mpro400gc Global Controller

Transcription

1 Programming Manual PL12EN mpro400gc Global Controller For additional product information visit our website at

2 About this programming manual This programming manual is the -- original programming manual -- and is intended for all persons who configure settings on the mpro400gc controller. The programming manual does the following: It provides important instructions for safe and effective operation. It describes the function and operation of the mpro400gc controller. It points out options. The following documents provide additional information for the operation and service of the mpro400gc controller. Further information on complete software configuration is contained in the Parts manual, no. PL EN Quickstart, no. PL Recovery Installation System description, Fastening technology, no. P1730E Symbols in the text: italics Identifies menu items such as Diagnosis > Identifies the selection of a menu item from the menu such as File > Print < > Identifies elements such as buttons, push button or external keyboard input, e. g. <F5> Courier Identifies elements such as input fields, checkboxes, radio buttons or drop-down menus. Indicates the name of paths and files, e. g. setup.exe / Separates the subdirectories of file paths, e. g. file/print (OS9 operating system) Identifies lists Identifies instructions to be followed Disclaimer: Apex Tool Group reserves the right to modify, supplement or improve this document or the product without prior notice. This document may not be reproduced in whole or in part in any way, shape or form, or copied to another natural or machine-readable language or to a data carrier, whether electronic, mechanical, optical or otherwise, without the express permission of Apex Tool Group. DGD and Cleco are trademarks of the Apex Tool Group Division. 2 PL12EN en00d441.fm,

3 Contents 1 Set-Up Guide Controller description General Information Checking your unit Software Installing the Unit Mounting the Controller Making Connections to the Controller Accepting a Corded Tool Accepting a LiveWire Tool Programming a Basic Fastening Strategy Auto Programming (Torque Control / Angle Monitor Only) Manual Programming Controller specifications Technical Data Programming Navigator Basic Standard Advanced Run Screen Communications Tool Setup Archive Diagnostics Utilities Administration Troubleshooting 59 5 Glossary 63 PL12EN-1001_ _mPro400GC_V1.2.0_aIVZ.fm, PL12EN

4 4 PL12EN PL12EN-1001_ _mPro400GC_V1.2.0_aIVZ.fm,

5 Workplace safety symbols Warning notes are identified by a signal word and a pictogram: The signal word describes the severity and the probability of the impending danger. The pictogram describes the type of danger. Observe these notes and proceed with special care in the situations described. Pass all safety instructions on to other operators. In addition to the safety instructions in these programming instructions, all local safety and accident prevention rules must be observed. WARNING! Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. CAUTION! Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury or property and environmental damage. If this warning is not observed, injuries, property or environmental damage may occur. ATTENTION! This pictogram identifies all references to potential electrical shock, alerting of hazards to life and health of personnel. This sign warns of a possibly damaging situation. If the note is not adhered to, the product or parts of it may be damaged. NOTE General notes include application tips and useful information but no hazard warnings. en01d441_bedingt.fm, PL12EN

6 1 Set-Up Guide 1 Set-Up Guide 1.1 Controller description The mpro400gc product line consists of three controllers; Master, Primary and Secondary. Primary - Controls up to sixteen (16) tools. This unit includes a servo. One (1) standard corded handheld or fixtured tool could directly connect. For further corded tools / fixtured spindles are Secondary controllers required. Master - Controls up to sixteen (16) tools. This controller does not include a servo. For corded tools / fixtured spindles are Secondary controllers required. Secondary - Controls one (1) corded handheld or fixtured tool. Must be used with a Master or Primary controller. Controller Order no. Controls up to ( ) tools Servo included Tool compatibility Primary mpro400gc-p AirLB 1) Cordless EC tool DGD-Intelligent-Spindles (BTS Series) 2) Master mpro400gc-m 16 Cordless EC tool DGD-Intelligent-Spindles (BTS Series) 3) Secondary mpro400gc-s AirLB 1) 1) Limited to 1 tool 2) Additional Hardware necessary. For programming mark Advanced > Controller Settings > Display Mpro Button. c01259.png Fig. 1-1 Controller Description 6 PL12EN en01d441_bedingt.fm,

7 Set-Up Guide General Information CAUTION! It is mandatory that national, state and local safety and wiring standards be followed during installation. These standards take precedence over any information presented in this section. To avoid the hazard of electrical shock or burn, the following instructions must be adhered to. Failure to follow these instructions may also cause damage to your unit and void existing warranties. Do not energize the unit until all connections have been properly made. Equipment must be properly grounded before applying power. Units energized by cord and plug must be connected to an approved and properly grounded receptacle. All units must be energized by an isolated line. The unit must always be closed and secured prior to energizing the unit. Ensure the power switch is in the off position prior to connecting the power cord. Though it is not mandatory, the following instructions are highly recommended for the protected operation of your unit. Use oversized feeder lines to reduce electrical noise and voltage drop. 1.3 Checking your unit Take time to ensure you have the required peripheral equipment and cables necessary to set-up and run your unit. If you do not have all the necessary items, contact your distributor. Refer to Fig. 2-2 for an illustration of your unit. 1.4 Software Your unit has been preloaded with software and requires no additional software to begin your fastening process. If you are interfacing your unit with an external computer, mpro-remote interfacing software is required. 1.5 Installing the Unit Assembly Each unit is used primarily as a single or multiple tool process/controller/monitor installed in a work station or work area. It may be wall mounted, beam mounted, suspended overhead or pedestal mounted. Always choose a stable location to avoid the possibility of unit damage and/or operator injury through hitting, falling, vibration or inconvenient mounting. All cables attached to the unit should be located and secured so that they cannot cause injury to the operator or to passersby. Like all electrical devices, the control system emit some heat. It should therefore be positioned where air can circulate freely around the housing. Refer to Fig. 2-3 for mounting hole dimensions Location considerations Your unit should be located to allow access to the front panel and connectors. The unit should be installed for unrestricted and comfortable viewing of the LCD screen by the operator. The LCD menu screen, key pad and connectors must be readily accessible for the set-up. Dependent on the peripheral equipment purchased, the unit may be located in a remote position but should still be accessible. Attachment of accessories and tools should also be considered with the installation locations. Items to be considered are: en01d441_bedingt.fm, PL12EN

8 1 Set-Up Guide Location of printer Attachment of a data collection unit, if desired. Attachment of remote annunciators, socket nest, or remote parameter select. Attachment of the unit in a network to a computer. Operation convenience/safety keep cables off the floor or dangling in operator areas Power source The controller requires a power supply connection of: VAC or VAC / Hz single phase / 1A Input current (rated), 16A (peak) Intended use The mpro400gc may be used only under the following conditions: Industrial EMC limit value class A Only cables of type authorized by Apex Tool Group may be used. Only accessory parts authorized by Apex Tool Group may be used. Unauthorized alterations, repairs and modifications are prohibited for reasons of safety and product liability EMC measures The filters required to satisfy the EMC regulations are built into the unit. The sealed control cabinet and shielded cable provide very good protection against irradiated and radiated interference. The tool complies with the following applicable EMC standards: - EN : EN 55011: EN : A1: A2: EN : A1: EN : EN : EN : EN : A1: EN :2004 This is a Class A device. The device may cause signal interference; in this case, the operator may be ATTENTION! required to implement suitable EMC measures. It is prohibited to operate the unit unless the control cabinet is closed. The properties of the shielding would change and the noise emission would increase. 1.6 Mounting the Controller 1. Loosen the two long mounting screws at the bottom of the controller so the mounting plate can be separated from the controller. See Fig Fig. 2-3 illustrates the bolt pattern for hanging the mounting plate on a wall. Note the hole size dimensions so the correct size bolts are chosen. Size ¼ or M6 bolts (4) should fit the mounting plate holes and support the controller. 3. Once the mounting plate is installed in its location the controller can be hung on the bracket utilizing the four studs protruding from the back of the controller. Once in place, the controller can be secured at the bottom using the two long screws removed in Step 1. 8 PL12EN en01d441_bedingt.fm,

