MFC-EN Ethernet-I/P Fieldbus expansion Unit AFC3000E-FB-EN-2

Transcription

1 MFC-EN Ethernet-I/P Fieldbus expansion Unit AFC3000E-FB-EN-2

2 Revision History Ethernet-I/P Fieldbus Expansion Unit Revision Date Manual No. Contents of Revision 08/20/2014 AFC3000-FB-EN-1 First Release 02/18/2016 AFC3000-FB-EN-2 Added Message Write Data info (pg ) 01/19/2018 AFC3000-FB-EN-2 Minor revision - Message Output formats fixed (pg.13-24) Manual Numbering Convention AFC3000E-FB-EN-1 DSP1500 = = Servo Servo Press Press AFC1500 AFC3000 = = Nutrunner FUSION = DC DC Hand Hand Tool Tool E = English Version S = Spanish Version *Japanese Version furnished by DDK uses DDK numbering convention. Version Number (Major Revision Level) CC = CC-Link DN = DeviceNet PB = Profibus PN = ProfiNet EN = Ethernet-I/P HW = Hardware Operation Manual SW = Software Manual FB = Fieldbus Manual Any questions regarding the contents of this document or any related matter should be directed to FEC Automation Systems at (586) , faxed to (586) or ed to support@fec-usa.com. The information set forth in the following document is the property of FEC Automation Systems. This document shall not be released to or copied for any person and/or organization without the expressed prior consent of FEC Automation Systems. Unauthorized reproduction or distribution of this manual is strictly prohibited. Please contact FEC Automation Systems if you require additional copies. PAGE 2

3 Forward Ethernet-I/P Fieldbus Expansion Unit This manual is intended as a supplement to the AFC3000 Hardware Operation Manual and should be used in conjunction with information provided in that manual. FEC recommends reading that manual before the contents of this manual (which only applies to systems requiring the optional Ethernet I/P interface). Ethernet-I/P The AFC3000 Ethernet-I/P System conforms to the open field network Ethernet-I/P. Control of tools and transactions of message information are executed by Ethernet-I/P explicit message communication. Due to conformance with the open field network Ethernet-I/P System, connections with Ethernet-I/P devices (master/slave) of other manufacturers are enabled. Also, remote I/O communication and message communication can be executed at the same time. System Structure (Ethernet-I/P) PLC (Ethernet-I/P Master Station) Remote I/O Communication Message Communication Ethernet-I/P Slave Station MASTER (1st Spdl.) Ethernet-I/P Slave Stations of Other Manufacturers 2nd Spdl 3rd Spdl 32nd Spdl SLAVE AFC3000 Ethernet-I/P System PAGE 3

4 Description of the Hardware (Ethernet-I/P) Module Status LED Link/ Activity LED Ethernet-I/P Connector Network Status LED PAGE 4

5 EDS File An EDS file is an information file related to the communication specifications of Ethernet-I/P compatible device and a separate, individual file exists for each device. The EDS file is necessary for using the Ethernet-I/P configuration software to connect the MFC-EN and the PLC. The EDS file is included in the installation CD for the AFC3000 User Console or may be downloaded from the FEC website. Please refer to the instruction manual for the Ethernet-I/P configuration software concerning the appropriate method for using the EDS file. Module Pin Configuration No. Signal Description 1 TD+ Send data + 2 TD- Send data - 3 RD+ Receive data Not used. 5 - Not used. 6 RD- Receive data Not used. 8 - Not used. 1 8 * The cable is not included with the equipment. Please prepare a LAN cable of Category 5e or higher on your own equipment. Please prepare these on your own. Caution Be sure to connect the cable with all power turned OFF. PAGE 5

6 List of LED Indications The module LEDs indicate the states of the nodes of the AFC3000 Ethernet-I/P System and the network state. A : Network Status LED B : Module Status LED C : Link Activity LED A B C LED Color State Details Network Status LED Module Status LED Link Activity LED Off Off Offline Offline, No power or no IP address Green Red Lit up Online Online, One or more connections established Flash Communication not established online, connection is not establishe Lit up Flash Error Connection timeout Fatal error has occurred. / Conflicting IP address. Off Off Power OFF Power is not supplied. Green Red Off Green One or more connection timeout has occurred Lit up Online Controlled by a scanner in RUN state - Communication Incomplete / wrong configuration or scanner in Flash not established idle state Lit up Error Major Fault -A critical error has occurred. Flash Error A recoverable error has occurred. Off Link not ETHERNET link is not established and established communication is not performed. Lit up Link Established ETHERNET link is established but not communicating Flash Communicating ETHERNET link is established and communication is in progress. PAGE 6

