In connection with the GRAPH10 (E) curve viewer as a direct download from the controller The following data is recorded: Rotation speed Torque Angle Program step Current strength Temperature of the electronics 56

57 14.3 Statistic If the command "statistic" is used in the screwing program then in the sequence controller AST5 a statistic is kept about the last 100 values for the respective program. The following values are calculated for moment and angle: Mean value Standard deviation absolute Standard deviation percentages, based on mean value CP value / CPK value The limits for the Cp/CPK value calculation can be entered. If no limits are set then the calculation is done automatically with ±15% of the mean value. The limits entered are maintained even after switching off the sequence controller AST5. The statistic can be displayed via the sequence controller AST5 as well as via the web interface (also see Process data menu and Statistic). The statistic can be deleted for individual programs or completely for all programs. The statistic is deleted when the sequence controller AST5 is switched off. 57

58 15 Maintenance and servicing Incorrect disassembly or assembly can lead to injury of an operator and damage of the machine. Disassembly and assemb ly work may only be carried o ut by DEPRAG or qualifi ed personnel. Recommendations should help to uphold warranty claims. Keep the device in a dry place. Precipitation, dampness and all types of fluids or wet conditions may contain minerals which corrode electric circuitry. Do not keep or use the device in dusty or dirty surroundings. The moveable parts and electronic components could be damaged. Do not keep the device in hot conditions. High temperatures can shorten the life of electric devices and deform or melt certain plastics. Do not keep the device in cold conditions. Internal dampness can build up and damage the electric circuitry when the device then is moved to normal temperature conditions. Do not try to open the device in any other way than in the instructions. Do not let the device fall, be hit or bumped and do not shake it. Rough handling can damage electronic circuitry and mechanical parts. Do not use any harsh chemicals, cleaning solvents or strong cleaning agents to clean the device. Do not paint the device. Paint could stick together moveable parts and prevent correct operation of the device. WARNING To avoid damage to surface finish, avoid using chlorine bleach, chlorine based cleaners, abrasive substances, ammonia, rags or cleaning pads containing metallic particles! Use adequate cleaning agent! Clean the TFT-Touch-Display with a soft, clean and lightly dampened cloth (mild liquid soap). Unauthorised alterations or additions can damage the device and violate specifications. 58

59 15.1 Updating the software Main control and touch display Updating can only be done via the web interface. Registration is done as described in section Start. Click on settings >> and then update. In order to update the main control including the display, enter the file name and path in the input field and click "load". Alternatively you can select the file by clicking the "Search.." button next to the input field. After you clicked the "load" button the inscription "the update is being transfer to the controller" appears. Wait until the update file is transfered and the AST5 is started anew. "Updating Main Unit" appears on the display of the sequence controller AST5. After updating the main controller the display is updated. You will recognize this by the red loading bar on the display of the AST5 that will slowly become green. The update is completed when the main screen with the process display is displayed on the display Power element Updating can only be done via the web interface. Registration is done as described in section Start. Click on settings >> and then update. In order to update the power element, enter the file name and path in the input field and click "load". Alternatively you can select the file by clicking the "Search.." button next to the input field. After you clicked the "load" button the inscription "the update is being transfer to the controller" appears. Wait until the update file is transfered and the sequence controller is started anew. "Updating Main Unit" appears on the display of the AST5. The update is completed when the main screen with the process display is displayed on the display Calibrating the touch display Due to aging and use it might be required that the touch display must be calibrated anew with the following procedure: 1. Switch off the sequence controller AST5 using the main switch. 2. Touch the touch display during switching on the sequence controller AST5 and keep pressing it. 3. After the message "touch adjustment" appears let go of the touch display. 4. Within a second you must touch the touch display for at least one second. 5. Touch as accurately as possible the point left on top and subsequently right bottom. 6. Switch off the sequence controller AST5. 59

60 15.2 Exchanging the battery WARNING Risk of fatal injury due to electrocution! Switch off the sequence controller AST5 at the main switch and disconnect the power plug; prior to exchanging the battery! The battery exchange must only be done by trained electricians! 1. Switch off the sequence controller AST5 at the main switch and disconnect the power plug. 2. Remove the six pan head screws (Allen screw SW 2.5) at the back of the sequence controller AST5 and open the housing. IMPORTANT Ensure polarity when inserting the battery. 3. Remove the old battery and replace it with a new battery. (Order no. see 15.3 Spare Parts) 4. Screw the back of the sequence controller AST5 on using the six pan head screws. 5. Plug the power plug in and switch on the sequence controller AST5 via the main switch Spare parts Designation Part no. Battery CR