9 Set-Up Guide Making Connections to the Controller 1. Connect the cable to the tool. 2. Connect the other end of the cable to the controller. The connector at the controller is an Air-LB connector and utilizes a push-pull style connector. Before attempting to attach the cable verify that the collar on the controller connector is pushed towards the controller. If the collar is pulled away from the controller the cable will not connect to the controller. Insert the cable connector and pull the collar away from the controller (towards the cable) to lock the cable in place. 3. Insert the power cord into the controller and into a 115 or 230 VAC power source. 4. Using the ON/OFF power switch at the front of the controller power the controller ON. en01d441_bedingt.fm, PL12EN

10 1 Set-Up Guide 1.8 Accepting a Corded Tool Fig. 1-2 Run Screen 1. When the controller has finished booting up it should advance to the Run screen. The screen is a touch screen. At the lower right corner of the screen press <Navigator>. c01210en.png c01209en.png Fig. 1-3 Navigator Screen 2. Press Navigator Menu > Tool Setup. 10 PL12EN en01d441_bedingt.fm,

11 Set-Up Guide 1 Fig. 1-4 Tool Setup Tool List 3. Touch the horizontal bar indicating the Primary tool to highlight it. Touch <Tool Settings>. c01212en.png c01211en.png Fig. 1-5 Tool Setup Tool Settings 4. Verify that the tool shown is the tool connected. Check the Model number and Serial Number. If the tool is correct press <Accept>. In the screen that appears press <Accept> for that screen. A screen will appear indicating that the settings are being saved. When the save process is complete, the Tool Setup - Tool List screen is displayed. Press <Navigator>. Advance to 1.12 Manual Programming, page 16 for programming instructions. en01d441_bedingt.fm, PL12EN

12 1 Set-Up Guide 1.9 Accepting a LiveWire Tool Live wire communication requires three items; Tool, Controller, and Access point. Each item will require an IP address. All the IP addresses will be similar in structure such as , , , etc. The access point will also have a SSID name, which will need to be entered in the controller. Hardware Connections 1. Connect the access point to the controller using the cable provided with the access point. The cable should be a crossover cable. Plug the cable into the X1 Ethernet port. See Fig Apply power to the controller and access point Network Settings Controller IP address: c01213en.png Fig. 1-6 Communications Network Settings 1. Select Navigator > Communications > Network Settings. 2. If not using server assigned addresses disable DHCP for Card One. 3. Enter the IP address and Subnet Mask that will be assigned to the controller. 4. Press <Navigator> key to accept entries. 5. Click <Accept> on the message screen that appears. The screen will return to the Navigator Menu then begin storing data. 6. A message will appear to restart the controller. 12 PL12EN en01d441_bedingt.fm,

13 Set-Up Guide RF (Radio Frequency) Settings Setting Up the LiveWire Tool Fig. 1-7 Tool Setup RF Settings 1. Select Navigator Menu > Tool Setup > RF Settings > IRDA Serial. Correct port depending on the port connected to at the base of the controller. (CON 1 and CON 2 are X4 and X5 respectively at the controller.) 2. If serial connectivity has been made the SSID, Encryption, and remaining fields will become available for programming. Enter a value for SSID. If Encryption is selected enter a Network Key and confirm it by re-entering it below the initial Network key entry. If DHCP is not being used select Use the following IP address and enter the IP address and Subnet mask. Press <Write RF settings> Tool Install c01211en.png c01215en.png Fig. 1-8 Tool Setup Tool List 1. Select Navigator Menu > Tool Setup. Press the screen at the tool number location you wish to install the tool. The row should highlight in orange. Position 1 is reserved for the Primary or corded tool. en01d441_bedingt.fm, PL12EN

14 1 Set-Up Guide Fig. 1-9 Tool Setup Install 2. Press <+ Install> and select the LiveWire w/wlan choice from the popup screen that appears. Enter the Live Wire IP Address for the tool. Without DHCP this should be the same address as entered in Step 2, RF (Radio Frequency) Settings, page 13. Using DHCP should same IP address as displayed on Tool display entered. Press <OK> and save the settings. c01217en.png c01216en.png Fig Tool Setup Accepting the Tool 3. Select Navigator Menu > Tool Setup > Tool Settings button. Verify the Model Number and Serial Number. If the information is correct press <Accept> at the bottom of the screen. Continue with saving settings. 14 PL12EN en01d441_bedingt.fm,

15 Set-Up Guide Programming a Basic Fastening Strategy Fig Tool Application Fastening Strategy Select Navigator Menu > Basic and the Basic Application Builder screen with appear. Verify that the Tool and Application are correct. Select a Fastening strategy, Torque Control/Angle Monitor or Angle Control/Torque Monitor. The parameters can be programmed manually or by pressing <Auto Program> Auto Programming (Torque Control / Angle Monitor Only) c01219en.png c01218en.png Fig Controller Settings 1. Before using the Auto Program feature select Navigator Menu > Advanced > Controller Settings and choose the desired Engineering units. Press <Navigator> to save settings. en01d441_bedingt.fm, PL12EN

16 1 Set-Up Guide Fig Torque Control/Angle Monitor 2. Select Navigator Menu > Basic > Auto Progr. Enter the desired final stage torque value using the virtual keypad. Press <Enter> to close the keyboard. Press <OK> from the Auto Program screen. Limits of ±15% will be provided. Parameters can be adjusted if needed. Press <Navigator> button to return to the Navigator Menu and save parameters Manual Programming c01219en.png c01220en.png Fig Controller Settings 1. Before programming the application select Navigator Menu > Advanced > Controller Settings and choose the desired Engineering units. Press <Navigator> to save settings. 16 PL12EN en01d441_bedingt.fm,

17 Set-Up Guide 1 c01221en.png Fig Manual Programming 2. Touch the Torque High Limit field and a keyboard will appear. Enter the desired High Torque value. Whole numbers do not require decimal points. They will be added automatically. Use the Tab key on the keyboard to move the keyboard to the next field. When finished, press <Enter> on the keyboard. Select <Navigator> and the screen will return to the Navigator Menu and begin saving parameters. en01d441_bedingt.fm, PL12EN

18 2 Controller specifications 2 Controller specifications d01222.png Fig. 2-1 System Overview 18 PL12EN en02d441_bedingt.fm,

19 Controller specifications 2 d01223_1.png Position Description Position Description 1 System Bus Connector 8 Serial Connector #2 2 Tool Connector 9 Anybus Fieldbus 3 Power Connection 10 Serial Connector #1 4 Mounting Bracket Screw 11 USB ports (2) 5 Mounting Bracket Screw 12 Ethernet Connector #2 6 I/O Connectors 13 Ethernet Connector #1 7 Anybus Fieldbus Fig. 2-2 Connector Locations en02d441_bedingt.fm, PL12EN

20 2 Controller specifications 1.825" (46.4 mm) " (33.4 mm) 10.38" (263 mm) " (197 mm) a01224.png " (31.8 mm) 14.88" (378 mm) " (318 mm) 0.075" (1.9 mm) (6.86 mm) (12.8 mm) (1.95 mm) Fig. 2-3 Mounting Information 20 PL12EN en02d441_bedingt.fm,