7 I/O Signal Specifications (Ethernet-I/P) Maximum Setting Standard Setting MASTER Spindle PLC I/O Input/Output PLC MASTER Spindle MASTER Spindle PLC Message Input/Output PLC MASTER Spindle 32bytes (256 points) 12bytes (96 points) 2048 word (4096 bytes) 16 word (32bytes) 32bytes (256 points) 8bytes (64 points) 2048 word (4096 bytes) 16 word (32bytes) AFC3000 Ethernet-I/P System Signal Specifications (PLC MASTER Spindle) Number of MASTER Spindle Input Points 4 words 8 bytes (256 points) Input signals are factory set and cannot be changed. Word No. BIT Signal Word No. BIT Signal 0 STOP 0 SEQ SELECT No.17 1 RESET 1 SEQ SELECT No.18 2 REVERSE 2 SEQ SELECT No.19 3 START 3 SEQ SELECT No.20 4 SEQ SELECT BIT 0 4 SEQ SELECT No.21 5 SEQ SELECT BIT 1 5 SEQ SELECT No.22 6 SEQ SELECT BIT 2 6 SEQ SELECT No.23 No.01 7 SEQ SELECT BIT 3 7 SEQ SELECT No.24 8 SEQ SELECT BIT 4 No.03 8 SEQ SELECT No.25 9 CYCLE COUNT UP 9 SEQ SELECT No CYCLE COUNT CLEAR 10 SEQ SELECT No SEQ SELECT No. ENABLE 11 SEQ SELECT No INPORT 1 12 SEQ SELECT No INPORT 2 13 SEQ SELECT No INPORT 3 14 SEQ SELECT No INPORT 4 15 SEQ SELECT No.32 0 SEQ SELECT No.1 0 BYPASS SPDL No.1 1 SEQ SELECT No.2 1 BYPASS SPDL No.2 2 SEQ SELECT No.3 2 BYPASS SPDL No.3 3 SEQ SELECT No.4 3 BYPASS SPDL No.4 4 SEQ SELECT No.5 4 BYPASS SPDL No.5 5 SEQ SELECT No.6 5 BYPASS SPDL No.6 6 SEQ SELECT No.7 6 BYPASS SPDL No.7 No.02 7 SEQ SELECT No.8 No.04 7 BYPASS SPDL No.8 8 SEQ SELECT No.9 8 BYPASS SPDL No.9 9 SEQ SELECT No.10 9 BYPASS SPDL No SEQ SELECT No ID DATA CLEAR 11 SEQ SELECT No ID SELECT ENABLE 12 SEQ SELECT No SEQ SELECT No SEQ SELECT No SEQ SELECT No (Please refer to AFC3000 Operations Manual Section and for description of respective signals) PAGE 7

8 Word No. BIT Signal Word No. BIT Signal 0 BYPASS SPDL No.11 0 BYPASS SPDL No.27 1 BYPASS SPDL No.12 1 BYPASS SPDL No.28 2 BYPASS SPDL No.13 2 BYPASS SPDL No.29 3 BYPASS SPDL No.14 3 BYPASS SPDL No.30 4 BYPASS SPDL No.15 4 BYPASS SPDL No.31 5 BYPASS SPDL No.16 5 BYPASS SPDL No.32 6 BYPASS SPDL No.17 6 No.05 7 BYPASS SPDL No BYPASS SPDL No.19 No BYPASS SPDL No BYPASS SPDL No BYPASS SPDL No BYPASS SPDL No BYPASS SPDL No BYPASS SPDL No BYPASS SPDL No * The word No. at the PLC side differs according to the setting of the node address, etc., so please be sure to confirm before using. Please refer to the AFC3000 Operation Manual, Section and for description of the respective signals. Caution The allocation of the input signals is fixed (cannot be changed). The unused area of the inputs is also secured (and cannot be used by other devices). Cautio n Be careful of the following points when using the BYPASS No. # (1 to 32) signals. If a certain Unit is to be put in the BYPASS mode, set the corresponding signal among the BYPASS No. # (1 to 32) signals to ON with the START signal of the Unit being in the OFF state and the BUSY signal of the MASTER Spindle for PC communication and I/O (PLC) control being in the OFF state. When fastening is executed with any of the spindle BYPASS No. # (1 to 32) signals in the ON state, the fastening judgment of that Unit will be ignored as if it does not exist. Also, when any of the BYPASS No. # (1 to 32) signals is set to ON with the BUSY of the MASTER Spindle being in the ON state, the sequence judgment may result in REJECT. PAGE 8