61 16 Error display and troubleshooting 16.1 System error Number Component Meaning -- Screwdriver Screwdriver not found 001 Screwdriver Temperature too high 002 Screwdriver Temperature sensor defective 003 Screwdriver Test sum error 1 in EEPROM (repairable via the main controller) 004 Screwdriver EEPROM not writable (not repairable) 005 Screwdriver Test sum error 2 in EEPROM (not repairable) 006 Screwdriver Test sum error in RAM 007 Screwdriver Test sum error in FLASH 008 Screwdriver EEPROM error: Maximum amount of screwing cycles reached -- Power element Power element not found 101 Power element Position indicator index signal not found 102 Power element QEP position indicator signal missing or wrong 103 Power element Initialization error, spindle free? 104 Power element Loading error of condensers, power element defective 105 Power element External watchdog or over current fault in power element 106 Power element Temperature too high 107 Power element Area error 108 Power element Under voltage 117 Power element RAM error or set-up information / adjusting values in flash not legible. 118 Power element 5V supply error 119 Power element 3.3V supply error 121 Power element Supply voltage error 122 Power element Driver supply nominal 14 Volt error 127 Power element The Directory of the flash file system could not be read 128 Power element A system file could not be found in the Flash file system 132 Power element Trial to drive onto the write protected Flash area 133 Power element The external 24 Volt supply is in overload 134 Power element The 8V supply for the internal as well as the screwing logic is faulty. 135 Power element Initial stage of the motor controller is defective 201 Main controller Not in use 202 Main controller Software version of main controller and power element are not compatible. 203 Main controller Screwdriver and power element are not compatible. 204 Main controller Lost settings, default values will be loaded 205 Main controller Error in the data storage 206 Main controller Error in the communication power element 207 Main controller External E/A module not available 61

62 Number Component Meaning 301 Communication No connection 302 Communication General fault 303 Communication Checksum error 304 Communication Module not found 305 Communication Unknown command 306 Communication Timeout Table 4: System error 16.2 Error in the screwing sequence Number Displayed text Meaning Troubleshooting 0 OK No error, the screwing application was ended - properly 1 Timeout The set monitoring time of the screwing level has been exceeded 2 Angle below target The indicated minimum angle of the screwing level was not reached 3 Angle exceeded The set maximum angle of the screwing level has not been reached 4 Torque not reached 5 Torque exceeded The indicated minimum torque of the screwing level was not reached The set maximum torque of the screwing level has been exceeded 62 Check the screw process and adapt the program if required. 6 Power unit: Invalid An invalid program was Transfer the program over program transmitted to the Power unit again. 7 To many E/A The program contains too Check the screwdriver commands many E/A commands program. 8 reserved Invalid program Program is not valid (does not exist, or was created for another screwdriver) Check the program and adapt if required or select a different program. 10 Abort 11 Over current Error during holding torque Power unit: Write error The start signal has been reset prior to the normal end of the screwing application. Current exceeds maximum permissible value While holding the torque the moment dropped at the end below the target torque Error while writing the program The start signal must be present until the end of the screwdriver operation. Check the screw process and adapt if required. If necessary please contact DEPRAG Service. Check the screw process and adapt the program if required. Transfer the program over again.

63 Power unit not initialized. Fault during position hold Friction torque undercut Friction torque exceeded 18 I²t - overload Power element not initialized with screwdriver data. Fault during position hold, position could not be loaded Friction torque in monitored window too small Friction torque in monitored window too large Overload of the tool via a defined time frame Prog-no greater This program number is 19 than 99 invalid. 20 General fault general fault - Table 5: Fault in the screwing sequence Switch the cordless ECscrewdriver on again. Check the screw process and adapt the program if required. Check the screw process and adapt if required. If necessary please contact DEPRAG Service. Specify a program number between

64 17 Trouble Shooting If you experience any problems, please check first if all instruction included in the safety and operating instructions have been observed. Take appropriate precautions, if required. Possible problems are listed in the following table: Problem Display remains dark AST5 indicates a fault A connection to the controller is not possible Display does not react to touch Resolution Check if the power adapter is connected with the power socket. Check that the AST5 Sequence controller is switched on at the mains switch. see 16 Fault display and troubleshooting Check if the IP address set at the AST5 is correct. Press a bit harder onto the touch display. Ensure that the touch display is only touched with a finger or with the optionally available pen. Check that you are touching the touch display at a location where a key, a button, or an input field is displayed. Perform a new adjustment of the touch display by (see Calibrating the touch display) Table 6: Troubleshooting If you detected that the sequence controller AST5 is defective, then send it to DEPRAG. Under no circumstances should you try to find or remedy the electrical fault. 18 Required accessories 18.1 Power Cable Designation Part no. Power cable 230V-1.8m / 5.9 ft Power cable 115V-1.8m / 5.9 ft Motor Cable for MICROMAT-E Designation Motor cable Length 2.5 m / 8.2 ft. (standard) Motor cable Length 5 m / 16.4 ft. Motor cable Length 8 m / 26.2 ft. Motor cable Length 12 m / 39.4 ft. Altanativ: with 90 angle connection Designation Motor cable Length 2.5 m / 8.2 ft. (standard) Motor cable Length 5 m / 16.4 ft. Motor cable Length 8 m / 26.2 ft. Motor cable Length 12 m / 39.4 ft. Part no A B C D Part no E F G H 64