21 Controller specifications Technical Data Housing The Global Controller is factory sealed with external access to all connectors. The front of the unit has a USB and power switch. On the back of the enclosure is a cover plate that can be removed to access the Compact Flash card which contains all program data. This secondary level of access requires removing the controller from the mounting plate. All other connectors are located on the bottom of the enclosure. The mounting bracket has been designed to also assist with cable management. Model Weight* Width Height Depth lb kg in mm in mm in mm mpro400gc Primary/Master Configuration Display 10.4" TFT Liquid Crystal Display Touchscreen 800 x 600 resolution Keyboard No separate keypad is required. The touchscreen will provide a keyboard image on the screen that can be used for alphanumeric entry. A USB keyboard can also be connected to the unit and used for typing. Ports Compact Flash accessed through the back of the enclosure Any bus CC 2 x RS232 Serial Ports 3 x USB 2.0 Ports 2 x 10/100MBit RJ45 Ethernet Ports Discrete I/O 8 inputs / 8 Outputs / 2 +24Vdc / 2 GND Output Current: 500 ma per output, 2000 ma total en02d441_bedingt.fm, PL12EN

22 2 Controller specifications Pin 12 Pin 24 d01223_1.png Pin 1 Pin 13 Fig. 2-4 Primary / Master Pin Configuration Pin # I/O Description Pin # I/O Description 12 Out GND2 24 Out GND2 11 In Common GND 23 In Common GND 10 Output O Output O 07 9 Output O Output O 06 8 Output O Output O 05 7 Output O Output O 04 6 Input I Input I 07 5 Input I Input I 06 4 Input I Input I 05 3 Input I Input I 04 2 In Output Common O0-O3 14 In Output Common O4-O7 1 Out +24 V2 13 Out +24 V2 System Bus Connection Looking at Controller 1 PE 2 DATA-B 3 GND 4 +5VDC 5 DATA-A 6 N.C. 7 0VDC 8 +24VDC Input (Pins) Output (Sockets) Fig. 2-5 System Bus Connection 22 PL12EN en02d441_bedingt.fm,

23 Controller specifications 2 Note: The Primary configuration has an output connector only. The Secondary and Master configurations have both an input and output connector. AC power supply VAC or VAC Hz single phase 1 A Input current (rated), 16 A (peak) Secondary Configuration Pin 12 Pin 24 d01223_2.png Pin 1 Pin 13 Fig. 2-6 Secondary Pin Configuration Pin # I/O Description Pin # I/O Description 12 Out Common GND2 24 Out Common GND 11 In Common GND 23 In Common GND 10 Output O Output O 07 9 Output O 02 (Yellow LED) 21 Output O 06 8 Output O 01 (Green LED OK) 20 Output O 05 7 Output O 00 (Red LED NOK) 19 Output O 04 6 Input I Input I 07 5 Input I Input I 06 4 Input I 01 (Reverse) 16 Input I 05 3 Input I 00 (Start) 15 Input I 04 2 N. C. 14 N. C. 1 Out +24 VDC 13 Out +24 VDC Serial Port RS232 System Bus Connectors - 1 Male - 1 Female en02d441_bedingt.fm, PL12EN

24 2 Controller specifications System Bus Address Two rotary dials are used to manually set the address for System Bus Devices. Turn the dial until the desired number appears in the slot. The dial closer to the front of the unit is the most significant digit. The dial closer to the system bus connectors is the least significant digit. No two system bus devices can have the same address. After address change is a reboot required. AC power supply VAC or VAC Hz single phase 1 A Input current (rated), 16 A (peak) 24 PL12EN en02d441_bedingt.fm,

25 Programming 3 3 Programming 3.1 Navigator c01228en.png Fig. 3-1 Navigator Menu Application Builder <Basic> Allows the user to graphically select and program a two-stage rundown for Torque Control/Angle Monitor (SEQ 11 + SEQ 30) or Angle Control/Torque Monitor (SEQ 11 + SEQ 50) for any of the 99 Applications. The user only enters Torque, Angle, and Speed parameters in one screen. Other parameters such as timers, etc are automatically defaulted to predetermined values. <Standard> Allows the user to program up to a 6-stage rundown for any of the 99 Applications. Once the sequences are selected for each stage, the associated Torque, Angle, Speed, and Advanced parameters can be programmed. <Advanced> Allows the user access to the Matrix, Inputs, Outputs, Linking, Controller Settings and Tool Settings. <Run Screen> Takes the user directly to the display for Torque, Angle, and Status Indicator Labels. The Oscilloscope function used for diagnosing torque traces is also located in the Run Screen. <Communications> Allows the user to configure the Serial and Ethernet protocol data transmissions, the Part ID settings, and Network settings. <Tool Setup> Allows the user to install, uninstall, and configure tool settings. en03d441.fm, PL12EN

26 3 Programming <Archive> Chronological History are viewable from this screen. Data can be erased as well. <Diagnostics> Contains screens to determine if the system is functioning properly. <Utilities> Contains functions for upgrading or changing the system software. From the Utilities the user can update the mpro400gc application software, or install a new firmware version in the Tightening Module. <Administration> The user can load, save and configure system information. Administration functions include loading and saving the system configuration, setting date and time, setting password protection, and printing the system configuration, and selecting the application software language (English and German). From Administration > Counter screen, the user may view or reset any of the available counters. 3.2 Basic Allows the user to select a typical two-stage rundown where the first stage is a high speed rundown and the second stage is a different speed rundown that controls on either torque or angle. Fastening Strategies Torque Control/Angle Monitoring (SEQ 11/SEQ 30) or Angle Control/Torque Monitoring (SEQ 11/SEQ 50) are selectable from the drop-down list in the upper right hand corner of the screen. Once a Strategy is selected, the appropriate parameters will be displayed for programming. Basic Parameters for Torque Control/Angle Monitor: Trigger Torque [Nm] Torque to start collecting oscilloscope data. Turnoff Torque Stage 1 [Nm] Torque to change from stage 1 to stage 2. Threshold Torque [Nm] Torque to begin counting angle in stage 2. Torque Low Limit [Nm] Minimum acceptable torque. Turnoff Torque Stage 2 [Nm] Torque to turnoff the tool. Torque High Limit [Nm] Maximum acceptable torque. Angle Low Limit [Deg] Minimum acceptable angle. Angle High Limit [Deg] Maximum acceptable angle. Basic Parameters for Angle Control/Torque Monitor: Turnoff Angle [Deg] Angle to turnoff the tool. The rest of the Parameters are the same as Torque Control/Angle Monitor except Turnoff Torque Stage 2 is eliminated. Following are the acceptable ranges for each Parameter. 26 PL12EN en03d441.fm,