9 AFC3000 Ethernet-I/P System Signal Specifications (MASTER Spindle PLC) Number of MASTER Spindle Output Points 32 bytes (256 bits) The table below is an example of the Output mapping using Ethernet I/P. Output bits (256) are allowed to be user-programmed using the AFC3000 User Console Software. The allocation of the signals can be set on any bit/pin through the PLC Output Layout setting function of the AFC3000 Software. Please refer to PLC Output Layout of the <<AFC3000 Operation Manual>> for list of available output signals (Master and individual spindle signals) EXAMPLE ONLY: Actual signal placement may vary upon user configuration Word No. BIT Signal Word No. BIT Signal 0 TOTAL REJECT 0 SEQ No.17 SELECTED 1 TOTAL ACCEPT 1 SEQ No.18 SELECTED 2 TOTAL ABNORMAL 2 SEQ No.19 SELECTED 3 TOTAL READY 3 SEQ No.20 SELECTED Output word 4 TOTAL BUSY 4 SEQ No.21 SELECTED Output word No. 1 5 END 5 SEQ No.22 SELECTED No. 3 6 SEQ SELECT BIT 0 6 SEQ No.23 SELECTED Output 7 SEQ SELECT BIT 1 7 SEQ No.24 SELECTED Output Signal 8 SEQ SELECT BIT 2 Signal 8 SEQ No.25 SELECTED Setting 9 SEQ SELECT BIT 3 Setting 9 SEQ No.26 SELECTED Example 10 SEQ SELECT BIT 4 Example 10 SEQ No.27 SELECTED 11 SPINDLE IN BYPASS 11 SEQ No.28 SELECTED 12 DATA AVAILABLE 12 SEQ No.29 SELECTED 13 CURRENT WARNING 13 SEQ No.30 SELECTED 14 CAL WARNING 14 SEQ No.31 SELECTED 15 ZERO LEVEL WARNING 15 SEQ No.32 SELECTED 0 SEQ No.1 SELECTED 0 REJECT No.1 1 SEQ No.2 SELECTED 1 ACCEPT No.1 2 SEQ No.3 SELECTED 2 ABNORMAL No.1 3 SEQ No.4 SELECTED 3 BYPASS No.1 4 SEQ No.5 SELECTED 4 REJECT No.2 Output word Output word 5 SEQ No.6 SELECTED 5 ACCEPT No.2 No. 2 No. 4 6 SEQ No.7 SELECTED 6 ABNORMAL No.2 Output 7 SEQ No.8 SELECTED 7 BYPASS No.2 Output Signal 8 SEQ No.9 SELECTED Signal 8 REJECT No.3 Setting 9 SEQ No.10 SELECTED Setting 9 ACCEPT No.3 Example 10 SEQ No.11 SELECTED 10 ABNORMAL No.3 Example 11 SEQ No.12 SELECTED 11 BYPASS No3 12 SEQ No.13 SELECTED 12 REJECT No.4 13 SEQ No.14 SELECTED 13 ACCEPT No.4 14 SEQ No.15 SELECTED 14 ABNORMAL No.4 15 SEQ No.16 SELECTED 15 BYPASS No.4 PAGE 9

10 Word No. BIT Signal Word No. BIT Signal 0 REJECT No.5 0 RUN REV HI REJ No.5 1 ACCEPT No.5 1 RUN REV LO REJ No.5 2 ABNORMAL No.5 2 LO CUR LIMIT WARNING No.5 3 READY No.5 3 HI CUR LIMIT WARNING No.5 Output word 4 BUSY No.5 4 CURRENT WARNING No.5 Output word No. 5 5 BYPASS No.5 5 CAL VOLTAGE WARNING No.5 6 TORQUE HOLD No.5 No. 7 6 ZERO VOLT WARNING No.5 Output 7 PAR SEL (BIT0) No.5 7 JUDGE COMBO (BIT1) No.5 Output Signal 8 PAR SEL (BIT1) No.5 Signal 8 JUDGE COMBO (BIT2) No.5 Setting 9 PAR SEL (BIT2) No.5 Setting 9 JUDGE COMBO (BIT3) No.5 Example 10 PAR SEL (BIT3) No.5 Example 10 JUDGE COMBO (BIT4) No.5 11 PAR SEL (BIT4) No.5 11 JUDGE COMBO (BIT5) No.5 12 TORQUE HI REJ No.5 12 JUDGE COMBO (BIT6) No.5 13 TORQUE LO REJ No.5 13 JUDGE COMBO (BIT7) No.5 14 FTQ HI REJ No.5 14 JUDGE COMBO (BIT8) No.5 15 FTQ LO REJ No SNUG TQ HI REJ No TQ INHIBIT HI REJ No F ANGLE HI REJ No F ANGLE LO REJ No.5 3 Output word 4 DIFF + ANG REJ No.5 4 Output word 5 DIFF ANG REJ No.5 No. 8 5 No. 6 Thru 6 RATE 1 HI REJ No.5 6 No. 16 Output 7 RATE 1 LO REJ No.5 7 Signal 8 RATE 2 HI REJ No.5 Output 8 Setting 9 RATE 2 LO REJ No.5 Signal 9 Example 10 RATE 3 HI REJ No.5 Setting RATE 3 LO REJ No.5 Example ST TIME HI REJ No ST TIME LO REJ No ND TIME HI REJ No ND TIME LO REJ No.5 15 The example above (output word 5-7) shows an example of all available signals for each spindle. While normally not all signals are used, any of the signals (for each spindle) can be preset (programmed using the AFC3000 software) to any output bit. * The word No. at the PLC input side differs according to the setting of the node address, etc., so please be sure to confirm before using. Please refer to the AFC3000 Operation Manual, Section and for description of the respective signals. Caution The unused area of Word 01 to 16 is also secured. PAGE 10