65 19 Optional Equipment 19.1 AST5 to PC connecting cable This cable is intended for the connection of the sequence controller AST5 with the Firm network or the network interface of the PC. it is required to access the controller. Designation Part no. Patch cable Base The base for the table set-up of the sequence controller AST5. Designation Base Part no A 19.3 Plug connector voltage supply Plug connector to connect the sequence controller AST5 to the available 25V supply. Designation Part no. Cable socket Plug connector clearance to start / PLC Plug connector for the connection of a PLC and/or clearance to start signal at the sequence controller AST5. Designation Part no. Plug Touch-Pen Special pen for simple operation of the touch display. Designation Part no. PIN

66 19.6 Motor extension cable for MICROMAT -E Motor extension cable for MICROMAT-E on which the motor cable is permanently connected to the screwdriver. Designation Part no. Motor extension cable Length 2,5 m A Motor extension cable Length 5,5 m B Motor extension cable Length 9,5 m C Further accessories such as motor extension cable etc. leaflet D3490 All catalogs are available for download from our web site: External I/O module Figure 41: External I/O module External module for preselecting programs via a subordinate controller. With this module the following signals can be exchanged with a subordinate controller. Program pre-selection of subordinate controller to the sequence controller AST5 (7 bits). Signal OK, Not OK and Ready of the sequence controller AST5 to the subordinate controller. Designation Interface (External I/O module) Part no A 66

67 19.8 Optional software packages Friction value software package The software package friction values contain the following additional screwing samples: Friction value measurement Screwing on differential torque Screwing applications depending on friction For detailed description also refer to Friction value package (optional). The software package must be released as described under Extensions. Designation Part no. Software release key (AST10 friction coefficient) DataLogger Figure 42: DataLogger The data logger provides the possibility to record the end value data sets from up to 10 sequence controllers (AST) and to archive them. Designation Part no. AST10 Datalogger release

68 GRAPH10 - curve overlapping Figure 43: GRAPH10E The GRAPH10(E) program can be downloaded free of charge via the web interface of the sequence controller AST5. However, the use of the curve overlapping is subject to cost. Designation Part no. Curve overlapping release

69 20 Technical Data Type Part no. Amount of screwdriver that can be connected Protection class AST A 1 IP20 Operating temperature ( C) 0-45 Dimensions (cm) W x H x D 16.2 x 14.3 x 6.5 (mm) Weight (kg) 1.5 Voltage (V) 24 maximum input power (W) 150 Display and operation TFT Graphic display 4.3 (480x272 Pixel) with Touchscreen Storage temperature ( C) Humidity (%) Vibrations (g) 3 Impact load (g) 30 Type Mains unit AST5 Part no Network connection (V/Hz) AC / Dimensions mm W x H x D 168 x 70 x 38 Protection class IP20 Weight (kg) 0.5 Temperature range ( C) 0-45 Operating temperature ( C) 0-45 Storage temperature ( C) Humidity (%)

70 21 Glossary Term Sequence controller Sequence controller Description see sequence controller Controller to use with the EC or EC servo screwdriver Switching off criteria Impact start Command EC screwdriver EC servo screwdriver Encoder End value dataset Ethernet Handheld screwdriver Main controller High Signal level +24V Power element Low Process ability index (C p ) Process capability coefficient (C pk ) Criteria to which the screwing application should e done (e.g. torque, angle etc.). The screwdriver starts as soon as the blade is pressed and makes contact. General program step to create the screwing sequence (e.g. setting the output). The screwdriver has a brushless electronic drive (EC motor, English abbreviation for electronic commutate). The screwdriver has a brushless electronic drive (EC motor, English abbreviation for electronic commutate) and has an integrated, sensor controlled torque and angle of rotation measurement. visual sensor to detect the current position of a motor shaft or an drive unit The dataset in which all result data for the screwing application is stored. Data network technology for local data networks to exchange data between all devices connected in a network (computer, printer, etc.). Screwdriver to use at hand-work places Component for processing the screwing programs Component for the motor control of the screwdriver Signal level 0V C p = total specific torque tolerance of the Connection: 6 Sigma (s). This index just provides information about the spread angle of the torque values. Obergrenze Untergrenze C p 6 s Is defined as the minimum of: Obergrenze Mittelwert 1.) C pk or 3 s Mittelwert Untergrenze 2.) C pk 3 s This index provides information about the placing as well as the spreading of torque values. 70