27 Programming Basic Application Builder Parameters Parameter Name Range Typical Fastening Strategy Torque Control/Angle Monitor Torque Control/Angle Monitor Fastening Strategy Angle Control/Torque Monitor Angle Control/Torque Monitor Trigger Torque [Nm] 0 to Tool Max 10% of Turnoff Torque Turnoff Torque Stage 1 [Nm] 0 to Tool Max As appropriate Threshold Torque [Nm] Turnoff 1 to Tool Max 50% of Turnoff Torque Torque Low Limit [Nm] -Tool Max* to Tool Max 90% of Turnoff Torque Turnoff Torque Stage 2 [Nm] Low Limit to Tool Max As appropriate Torque High Limit [Nm] Turnoff to 1.2 TQ-Cal. value 110% of Turnoff Torque Angle Low Limit [Deg] 0 to % of Turnoff Angle Turnoff Angle [Deg] Low Limit to 9999 As appropriate Angle High Limit [Deg] Turnoff to % of Turnoff Angle Speed Stage 1 [RPM] 0 to Tool Max 80% of Tool Max Speed Stage 2 [RPM] 0 to Tool Max 50 Backoff Speed 0 to Tool Max 50% of Tool Max NOTE Negative values may be entered by preceding the value with a dash "-". In the Basic Application Builder some parameters are not programmable and are also set to default values. These values are located in the Standard Application Builder. However, if the parameters are changed using the Standard Application Builder, then the Basic Application Builder does not reset them back to the default values Advanced Parameter Default Values Parameter Name Stage 1 Stage 2 Start delay time [ms] 0 0 Start spike time [ms] 0 0 Max. Fastening time [ms] End delay time [ms] 0 0 (30 with Auto Program) Torque Filter Factor 1 4 (1 with Auto Program) If an Application with more than two stages is required, or if a different Fastening Strategy has previously been selected for the Application than described above, the Standard Application Builder must be used. From the Basic Application Builder, the Auto Program feature is available by pressing <Auto Program> only when a tool is connected to the controller and if the application is not already programmed. <Auto Program> is disabled if there is no tool or if the application is programmed or if Angle Control/Torque Monitoring is selected. The Auto Program feature accepts the Stage 2 target torque. Pressing <Cancel> exits the auto program screen without saving changes. Pressing <OK> causes the auto calculations to be done and the results are displayed on the basic screen. From the Basic Application Builder, the user can copy the parameters of an application to one or more other applications by pressing <Copy>. From this dialog box, the user can specify the source and target tool and en03d441.fm, PL12EN

28 3 Programming application. When using Copy function from the Basic Application Builder, all stages of the selected application are copied. Multiple target applications may be specified by separating the application numbers with a comma. Ranges could specified with minus, e.g. 2,10 15, Standard 5 1 c01229en.png Fastening stage summary 2 Spindle status summary 3 Fastening stages 4 Activate spindle 5 PS settings summary Fig. 3-2 Application 1 Standard Application Builder The parameters for the rundowns are entered. Settings > Channel activation Activation of channels for the selected application. Settings > Fastening stages Activation and setup of fastening stages for the selected application. Groups > Fastening groups Setup of fastening groups (= time delay of channels) for more channel applications. 28 PL12EN en03d441.fm,

29 Programming Fastening stages summary The summary shows which fastening stages are to be run, displayed and printed out. The functions are displayed as active if they have already been activated for at least one spindle. Display and Print are only displayed if the stage is activated (green = activated, red = deactivated) Spindle status summary The summary displays which spindles are installed and which of the installed spindles have been activated. NOTE In the Spindle status summary, only spindles that were previously entered in the configuration for the programmable I/O are displayed. If installed spindles do not appear in the summary, the settings for the programmable I/O level must be checked. The availability (= spindle installed) indicates whether or not a measuring board is present (Hardware, green = available, red = selected but not available). Spindle activated (green = activated, gray = deactivated and yellow = deselected). Spindles are activated in the Settings > Spindle activation menu. NOTE Only activated spindles participate in the rundown in this application and are taken into account for the evaluation. Deselected spindles are considered in as much as a total NOK is output for them Activate spindle (Softkey) Determines which spindles are used in a application. The screen headline displays the application you are currently programming. The configuration (existing hardware) appears in the Activate Spindle screen. A spindle in the rundown sequence must be activated for a application in order to become part of this application and appear on the overall evaluation for the workpiece. The highlighted spindle (color background) can be activated or deactivated for the current application by using Spindle > Activate or Spindle > Deactivate>. Additionally, the spindle can be deselected with <Deselect spindle> or the <Stop> softkey, i.e. it does not participate in the rundown sequence and will be evaluated as NOK and linked to the overall evaluation App settings summary Displays parameters that apply for the overall application. Any name can be entered in the Application name field for the application identifier. Fastening groups are displayed if they have been activated for at least one application. They are then displayed in the first activated fastening stage. Transmit data depends on the software. This field displays which communication protocol has been installed. Statistics is displayed if they are activated for at least one spindle in this application. They are then displayed for the first spindle with the programmed fastening stage Fastening stages (Softkey) Includes programming for the entire fastening sequence and all relevant fastening parameters in the selected application. en03d441.fm, PL12EN

30 3 Programming c01230en.png Fig. 3-3 Fastening Stages The headline shows the application and the spindle you are currently programming. In each application each spindle used (activated) must be programmed in this way. Various copy functions reduce the effort required when making inputs. Fastening stages shows which stages are activated and which sequences are processed by the spindle selected in which stage. The <Activated> and <Deactivated> softkeys determine which stages are processed. In turn, this determines the number of stages of the normal rundown (max. six stages). Stages that are not required must be deactivated. In a rundown sequence, it does not matter which stages are processed and which are skipped. This allows the user to switch stages on and off as required during set-up. However, the number of each programmed stage is included in the rundown data documentation. This is why deactivated fastening stages are also recorded in the documentation. We recommend copying the stages after set-up to achieve an uninterrupted sequence, beginning from stage one. NOTE The activation of stages applies to the selected application, also for a releasing stage that may have been programmed, i.e. to all spindles. If you change one spindle, the change automatically applies to all spindles. Only the display of the programmed sequence is spindle-related. The Copy menu allows the user to copy the entire fastening program spindle by spindle. The individual fastening stages are programmed in the Fastening stages menu. Alternatively, you can press the softkeys for the individual fastening stages. NOTE Copying from this menu includes all parameters that have to be entered in subordinate screen, i.e. the entire fastening stage program of a spindle in this application. Release The releasing stage is used at the end of a rundown to prevent mechanic locking of the nutsetter, without unscrewing the joint. 30 PL12EN en03d441.fm,

31 Programming 3 The target values for the releasing stage are stored permanently in the control unit. If the <Release> is activated, the spindle automatically moves 3 degrees or 1/6 of the min torque of the last activated stage. The evaluation of the releasing stage is shown in the spindle monitor only. The rundown data of the releasing stage cannot be printed, even in the event of an error. An error in the releasing stage leads to incrementation of the NOK rundown counter. Fastening stage programming In the Fastening stage menu, you can select the fastening strategy, enter time parameters and specify the sequence control for touch ups and error handling. The latter can be selected via the Settings menu item or with the respective softkey. The application with its identifier, the spindle, the stage to be programmed and the sequence currently selected are shown in the summary. c01231en.png Fig. 3-4 Fastening Stage Programming NOTE The parameters entered in this screen automatically apply to all spindles in the respective stage. If you change one spindle, the change automatically applies to all spindles. For this reason select the stage, than Options > Select stage. The menu Select stage appears. The Copy menu transfer parameters that apply to all spindles to other stages. Display rundown data This function displays a fastening stage in the rundown data table. The spindle monitor is processed independently of this function. Print rundown data This function prints the results of this stage. en03d441.fm, PL12EN