11 Fieldbus Setting (Ethernet-I/P) The fieldbus settings are set in the Fieldbus Setting menu of the AFC3000 User Console. The following setting window is displayed when Multi Fieldbus Setting is selected at the menu bar. In the Bus Type Select/communication window, selection of the fieldbus type, uploading, downloading, and verification of fieldbus settings with respect to the Unit, and browsing and saving of fieldbus settings with respect to the PC can be performed. Caution - The standard set values are set as the factory settings in the Unit. Do not change the settings unless there is a special reason. - Be sure to perform backup before changing the fieldbus settings of the Unit. Bus Type Select: The type of bus is selected from the list. Also, when Upload is executed, the bus type is judged automatically and reflected in the selection part. Configuration File Browse: A fieldbus configuration file (*.nrfcf) is read from the PC. Save: A fieldbus configuration file (*.nrfcf) is saved in the PC. Upload: Download: Verify: The fieldbus settings are read from the MASTER Spindle for PC communication and I/O (PLC) control. The fieldbus settings are written into the MASTER Spindle for PC communication and I/O (PLC) control. (Re-activate the control power after writing.) The fieldbus settings of the MASTER Spindle for PC communication and I/O (PLC) control and the fieldbus settings in the User Console are compared. PAGE 11

12 In the Ethernet-I/P screen (of the AFC3000 Software), setting of the Ethernet-I/P interface is performed. The network settings, the I/O size, and the message size can be changed. Default (the settings are set to the factory settings when this is selected) Network Settings IP address Subnet Mask Default Gateway I/O Setting Data Length [PLC to MASTER Spindle: 8 bytes [64 bits I/O Setting Data Length [MASTER Spindle to PLC: 32 bytes [256 bits Message Data Length [PLC to MASTER Spindle: 32 bytes [256 bits Message Data Length [MASTER Spindle to PLC: 4096 bytes [32768 bits * The number of message block bytes is fixed at 250 bytes. I/O Size setting Data Length [PLC to MASTER Spindle Setting range: 2 bytes [16 bits to 12 bytes [96 bits Data Length [MASTER Spindle to PLC Setting range: 2 bytes [16 bits to 32 bytes [256 bits Message Bytes Size Settings Data Length [PLC to MASTER Spindle Setting range: 0 byte [0 bit to 32 bytes [256 bits Data Length [MASTER Spindle to PLC Setting range: 0 byte [0 bit to 4096 bytes [32768 bits Note: Power must be cycled if any of this configuration is changed and downloaded to the Master controller PAGE 12

13 Fieldbus Message Setting (MASTER Spindle PLC) The message information output from the MASTER Spindle for PC communication and I/O (PLC) control is set in the AFC3000 User Console software. The maximum size of the message output that can be handled is 4096 bytes. The output order of the message data is: Multi Format Data Spindle format data of Spdl. No. 1 Spindle format data of Spdl. No. 2 Spindle format data of Spdl. No. 32. The message output format is selectable (in the AFC3000 Software) to output either BCD format or ASCII format, both examples are listed below. Please contact the PLC manufacturer regarding the setting at the PLC side. Multi Format Output Items (BCD Format) Output Items Number of Bytes Date 4 Fastening Data 2013/5/ 28 Multi Format LSB (1word) PLC Input Data MSB (16word) Time 4 12:34: ID *1 32 ABCDEF A B C D E F NUL NUL SEQ No (1 to 32) SEQ Judgment *2 2 REJECT ACCEPT ABNORMAL STOP RESET STOP BYPASS START OFF IN CYCLE SEQ Cycle Count *1: The ID is fixed at 32 bytes (16 words) and is output in ASCII format. NULL letters are set as unset values. *2: Please refer to AFC3000 Operation Manual, Sequence Judgment regarding the details of SEQ Judgment. Do not use the following characters when inputting the ID data. : backslash (yen mark), / : slash, Caution : : colon, * : asterisk,? : question mark, : double quotation, < > : inequality signs, : pipe sign - PAGE 13

14 Multi Format Output Items (ASCII Format) Output Items Number of Bytes Fastening Data Multi Format PLC Input Data Letter String Date /5/ / 0 5 / 2 8 Time 8 12:34: : 3 4 : 5 6 ID*1 32 ABCDEF A B C D E F NUL NUL NUL NUL NUL SEQ No. (1 to 32) REJECT R E J ACCEPT A C C SEQ Judgment *2, *3 4 ABNORMAL A B N STOP S T O P RESET STOP R S T BYPASS B Y P SEQ Cycle Count START OFF S O F F IN CYCLE I N C Y *1: The number of output bytes of the ID is fixed at 32 bytes (16 words). NULL letters are set as unset values. *2: Please refer to AFC3000 Operation Manual, Sequence Judgment regarding the details of SEQ Judgment. *3: (20H) is the ASCII code for (space). Do not use the following characters when inputting the ID data. : backslash (yen mark), / : slash, : : colon, * : asterisk,? : question mark, Caution : double quotation, < > : inequality signs, : pipe sign PAGE 14