71 The lower acceptable C pk - value for a screwdriver is 1.33 (corresponds to a calculation of the C pk on limits of 4 Sigma (s)). C p / C pk Limit values within limit Error values contribution 0.30 s 68.3 > 30% s 95.4 ~ 5% s s ppm s ppm s ppm s The mean value must not deviate from the target value by more than 3%!!! A correct statement about the process capability index is then no longer possible. Process capability examination Mean value Reload Profibus Program selection Prior to using a processing device for the series production it is possible to check if the requirements are met with sufficient safety. It is the objective of the process capability examination to verify that the a) processes to be examined is processing withe recognizable are legality. If legality is not recognizable then the process has no defined capability. Especially then it is not permissible to allocate a statistically calculated capability characteristic. b) the process is able to produce the parts in the indicated tolerances. The required documentation for this can only be provided under point a) found legality. The verification of the process ability must be done over a longer time period. Random sampling is done in set intervals from the running process and quality characteristics are recorded (measured). The influence of the machines, the materials and the operator are assumed by the process ability. The basis of the analysis is the Gauss distribution curve. Mean value on a certain amount of measuring values. n 1 x x n n i 1 Functionality for the control of screw feeders directly via the sequence control Industriebus for the control and data exchange with sequence control. Selection of the program to be started. The program selection can occur in different ways, depending on control and selected screw types (e.g. E/A interface at the control, direct 71

72 Ready signal Resolver Screwing sequence Screw driver logic Screwing sample Screwing program Standard deviations Clearance for start Starting via buttons Toolbox Monitoring criteria Web interface program switching at the screwdriver, etc.) The ready signal indicates that the control is ready for the start of a screwing application. If the ready signal is not available then either a screwing application is active or a state is present that prevents the screwing application (certain menus, system error). electro-magnetic transducer to change the angle position of a rotor in an electric size Sequence of the screwing process Consists of commands and screwing samples Electronic where all data of the screwdriver is stored. If the screwdriver is connected to the controller then it recognizes all data of the screwdriver. No settings have to be performed manually. Implementation of common screwing processes with predefined parameters which contain the correct value of a screwing application. (e.g. screwing application on torque with rotational angle control) Sequence of the screwing process Consists of commands and screwing samples mean deviation of measuring values from the mean value. s n i 1 x i x n 1 2 If the clearance for start is activated then the screwdriver will only start if there are 24V at the clearance to start input. Otherwise the controller is not ready to screw. The screwdriver starts as soon as a button on the screwdriver is actuated. Accessories for the automatic selection of a certain screwing program based on the used tools. Criteria that will lead to abort the screwing program even though the switching off criteria has not yet been reached (e.g. Time monitoring, angle monitoring during torque screwing applications). Software interface for the programming of the sequence control that are actuated via a standard Internet browser. 72

73 22 EC Declaration of Incorporation (according to 2006/42/EC dated 09 june 2006, appendix II, No. 1 B for incorporation of partly completed machinery) As manufacturer of the partly completed machine we declare that: the essential requirements of the Directive 2006/42/EC and where applicable the other Directives and Standards listed below apply to the specified machine. the relevant technical documentation is compiled in accordance with part B of ANNEX VII the relevant technical documentation in accordance with part B of ANNEX VII will be transmitted in response to a reasonable request by the national authorities in printed form or electronic form (pdf) Manufacturer DEPRAG SCHULZ GMBH u. CO. P.O. Box 1352, Germany Amberg Carl-Schulz-Platz 1, Germany Amberg Authorized Person for Documentation Designation Mr. Josef Bock, address see manufacturer Name SEQUENCE CONTROLLER Machine Type Serial Number Year of Manufacture Directives Date Applied and fulfilled essential requirements Machine directive 2006/42/EC ANNEX I, Article a) and b), 1.1.3, 1.1.5, 1.3.2, and Assembly instructions in accordance with Annex VII B a Low voltage directive 2006/95/EC ANNEX I basic requirements Directive for electromagnetic compatibility 2004/108/EC ANNEX I basic requirements Standards Date Remark EN ISO Machine safety fundamental rules, general fabrication directives EN Machine safety; electric equipment of machines, general requirements This partly completed machinery must not be put into service until the final machinery into which it is to be incorporated has been declared in conformity with the provisions of the Directive 2006/42/EC, where appropriate. Amberg, 12/22/2011 3/13/

74 23 Service Locations and Authorized Partners Contacts in Germany as well as contacts worldwide can be found on our web site If you need any further information then please either contact your representative or us directly at DEPRAG SCHULZ GMBH u. CO. During business hours our Service-Hotline + 49 (0) is available for German and English speakers. NOTICE: This hotline is subject to charges outside business hours! 74