32 3 Programming Number N The number N defines the rundown interval at which this stage is to be printed. The results for all spindles will be printed. If the stage is to be printed for every stage, N = 1 must be entered. NOK print This function prints all spindles in this stage with NOK results. If only spindles with NOK results are to be printed, enter N = 0. Stop NOK spindles If this function is activated, a spindle with an NOK result in this stage does not participate in the rest of the fastening sequence. Exception: in the event of error handling or touch up. If touch up or error handling have been activated, the rundown status at the end of fastening is identical to the status of this stage. If error handling or touch up results in an OK result, the spindle will continue to participate in the fastening sequence. If the function Stop NOK spindles is deactivated, a spindle with an NOK result in this stage continues to participate in the fastening sequence. Therefore, the NOK result in this stage is ignored in the overall result. In any case, the NOK fastening stage will be shown as NOK in the printout and the rundown data table. This is applied (mostly in pretightening) when it is assumed that the subsequent stage will either solve the problem or will also result in an NOK. NOTE The function Stop NOK spindles is not taken into account in the last stage performed for an OK/NOK evaluation. An NOK result in the last processed stage is evaluated as NOK in the total result, even if Stop NOK spindles has not been activated for that stage. The total result of the rundown of a spindle is therefore identical to the result of the last stage processed by the spindle. With one exception: If the last processed stage is an error stage, the total result is always NOK. The workpiece therefore remains NOK, even if the error stage has been completed successfully Fastening strategy programming c01232_1en.png Fig. 3-5 Rundown Programming 32 PL12EN en03d441.fm,

33 Programming 3 c01232_2en.png Fig. 3-6 Rundown Programming after pushing graphic button This summary shows the application with its identifier, the spindle, and the stage to be programmed. The sequence currently selected is displayed when you press <Sequences>; a different sequence can be selected here. The parameters to be entered are determined by the sequence selected. First select the sequence you want to use. The input fields for the fastening parameter are displayed automatically. The operator must then make the appropriate entries. Selecting Skip stage (drop-down list) allows the user to program the sequence without a fastening action in this stage for this spindle. This is also because of the general applicability of stage activation for fastening spindles. Fastening strategy and corresponding parameters Target values leading to the completion of a fastening stage are highlighted in yellow. When a shut-off criterion is reached, the spindle stops. The shut-off criterion is usually the target value (e.g. shut-off angle ANG). In the event of an error, shut-off is initiated by a monitoring value (e.g. ANGmax), the fastening time Tmax or another error (e.g. in the servo). The initial torque result is the value TQ reached at shut-off. If the torque should continue to rise during the dwell time (if programmed) due to the kinetic energy of the spindle, the highest value reached during the dwell time (peak value memory) is displayed and used for min/max evaluation. The initial angle result is the value reached at shut-off ANG. If further angle pulses occur during the dwell time in the preset direction of rotation for the sequence, due to the kinetic energy of the spindle, these are counted in and the total result will be displayed and used for min/max evaluation. The programmed direction of rotation depends on the sequence selected. Range of values The value ranges shown in the parameter tables of the sequences (see System description, Fastening technology) represent the general input ranges for the respective parameters. These ranges are checked upon termination of Rundown programming. en03d441.fm, PL12EN

34 3 Programming If a value is out of range or not plausible, the program displays an error message and returns to Rundown programming. Additional limitations result from process-related interdependencies of the parameters, e.g. minimum torque Tqmin must not be higher than maximum torque Tqmax. Both are also examined in a plausibility check when you exit Rundown programming. Another reason why input may be rejected is that it exceeds the value allowed for the spindle as defined in the spindle constants. NOTE The spindle constants must be set correctly. Refer to the spindle data sheets for the exact values. If the value range or the plausibility are violated, the user is alerted to the cause of the error. When fastening parameters are copied to another spindle, a plausibility check against the spindle constants of the target spindle is made. If an error occurs, the copying is terminated and an error message displayed. To ensure successful copying, you must either change the spindle constants of the target spindle or the parameters of the spindle currently selected. When fastening parameters are copied to all spindles, a plausibility check against the spindle constants of all these spindles is made. If an error occurs, an error message is displayed. If a spindle shows values that are not plausible, the program suggests to stop copying or to continue nonetheless. Subsequently you must either change the spindle constants or the parameters for the target spindle. The parameters are copied to all other spindles. Programming for fastening timing The timing automatically applies to all spindles in the respective stage of the selected application and fastening group. If you change the timing, it automatically applies to all spindles in the respective stage of the selected application and fastening group. The Copy menu transfers timing parameters that apply for all spindles to other fastening stages or applications. NOTE Copying parameters to other fastening groups is not possible. 34 PL12EN en03d441.fm,

35 Programming 3 c01233en.png Fig. 3-7 Fastening stage timing Range of values When Fastening stage timing is completed, the entered parameters are checked for agreement with the permitted value ranges. If a value is out of range, the program displays an error message and returns to Fastening stage timing. Parameters Fastening time (Tmax) ,000 Start delay time (TD) 0 60,000 Start pulse suppression (TS) Marking time (TC) 0 60,000 Dwell time (TN) Explanation Fastening time for the maximum duration of the rundown. TD (start delay time) and TN (dwell time) are not monitored by Tmax. Tmax > TS + fastening time + TN The fastening time begins with spindle start. If no shut-off criterion is reached at the end of the fastening time, the sequence is terminated (safety shutdown) and evaluated NOK (Tmax: Terminated because Tmax is exceeded). Tmax must always be higher than 0. The shut-off criteria are constantly checked, not only after timeout of Tmax. Delay time before spindle start. The start delay time at the beginning of the stage allows wait time to be programmed between stages. If grouping is activated, the delay time will not be available here, because this parameter will be defined for the entire group. Time beginning with spindle start, during which the torque is not recorded. For safety reasons, the calibration value is continuously monitored to ensure it is not exceeded. During startup, the inertia moments in the spindle generate a torque impulse at the transducer. To avoid misinterpretations in the rundown sequence, this should not be measured and evaluated. Time for color marking after OK rundown. At the end of an OK rundown, the output "Color" at the I/O level is set for the marking time programmed in the last stage to be processed. The output is designed for direct control of a color marking system for OK rundowns. The marking times of the other stages will be ignored. Measuring time after shut-off of the spindle. The kinetic energy of the spindle may cause it to continue rotating after shut-off, which increases torque and angle and continues measurement during the dwell time. During the dwell time, only the peak torque is detected and angle pulses are counted only for the nominal rotation direction! en03d441.fm, PL12EN

36 3 Programming Extended NOK Strategy Touch up / Error handling The NOK strategy comprises touch up and error-handling. Another fastening stage may be started after a touch up, while error-handling leads to the end of the process. This allows joint backoffs in the touch up routine and these can be retightened in the further fastening sequence to achieve an OK rundown. Since no further stage can follow the error-handling routine (the fastening sequence is terminated with NOK) it is often used to fully backoff the fastenings. Touch up and error handling can be programmed separately for each fastening stage, i.e. group assignments and backoff parameters can be entered in each stage for both touch up and error handling. Touch up is performed immediately after the completion of a fastening stage. Error handling can be initiated by any fastening stage, but will be performed after the last fastening stage using the stage-related backoff parameters. Performance features Groups can be programmed for touch up and error handling. Subsequent to touch up a preset stage may be started. Error handling leads to the end of the process. Separate backoff parameters can be programmed for each fastening stage and for both touch up and error handling. Each spindle can be assigned to more than one touchup group. 3.4 Advanced Matrix c01234en.png Fig. 3-8 Application Matrix The Application Matrix is a display matrix of 99 Applications vs. 6 Stages displaying the selected Sequence number for each stage. It gives the user an overview of controller programming in a single screen. The arrow following the sequence number for a stage indicates the direction of rotation (> for clockwise; < for counterclockwise). 36 PL12EN en03d441.fm,