15 Spindle Format Output Items (BCD Format) Output Items Number of Bytes Fastening Data LSB (1word) Spindle format MSB (2 word) Spindle No. (1 to 32) PAR No. (1 to 32) Spindle Judgment* Spindle Cycle Count (8 digits) TOOL Cycle Count (8 digits) Peak Torque* Final Torque* Snug Torque* st Peak Torque* nd Peak Torque* Final Angle* Differential Angle* Rate 1* Rate 1 Increment Torque* Rate 1 Increment Angle* Rate 2* Rate 2 Increment Torque* Rate 2 Increment Angle* Rate 3* Rate 3 Increment Torque* Rate 3 Increment Angle* st Time* nd Time* Cycle Time* Peak Current* Angle at Peak Torque* Rundown Revolutions* ZERO Voltage* CAL Voltage* Spindle Cycle Count (4 digits)* TOOL Cycle Count (4 digits)* Load rate *1: In regards to the Spindle Judgment, Judgment Data 1 is output as 1, Judgment Data 2 is output as 2, Error Data is output as 3, and 1st Reject Item is output as 4. The values output as 1, 2, and 3 are respectively set by bit allocation from Fieldbus Message Setting of the AFC3000 User Console. Note: shaded area described on next page PAGE 15

16 *2: With each of the output items (besides Spindle No., Parameter No., Spindle Judgment, Spindle Cycle Count (8 digits 4 digits), Tool Cycle Count (8 digits 4 digits), and Load rate ), the results are output in the order of: indication up to a maximum of 6 digits (without the decimal point) in 2 words (4 bytes), sign, and number of digits to the right of the decimal point Sign 2 Number of Digits to the right of the Decimal Point Indication Details Indication Details 0 + value 0 No digits right of decimal point 1 - value 1 1 digit right of the decimal point 2 2 digits right of the decimal point 3 3 digits right of the decimal point 4 4 digits right of the decimal point 5 5 digits right of the decimal point *3: With each of Spindle Cycle Count (4 digits) and Tool Cycle Count (4 digits), numerical values of the millions, hundred thousands, ten thousands, and thousands places are output as 4-digit BCD data. When the cycle count reaches 9,999,999 (99 99BCD), the next cycle will be 10,000,000, output as (00 00BCD). PAGE 16

17 Spindle Format Output Items (ASCII Format) Output Items Number of Bytes Fastening Data Spindle format 1 word 2 word 3 word 4 word 5 word Spindle No. (1 to 32)*1 2 1 PAR No. (1 to 32) 2 2 Spindle Judgment* Spindle Cycle Count (8 digits) TOOL Cycle Count ( digits) Peak Torque* Judgment Occurrence Final Torque* Judgment Occurrence Snug Torque* Judgment Occurrence 1st Peak Torque nd Peak Torque Final Angle* Judgment Occurrence Differential Angle* Judgment Occurrence Rate 1* Judgment Occurrence Rate 1 Increment Torque Rate 1 Increment Angle Rate 2* Judgment Occurrence Rate 2 Increment Torque Rate 2 Increment Angle Rate 3* Judgment Occurrence Rate 3 Increment Torque Rate 3 Increment Angle st Time* Judgment Occurrence 2nd Time* Judgment Occurrence Cycle Time* Peak Current* Warning Angle at Peak Torque Rundown Revolutions* Judgment Occurrence ZERO Voltage CAL Voltage Spindle Cycle Count (4 digits)* TOOL Cycle Count ( digits)* Load rate *1: (20H) is the space code (space). *2: In regards to the Spindle Judgment, Judgment Data 1 is output as 1, Judgment Data 2 is output as 2, Error Data is output as 3, and 1st Reject Item is output as 4. The values output as 1, 2, and 3 are respectively set by bit allocation from Fieldbus Message Setting of the AFC3000 User Console. PAGE 17

18 *3: With each of the output items for which there are set values of high and low limits, the results are output in the order of: sign, result indication (including the decimal point), judgment code, and 1st Reject (failure) item. Also with items besides the differential angle and rates 1 to 3, 1 is not output, and for the peak current, 3 is not output. 1Sign L X Judgment Code Indication Details Indication Details Space (20H) + value Space (20H) Within high and low limit, no warning (peak current) - (2DH) - value H (48H) Outside high limit, high limit warning (peak current) L (4CH) Outside low limit, low limit warning (peak current) 31st Reject Item Indication X (58H) Space (20H) Details 1st Reject item Reject item besides the 1st Reject *4: With each of Spindle Cycle Count (4 digits) and Tool Cycle Count (4 digits), numerical values of the millions, hundred thousands, ten thousands, and thousands places are output as 4-digit BCD data. When the cycle count reaches 9,999,999 (99 99BCD), the next cycle will be 10,000,000, output as (00 00BCD). PAGE 18