37 Programming Inputs Each of the physical inputs 0 7 can be programmed to have one of the following definitions: Not Used Tool Enable Tool Start External Tool Start Tool Reverse External Tool Reverse Application Select 0 Application Select 1 Application Select 2 Application Select 3 Application Select 4 Application Select 5 Application Select 6 Application Select 7 Reset Linking Unused When active, allows the tool to run in conjunction with Tool Start. Starts the tool. Allows external input to control the start of the tool. When active, causes the tool to run in the counterclockwise direction using the Backoff strategy. Allows external input to control tool running in the counterclockwise direction. Application Selects 0 7 are used to select Applications 1 99 using a binary count of 1 99 where Application Select 0 is the least significant bit. When Linking is activated, the Tightening Group is selected with these inputs. When active, Linking (batch counting) is reset to position one Outputs Not Used OK NOK Cycle Complete Linking Complete Linking OK Linking NOK Confirm App. Sel 0 Confirm App. Sel 1 Confirm App. Sel 2 Confirm App. Sel 3 Confirm App. Sel 4 Confirm App. Sel 5 Confirm App. Sel 6 Confirm App. Sel 7 Unused Active if Torque/Angle/Yield are within programmed limits. Active if Torque/Angle/Yield are outside limits or some other error has occurred. Active when a rundown has ended and there are status outputs to report Active when rundowns of all positions of the selected batch group are complete Active if all positions of Linking were OK Active if one or more positions of Linking were NOK Confirm application Selects 0 7 are used to indicate the currently selected applications 1 99 using a binary count where Application Select 0 is the least significant bit. en03d441.fm, PL12EN

38 3 Programming Linking c01235en.png Fig. 3-9 Linking Linking allows the user to automatically change from application to application for a predefined number of positions (cordless EC tools up to 40, corded tools up to 96). Each application is run when the start switch on the tool is activated in the order specified by its position. Upon completion of the cycle, the application will then automatically change to the next position. Up to 32 different linking strategies called Tightening Groups can be programmed. This feature can also be used for Batch Counting by entering the same application in the desired number of positions. To set-up a linking strategy, a Tightening Group 1 32 should be selected and given a name. This will designate which linking strategy is being used. The user can also program if the linking strategy should reset to position 1 after an NOK or set the number of times a fastener can be retightened after an NOK before advancing to the next position. If Part ID is activated then entering a new Part ID will always reset to position 1. To configure linking, an Application 1 99 must be associated with a position in the linking strategy. To do this, the user must enter App (1 99), and can also provide a Fastener ID and Position Name. Pressing <Add> will place the selected application in the user-specified position of the linking strategy. Pressing <Delete> will remove the user-specified position from the linking strategy. Once Linking is enabled, the controller will automatically run from position 1 to the last programmed position. Note that the tool start switch or remote start input will have to be toggled between positions. The Tightening Group and Position will also be displayed on the Run Screen. The following inputs and outputs will also be active when Linking is enabled: Linking OK, Linking NOK, Linking Complete, and Reset Linking. Please refer to the Inputs and Outputs section for more information on these signals. 38 PL12EN en03d441.fm,

39 Programming Controller Settings c01219en.png Fig Controller Settings Name Number Torque Units Allows the user to assign a name to the controller. Allows the user to assign a number to the controller. Allows the user to change the units for the controller. Available units are Nm, FtLbs, InLbs, dnm. <Navigator> anklicken und die Änderungen bestätigen. Special Function for LiveWire Tools as of installed software version S For an extremely long fastening sequence: Brake-Rope Adjust Mode <Advanced Settings> Allows the extension of the angle parameter (Min. angle, Shut-off angle, Max. angle) to 24,000 angular degrees (see Navigator menu > Basic) If this function is deactivated, angle parameter is reset to 9,999 angular degree. Input of time frame in seconds, in which an aborted fastening sequence can be continued. The LCD display of the tool shows the countdown until the final abort. If the 24,000 angular degrees are exceeded by cumulation over several stages, the last 24,000 angular degrees will be transferred. If the threshold torque of a partly completed stage is not within the last 24,000 angular degrees, the stage will not be transferred. en03d441.fm, PL12EN

40 3 Programming Tool Settings c01236en.png Fig Tool Settings Tool name Max Number of Rejects Release Method Allows the user to give the tool a name. This name will be displayed in all Tool drop down lists. Allows the user to enter the maximum number of rejects that will be permitted before a release signal is required. If 0 is entered, the function is disabled. Release on Backoff allows the user to release the tool by running the tool in reverse. Release Input Toggle allows the user to set a low-high-low pulse of the Reject Release input as a release signal. 40 PL12EN en03d441.fm,

41 Programming Run Screen c01209en.png Fig Run Screen From the Run Screen the user sees rundown data as it occurs. The Torque and Angle readings are displayed with a background color corresponding to the status of each. The background is red if the value is too high, yellow if it is too low, and green if it is within limits. The current tool model number, station name, and indicator labels are also displayed. The desired Application (1 99), Tightening Group (1 32, if enabled), and Part ID (if enabled) are selectable using the keypad. When enabled, the Part ID and Part ID Status boxes are displayed below the Tool and Application. When allowed, the Part ID edit box may be used to manually enter a Part ID using the keypad or an attached keyboard. NOTE When manually entering a Part ID, the <Enter> key must be pressed to validate the entry. Function Indicates the status of Part ID Data Function (screen in the middle): LED Data function Status Red Not configured Part ID Data Function is configured to None. Yellow None Part ID Configure Data is enabled, but the Part ID is invalid or does not match any Configure Data entries. Green Function XYZ Part ID Configure Data is enabled, and the current Part ID has engaged function XYZ (see Communications Part ID help screen for function definitions). en03d441.fm, PL12EN

42 3 Programming Input Status Indicates whether or not a new Part ID can be entered (screen above). LED Data function Status Yellow Accepting Part ID input A new Part ID may be entered. Red Not Accepting Part ID input A new Part ID may not be entered. A new Part ID may not be entered when the tool trigger is active. Red NEW INPUT IGNORED! This status is displayed if a new Part ID is entered while Not Accepting Part ID input is true. Green Barcode valid A valid Part ID is available Below the Torque and Angle display is the Status screen. This screen displays various messages related to the tool, rundown status, or errors. The <Oscilloscope> soft key displays the Oscilloscope function for evaluating Torque and Angle curves. It is automatically updated after each cycle. The Run Screen may be optionally configured to display Rundown Details or Counter information as shown (see Fig. 3-13). These options are available by pressing the <Configure> soft key. Counter information is available for individual spindle groups. See Administration > Counters. The rundown details include the application number, the stage number of the Torque/Angle results currently displayed, the total number of stages in the application, and the rundown status summary (Good, A>, Tq<, etc) Run Screen Configuration c01238en.png Fig Run Screen Configuration Run Screen > Configure allows customization of the Run Screen display. The user may select the display of counter information and/or rundown details. The counters are activated and reset using the Administration > Counter display. The <Station Name> checkbox enables the display of the station name, as entered in Advanced > Controller Settings. 42 PL12EN en03d441.fm,

43 Programming Oscilloscope The Oscilloscope function displays a Torque curve after each complete rundown in the tightening direction. The curve is colored in alternating red (pink) and blue lines to indicate the different stages. A green box is also displayed on the trace to indicate the torque and angle limits. There is a data point for each degree of angle rotation Archive The Archive allows the user to display the last rundowns with automatic update after each new rundown. 3.6 Communications Data Transmission c01239en.png Fig Data Transmission Serial and Ethernet communications can be configured. en03d441.fm, PL12EN

44 3 Programming Serial Protocol None, AVIS, PFCS Port COM1, COM2 Baud Rate 2400, 4800, 9600, 14400, 19200, 38400, 57600, Data Bits 7, 8 Parity None, Odd, Even Stop Bits 1, 2 Flow Control None, Hardware Ethernet Protocol None, Standard, Standard Plus, WinSPC, CooperNet, PFCS The Ethernet settings are Server IP Address Port Address Enable See your network administrator for proper settings Part ID c01240en.png Fig Part ID Part ID allow the user to specify the interface and functionality of the Part ID used on the Run Screen and archived with the rundown data. Changes to the Part ID and Configuration Data edit screens are saved when the Communications screen is exited (<Navigator> button pressed). At this time the request to save the configuration is confirmed with a password dialog box. The Part ID may be entered manually from the run screen, input using a barcode reader attached to a serial port, input using the barcode reader on the LiveWire tool or transmitted through a FieldBus. A Part ID may consist of any sequence of Alphanumeric characters, including spaces. 44 PL12EN en03d441.fm,

45 Programming 3 Settings Enabled Part ID Source Number of Chars. Keypad Entry Defines the level of functionality of the Part ID No: The Part ID interface is completely disabled. No Part ID information is present on the Run Screen. Yes: The Part ID interface is enabled and is present on the Run Screen. A valid part ID is NOT REQUIRED to run the tool. Following a rundown, the Part ID is archived with the rundown data. - <Advance Serial Settings> If you choose Yes at the drop-down menu Enabled the button <Advanced Serial Settings> appears. It defines the serial port used to interface to the barcode reader. NOTE: The default port for the serial barcode interface is COM2. Port COM1, COM2 Baud Rate 2400, 4800, 9600, 14400, 19200, 38400, 57600, Data Bits 7, 8 Parity None, Odd, Even Stop Bits 1, 2 Flow Control None, Hardware Yes, interlocked: The Part ID interface is enabled, and is present on the run screen. A valid Part ID is REQUIRED to run the tool. Following a rundown, the Part ID is archived with the rundown data. Following either a good rundown (linking disabled) or good linking sequence (linking enabled) the Part ID is invalidated and the tool is disabled. Defines a source of the Part ID. Serial port (i.e. Barcode reader) FieldBus Protocol (e.g. FEP) Key Input Only Scanner on tool The barcode scanner on the tool is activated by pressing the start button. - If a barcode is the condition for a rundown to be started, the barcode scanner is activated as soon as the start button is pressed. If the barcode has been read successfully, pressing the start button again starts the fastening sequence. - If a barcode is not a condition to start a rundown, you can use the menu scanner or the programmable left function key <F1> on the tool to manually activate a read cycle. Afterwards, the barcode scanner is activated whenever the start button is pressed. If the barcode has been read successfully, pressing the start button again starts the fastening sequence. If the barcode has been read successfully, the acoustic signal beeps for 500 ms. If the barcode cannot be read within 3 seconds or there is an interruption by opening the start switch, the acoustic signal emits 3 beeps in rapid succession. Defines the length of the Part ID, not including any termination characters which may be sent by the barcode reader. 1 to 25 are valid values. Only barcodes in this length are accepted. 0: All barcodes are accepted without bounds checking. Defines whether or not a Part ID can be entered manually Allowed: A Part ID can be entered manually by highlighting the Part ID box on the Run Screen and typing from the keypad or an attached keyboard. Disallowed: The Part ID can not be entered manually from the run screen. en03d441.fm, PL12EN

46 3 Programming Special Function Allows the tool functionality to be automatically controlled based on the Part ID. Disabled: The Part ID characters have no control over the tool functionality. Note: Setting this option to Disabled does NOT cause Configure Data table entries to be lost. Enabled: The Position/Value pairs on the Configure Data screen may be used to control the tool functionality. The user may enter Position/Character pairs with associated functions to control the tool based on the part ID. - <Configure> If you choose Enabled at the drop-down menu Special Function the button <Configure> appears. A user can set-up barcode masks. c01265en.png <New> <Insert> <Change> <Delete> <Copy> Insert a new barcode mask. Workpiece Description - An identifier for the selected mask. Barcode Mask - The mask from which we wish to select the data function. Alphanumeric characters are accepted, "#' is treated as don't cares. Comparing the line of the barcode table with the read in barcode, the passages marked by "#" are excluded. Barcode Function - Used to select what happens when a barcode matching mask is scanned. Use Application X (1-99)- use program X when barcode is scanned. Use Linking Group X (1-32)- use tightening group X when barcode is scanned. Tool Enable - enable the selected tool when barcode is scanned. Tool Disable - disable the selected tool when barcode is scanned Insert a new mask above the previously entered mask. Edit a mask. Removes a mask. Copies data of the currently set tool group to the requested tool group. 46 PL12EN en03d441.fm,

47 Programming Network Settings c01241en.png Fig Network Settings The Network settings tab is used to configure how the controller will communicate over a network. The Ethernet settings are Default Gateway Domain Suffix Primary DNS Secondary DNS Enable DHCP IP Address Subnet Mask Contact your network administrator for proper settings. en03d441.fm, PL12EN

48 3 Programming 3.7 Tool Setup For accepting a tool see 1.8 Accepting a Corded Tool, page 10 and 1.9 Accepting a LiveWire Tool, page Tool List c01211en.png Fig Tool List The Tool List displays installed tools, and gives a user the ability to install, edit and uninstall tools. Tool List Table: Tool Type Name Status Serial Number Tool Model Displays the associated tool's number. This number is assigned by the user once a tool is installed. Identifies the type of tool associated with the assigned tool number. Primary: the corded tool associated with a Primary unit LW: < IP address >: the LiveWire tool and matching IP address associated with a LiveWire tool installed on a Master or Primary unit Secondary: the corded tool associated with a Secondary unit paired to either a Master or Primary unit Column displays the user assigned name of a tool at installation Column displays the state of a given tool Online: tool is installed and ready for use Needs User Acceptance: tool is installed and waiting for user acceptance Not Compatible: tool is not supported by the controller Tool Not Connected: LiveWire tool is installed, but not online Servo Not Connected: tool is installed, but the secondary unit is not attached Displays the installed tool's serial number Displays the installed tool s model number Tube-Nut Tool The automatic selection of a tube nut tool depends on a 'T' in the tool model number. That means, if a 'T' appears in the model number a tube nut tool is expected. Every other trigger pull return a tubenut tool to the home position. 48 PL12EN en03d441.fm,

49 Programming 3 <RF Settings> <RF Settings> button brings up the LiveWire configuration application. Communication With Tool - IRDA off: IR communication with LiveWire tool is turned off - IRDA Serial: IR communication with LiveWire tool is set-up through the selected - IRDA Gateway IP: IR communication with LiveWire tool made through a Ethernet gateway. Tool Identification - Update Info: Refresh tool data - Software Update: Used to update software of a LiveWire tool - Enable Diagnostic: Enable diagnostics mode on a LiveWire tool. NOTE This option will clear the tool's memory. <Tool Settings> See 3.7.2Tool Settings <Install> Allows the user to install either a LiveWire tool or a corded tool attached to a Secondary unit. Corded tools attached to a Primary unit are installed automatically. <Edit> Is used to reconfigure set-up options for a given tool. <Uninstall> Allows the user to remove a tool from the unit's tool list Tool Settings c01212en.png Fig Tool Setup The <Tool Settings> button allows the user to view the tool's memory. The Tool memory data is displayed for the selected tool. The Torque Calibration (±20% of nominal) is editable, in order to correct the torque calibration of the selected tool. en03d441.fm, PL12EN