19 Judgment Data 1 and 2 Items (in common with BCD and ASCII) The Judgment data and Abnormal data of the fastening results are set by bit allocation. The actual bit configuration is setup in the AFC3000 Software. Please refer to Fieldbus Message Setting in the <<AFC3000 User Console Instruction Manual>>. Classification Item Details Logic - Message information to be output by a combination of OR and AND is set. Spindle Judgment Fastening Reject Items Auxiliary Information Signal REJECT ACCEPT ABNORMAL BYPASS STOP RESET STOP START OFF Torque Reject Angle Reject Rate Reject Time Reject Rundown Revolutions Current Value Warnings Judgment Combination Bits 1 to 8 This is output when a fastening result falls outside a judgment range. This is output when fastening ends with the fastening results being within the judgment ranges. This is output when an error occurs in the system or during the fastening operation. This is output when the BYPASS signal is set to ON at the start of fastening or during the fastening process. This is output when the STOP signal is set to OFF at the start of fastening or during the fastening process. This is output when the RESET signal is set to ON at the start of fastening or during the fastening process. This is output when the START signal is set to OFF during the fastening operation with Deadman being set as the start method in the sequence setup. Peak torque low limit Reject/peak torque high limit Reject Final torque low limit Reject/final torque high limit Reject Snug torque high limit Reject Start torque inhibit high limit Reject Final angle low limit Reject/final angle high limit Reject Differential - angle Reject/Differential + angle Reject Rate 1 low limit Reject/Rate 1 high limit Reject Rate 2 low limit Reject/Rate 2 high limit Reject Rate 3 low limit Reject/Rate 3 high limit Reject 1st time low limit Reject/1st time high limit Reject 2nd time low limit Reject/2nd time high limit Reject Rundown revolution high limit Reject/rundown revolution low limit Reject Low current value limit warning/high current value limit warning Allows the configuration of multiple REJECT items to be combined onto single outputs (8 combination outputs available). The configuration of these signals is set using the AFC3000 Software (Fieldbus Message Setup Screen). Abnormal Data Items (in common with BCD and ASCII) Abnormal State No. Abnormal State 1 Abnormal State 3 Abnormal State 4 Abnormal State 5 Abnormal State 6 Abnormal State 8 Abnormal State 9 Abnormal State 10 Torque transducer error Preamplifier error System memory error Servo apply error Servo type error Servo amplifier error Setting data error Multi signal error Details PAGE 19

20 1st Reject (Failure) Item (in common with BCD and ASCII) Identifies the reason or cause for a fastening that is stopped / interrupted BEFORE reaching the target torque (or angle) due to a Reject (outside of the programmed limits). (Some programmed limits can cause the fastening process to stop due to a Reject prior to fastening completion) Example: A cycle run with a missing fastener will cause a 1 ST Time High Limit Reject. A fastener that reached the Final Angle High Limit setting before reaching Standard Torque will cause a Final Angle High Limit reject. Note: If the fastening reaches the end of the fastening cycle and rejects, no data will be reported in this data item. The BCD output format data is shown below for each type of reject item. Item Output Format (BCD Format) No REJECT 00 Peak torque high limit REJECT 01 Final torque high limit REJECT 03 Final angle high limit REJECT 05 Rate 1 high limit REJECT 09 Rate 1 low limit REJECT 10 Rate 2 high limit REJECT 11 Rate 2 low limit REJECT 12 Rate 3 high limit REJECT 13 Rate 3 low limit REJECT 14 1st time high limit REJECT 15 2nd time high limit REJECT 17 Rundown revolution high limit REJECT 19 Snug torque high limit REJECT 21 Start torque inhibit high limit REJECT 22 PAGE 20

21 Fastening Judgment Data Output Items: Example of Spindle Judgment Output Data 1 & 2 (common with BCD and ASCII format) The spindle fastening judgment (from a performed fastening cycle) is set by bit allocation of these 2 data bytes. These judgment status bits are set at the end of a completed fastening cycle. Note: Actual Bit configuration is set using the AFC3000 software in the Fieldbus Message Setup screen Actual bit placement may differ than what is shown. Judgment data setting (example from AFC3000 software) Judgment Data 2 (BIT) Judgment Data 1 (BIT) Item Logic OR OR OR OR OR OR OR OR OR OR OR OR OR OR OR OR ACCEPT REJECT ABNORMAL BYPASS STOP RESET STOP Peak Torque High Limit REJECT Peak Torque Low Limit REJECT Final Torque High Limit REJECT Final Torque Low Limit REJECT Final Angle High Limit REJECT Final Angle Low Limit REJECT Error (Abnormal) Data Setting The error data (Abnormal reason) of Spindle judgment is set by bit allocation of 1 byte. The data corresponds to the abnormal state No. when an abnormal condition occurs. Item Error (Abnormal) Data BIT Abnormal state 1 (Torque Transducer) Abnormal state 3 (Preamplifier) Abnormal state 4 (System Memory) Abnormal state 5 (Servo Amp Reply) Abnormal state 6 (Servo Type) Abnormal state 8 (Servo Amp) Abnormal state 9 (Parameter) Abnormal state 10 (Multi Signal) PAGE 21

22 Example 1: Spindle judgment is ACCEPT (Using setup of Judgment data from previous page) Output Item Spindle Judgment 1 Judgment Data 1 1word 2word 2 Judgment Data 2 3 Error Data 4 Occurring Fastening Reject Example 2: Spindle judgment is REJECT : Final Torque Low Limit Reject Output Item Spindle Judgment 1 Judgment Data 1 1word Example 3: Spindle judgment is ABN3-3 Output Item Spindle Judgment 2word 2 Judgment Data 2 3 Error Data 4 Occurring Fastening Reject Judgment Data 1 1word 2word 2 Judgment Data 2 3 Error Data 4 Occurring Fastening Reject Example 4: Spindle judgment is REJECT : Peak Torque Low Limit Reject Output Item Spindle Judgment 1 Judgment Data 1 1word 2 Judgment Data 2 3 Abnormal Data 2word 4 1st Reject Item Also, if the fieldbus message is unset, the following contents are output. Data Format Output Item Number of Bytes Spindle cycle count (4 digits) 2bytes BCD Format Tool cycle count (4 digits) 2bytes For each of the cycle counts, numerical values of the millions, hundred thousands, ten thousands, and thousands places are output as 4-digit BCD data. When the cycle count reaches 9,999,999 (99 99BCD), the next cycle will be 10,000,000, output as (00 00BCD). In the case of a 32-Spindle system, the total length of the message data is 64 words (128 bytes). Fieldbus Message Output Example (when not set) (Note:PLC output ref. for Allen Bradley) Spindle No. 1 2 Format Output Item Result Output PLC Output Spindle cycle count 1234 C Tool cycle count C Spindle cycle count C Tool cycle count C Spindle cycle count C Tool cycle count C PAGE 22

23 Message Information Output Example (Multi Format) (Note:PLC output ref. for Allen Bradley) Multi Format Output Item Result Output PLC Input (BCD Format) PLC Input (ASCII Format) Sequence C C00 to 216 Cycle Count C C07 Date C C08 to C C17 Time 10:23:36 C C18 to C C25 Sequence Judgment REJECT C C26 to C29 Sequence No. 1 C C30 to C :23:36 REJ_ _1 Final Message Information Area (when 250 bytes are set) * (20H) is the space code (space). C124 C124 PAGE 23

24 Message Information Output Example (Spindle Format) (Note:PLC output ref. for Allen Bradley) Spdl. No. 1 Output Item Result Output Peak Torque [N m Final Torque [N m Final Angle [deg Rate 1 [N m/deg Rate 2 [N m/deg Rate 3 [N m/deg st Time [sec nd Time [sec Peak Torque [N m Spindle Format PLC Input (BCD Format) C00 C C00 to C07 C C08 to C C15 C C16 to C C23 C C24 to C C33 C C34 to C C43 C C44 to C C53 C C54 to C C63 C C64 to C C73 C C PLC Input (ASCII Format) _12.34 _12.34 _123.4HX _ Peak Torque [N m C C Peak Torque [N m C C Free area C74 C74 Final Message Information Area (when max 4096 bytes setup) * (20H) is the space code (space). C4095 C4095 Note: Each spindle s data will reside in the same location regardless of whether the spindle is used in a particular fastening cycle. (Example: If a system has 3 connected spindles and spindle #1 is not used in a sequence (for a particular model for example), then the data for spindle #2 & #3 will only be sent and will reside in their spindles data location skipping the spindle #1 location) PAGE 24

25 PLC Setting Example Ethernet-I/P Fieldbus Expansion Unit This procedure is written for using Rockwell Automation RXLogix5000 V and Allen Bradley CompactLogix L32E. If the system is not the same as listed above, setup may be different. Please contact to PLC manufacturer for detail as each PLC may be different 1. Register MASTER Spindle Fieldbus unit to network In the PLC I/O configuration, right click on Ethernet Port Local ENB and select New Module Select Generic Ethernet Module from module list and click the OK button. PAGE 25

26 Specify Name (FEC AFC3000), IP address, and Connection Parameters that matches the parameters set to the Fieldbus setup using the AFC3000 User Console software. Note: Input / Output size MUST match the settings programmed in the Ethernet I/P setting of the AFC3000 Fieldbus setup or PLC (Ethernet I/P) error will occur. AFC3000 Click on the Connection tab and set connection setup as below. PAGE 26

27 When the Master Spindle Fieldbus unit is added to the I/O configuration, the data table will be added to the controller tags automatically. AFC3000_2:I (shown as AFC1500 in above screenshot) Input signals from AFC3000 controller. (FEC to PLC) AFC1500_2:O (shown as AFC1500 in above screenshot) Output signals to AFC3000 controller. (PLC to FEC) AFC1500_2:C (shown as AFC1500 in above screenshot) Message communication data from the AFC3000 controller. (AXIS to PLC for fastening result data.) An additional program/command needs to be added for sending/retrieving the data. PAGE 27

28 2. Transferring the fastening result data using the MSG function. For setting up the MESSAGE function, first the AFC3000 needs to be configured for the data type that needs to be sent to the PLC. Configuration is done in the AFC3000 Userconsole Software. Select Field Bus Message Setup from Multi pull down menu. Select the DATA TYPE format (BCD or ASCII). Data from the Master (Multi) and Spindle (Axis) must be configured in the table below each tab. The Multi format contains the Header data (such as Date, Time, Sequence #, Cycle Count, etc. aka data that comes from the Master Unit) The Axis format contains the actual spindle fastening data (such as Torque, Angle, Time, Rate, etc.) Right click on the table and select the item from the pop up window that you wish to be transferred. (Example of Multi format selection shown above) Note: Selecting Null deletes the item from the list. PAGE 28

29 (Example of Axis format selection shown below this format will be for EACH spindle connected in the system to the Master Unit) When the system has more than 1 spindle, the data will be output in spindle sequential order as shown below. Data from total fastening status (Multi data) Data from SPINDLE 1 Data from SPINDLE 2 Data from SPINDLE 3 Data from up to SPINDLE 32 After the fastening result data has been setup, download the changed configuration to the Master controller. PAGE 29