50 3 Programming 3.8 Archive c01244en.png Fig Archive In the archive, all rundown data is saved in a ring buffer. The number of entries it can hold depends on the number and scope of the individual archived rundown sequences. Approx. 400 rundown sequences with no archived graphics or 100 rundown sequences with archived graphics can be saved. The required memory capacity depends heavily on the plotted curve length (plotting begins at the trigger torque). To help locate lines, the current position is displayed in the headline. A rundown sequence can be selected by touching the relevant line on the touch screen. The selected rundown can be further analyzed using the spindle monitor and, if graphic data has been recorded, with the graphics display. Additional rundown information can be viewed for a rundown by selecting the Graph button. Further rundown data stored on the flash memory and visible by selecting the HD button. 50 PL12EN en03d441.fm,

51 Programming Diagnostics c01245en.png Fig System Test Inputs/Outputs <Data Transmission> Allows the user to analyse Serial and Ethernet data transmission. <System Bus> A Map of all available Arcnet users is displayed by node, status, ID, serial number, and software version. <I/O-Level> A light box for each available input and output is displayed to show the current status. Active input and output signals are highlighted. You will find a detailed description of these signals under Advanced > Inputs, Advanced > Outputs Tool <TQ Calibration> This test function cyclically recalibrates the system. The start switch must be released for this function! The values "Offset Voltage" and "Full Scale Voltage" of the torque transducer are displayed. If a value is out of tolerance, it is shown in red. NOTE Entering a password and viewing of a warning is required prior to running any "active" tool diagnostics. Measurement Rated Value Tolerance Offset Voltage 0 V ±200 mv Full Scale Voltage 5 V ±150 mv en03d441.fm, PL12EN

52 3 Programming <Angle Encoder> The button <Start> starts the spindle with a speed of 30% of the maximum. After one revolution of the output shaft (set angle 360 deg), measured with the tool resolver, it is stopped. During a permanently set dwell time of 200ms any further angle pulses occurring are traced. The total result is shown as Actual Angle. The Shutoff Torque displayed is the torque prevailing at shut-off or the maximum value reached during the dwell time if that value is higher than the torque at shut-off. If the test run is not terminated by a monitoring criterion, the total result equals or is higher than 360 degrees and is evaluated as OK. Monitoring criteria are the torque of transducer 1 and a monitoring time. If the torque of transducer 1 exceeds 15% of its calibration value (even during the dwell time), or if the monitoring time of 5 seconds is elapsed, the test run is terminated with NOK. The user must check, if the output shaft has actually turned by the value indicated (e.g. put mark on the spindle). If the angle reached by the output shaft does not agree with the value displayed, either the angle factor is or the resolver is defective. <Voltages> The table displays the measured voltages of a channel. These are the most important supply voltages on the voltages on the measuring board, required for proper torque and angle measurement. Therefore, these must be monitored continuously. If a voltage is out of tolerance, it is shown in red. Designation Voltage Corded tools Fixtured spindles Rated Value Tolerance Rated Value Tolerance Logic +5 V ±0.3 V +3.3 V V/-0.06 V Pos. analog +12 V ±0.6 V +12 V ±0.6 V Neg. analog / Pos. Supply -12 V ±0.9 V +24 V ±3.6 V <TQ Measurement> This test function recalibrated the system with the values used immediately before the start of a rundown. The spindle must therefore be free from load when this function is called! Then the tool is started at zero speed and the torque is continuously measured and displayed. The field Current torque displays the current torque, Peak torque displays the highest value measured since the start of the function. If Redundancy is activated, the values of the second transducer are also displayed. <RPM> When you press <Start>, the spindle starts with maximum speed. The current output shaft speed is displayed. To achieve this, the angle factor must have been entered correctly, since the integrated speed measurement is derived from the resolver signals. When you release the start switch the spindle stops. As a safety function the torque is monitored by the tool transducer. If it exceeds 15% of its calibrated value, the tachometer function is terminated. 52 PL12EN en03d441.fm,

53 Programming Utilities Installed Versions Fig Utilities, Installed Versions Displays the installed controller software version Software Update c01247en.png c01246en.png Fig Utilities, Software Update Allows to update the controller software and the tightening module software. en03d441.fm, PL12EN

54 3 Programming System Settings Fig System Information <System information> displays information pertaining to the controller. It allows the user to select specific information or display all information Administration c01250en.png c01249en.png Fig Administration 54 PL12EN en03d441.fm,

55 Programming Counters Fig Counters The counter allows the user to count the number of OK and NOK rundowns. This data will be displayed on the Run Screen Print c01252en.png c01251en.png Fig Print Parameters Selecting the <File> option saves the selected print data in a file. The file name should have a maximum of 8 characters, not including the file extension. The other items allow the selection of parameters that are to be printed. Individual applications and fastening groups can be entered in the Applications and Spindle groups fields. NOTE Corresponding programming may result in a larger printout (>100 pages) and could take some time. When printing text from a file, the printout cannot be terminated. en03d441.fm, PL12EN

56 3 Programming Date / Time Fig Date / Time Each parameter that the mpro400gc saves with the date or time refers to the realtime clock. This is the case e.g. for the rundown process time. The setting must therefore be checked regularly. Date and time must be entered in the required format. The format depends on the language selected. When you press the green check button, all values in the input field are adopted by the mpro400gc realtime clock Touch Calibration The touch screen can be recalibrated by activating this function. Please follow the instructions as they are displayed on the screen. You must touch several displayed items until they are highlighted green. This redefines the coordinates and therefore completes the reconfiguration process. The recalibrated settings can then be tested, saved or discarded Data Export c01254en.png c01253en.png Fig Generating CSV File Data export allows the user to export rundown data to a file. 56 PL12EN en03d441.fm,

57 Programming Users Fig Users Access to the functions and parameters can be protected by registering users and allocating access rights. Ten different users can be registered. Password protection is deactivated if no users are registered. A password prompt will not appear for any function. Password protection is only activated when a user is registered. A user identification name is always required for service functions Load Parameters c01256en.png c01255en.png Fig Load Parameters The data can be loaded from the internal data storage facility (CF card) or a connected USB drive. Selecting a file and confirming loads the parameters. Parameters loaded from file are transferred to the main memory of the station and are available as current fastening parameters. This should only be done between two rundowns, not while a workpiece is being processed. The "Transfer to station" must therefore be confirmed separately after the parameters are loaded from the file. Two safety prompts will appear. After then same message as during programming will appear. en03d441.fm, PL12EN

58 3 Programming Save Parameters Fig Save Parameters All settings and parameters are saved during the data backup. The backup can be performed for all or only for individually selected parameters and settings. The data can be saved on the internal data storage facility (CF card) or a connected USB drive Factory Reset c01258en.png c01257en.png Fig Factory Reset All settings and parameters are cleared and returned to the factory settings. All data, such as Archive data, Communication settings, Application parameters, Tool settings, and Advanced settings will be deleted. The controller must be restarted Screen Saver The screen off timer can be set to the number of minutes the screen backlight will remain activated while the controller is idle. The backlight is turned off when the timer expires. The backlight is reactivated whenever a keypad key is pressed, an external input signal is changed, or when the tool is started. Setting the screen off timer to 0 minutes will keep the backlight activated indefinitely. It is recommended that the timer be activated so that the backlight lifetime can be extended. Uncheck the Activate screen when tool I/O changes box if the screen backlight should be turned on only when a keypad button is pressed or a keyboard key is pressed. Otherwise, any change in external I/O (e.g. tool enable, tool start) will turn on the screen and reset the screen off timer Language Select the language for the user interface. Available languages: English, German, Spanish and Chinese. 58 PL12EN en03d441.fm,