30 PLC program. Ethernet-I/P Fieldbus Expansion Unit 1. Read_Tag needs be added to the Controller Tags for message transfer This data tag contains the configuration of the message transfer. Each MSG command needs to have its own Read_ tag. AFC3000 AFC3000 AFC3000 The MSG command is used for transferring the fastening result. PAGE 30

31 Property of the MSG command is shown below. (Right Click in MSG command) A2 5 AFC3000:C.Data[0 Message Type CIP Generic Service Type Get Attribute Single Service Code E Class A2 Instance 1 17 Attribute 5 Destination The controller tag C should be selected Note: Each message command can only handle 250 bytes. If more than 250 bytes of data needs to be transferred, another controller tag needs be added (Read_tag) for the buffer and another MSG command needs be added. The second MSG command should have its instance as 2 with its Destination address incremented to the next block of data (250, 500, 750, 1000, etc.) and so on up to a maximum of 17 for up to 4096 bytes of message data). Example: [AFC3000:C.Data(250) for the second block of 250 bytes PAGE 31

32 At the communication tab screen, select Path. The AFC3000 controller will show up in the browser as shown below. AFC3000 AFC3000 AFC3000 AFC3000 ETHERNET-MODULE AFC3000 ETHERNET-MODULE AFC3000_2 PAGE 32

33 An example of a message transfer PLC program is shown below. AFC3000:C.Data[0 AFC3000:C.Data[ This program transfers up to 250 bytes of fastening result data. The first MSG command has 1 as Instance and is sending the data into AFC1500:C[0 memory block. The second MSG command has 2 as Instance and sending the data into another data memory block AFC1500:C[250 that would have been manually added when the second Read_tag was added. Note: All instructions above that show AFC1500 would be AFC3000 for the AFC3000 setup. Note: The above information contained in this procedure are meant for REFERENCE ONLY when configuring an FEC Ethernet I/P interface using FEC AFC3000 User Console Software, FEC AFC3000 Nutrunner System, Rockwell Automation RSlogix 5000 software and Allen Bradley CompactLogix L32E hardware. Actual application configuration may differ from this set-up depending on the PLC chosen for the application. PAGE 33

34 Message Data Example written for an AFC1500 System showing the :C register data ( AFC1500 would be AFC3000 for AFC3000 system) AFC1500 User Console MONITOR Screen for above Data PAGE 34

35 Fieldbus Message Setting (PART ID Data - PLC to FEC Master Spindle) 1. Contents of Sent Data: ASCII Data Refer to 3. below regarding the actual sent results. 2. Max. message length: 16words/32 bytes (As configured in AFC3000 Software) 3. Input Example Select ASCII letters to send message information from the PLC to the MASTER Spindle for PC communication and I/O (PLC) control. (Only ASCII Data can be recognized by FEC Master) The message information sent from the PLC to the MASTER Spindle for PC communication and I/O (PLC) control is reflected in the fieldbus communication, the AFC3000 User Console, the Unit RS232C, and the expansion RS232C. - The standard set value for the ID input data is 32 bytes (16 words). Be careful because even when a value beyond this is set, only the 32 bytes from the start are saved in the fastening result retention of the Unit. - Do not use the following characters. Caution : backslash (yen mark), / : slash, : : colon, * : asterisk,? : question mark, : double quotation, < > : inequality signs, : pipe sign PLC configuration PAGE 35

36 PLC CONFIGURATION DATA WRITE A Write_Tag needs to be added to the Controller Tags for data to be sent from the PLC to the FEC Master Spindle. (Such as part ID Data) This data when received by the FEC Master spindle will be Married with the fastening result data so that the fastening data would now contain the part ID number providing a birth history for the part being fastened. The Write_Tag contains the configuration of the message transfer. A MSG command (Message command in the PLC logic) must be used in conjunction with a Write_Tag to send data. In the case below, VIN_Number_Write tag has been setup and configured (following pages) PAGE 36

37 Below are the properties which must be setup for the Message Configuration of the Write_Tag. (Right Click in MSG command) Message Type CIP Generic Service Type Get Attribute Single Service Code 10 Class A2 Instance 1 Attribute 5 Destination The controller tag VIN_Number or whatever Write Tag you setup should be selected Note: The FEC Master spindle will only take a maximum of 32 Bytes for the Write_Tag (Part ID data) configurable (between 0-32 bytes) in the AFC3000 software for the Fieldbus Message Setup. So an instance of 1 is all that is required in the above setup for WRITING data using the Message Command. PAGE 37

38 PLC Logic Example: Sending Message data to FEC Master Spindle The MSG message command initiates the message data to be sent or received. The Write tag sends the data to the device connected, and the Read tag retrieves the data from the connected device. In the example above, the Write MSG command takes place at or near the start of the machine cycle before the FEC controller has been issued a START command. (The FEC Master Spindle, can receive the Write Data any time before the end of the fastening cycle. Once received, the data is buffered and will be used until new message data is received or the ID DATA CLEAR Input signal is enabled (See Input signals). (The ID data received by the FEC Master Spindle will be married with the fastening data and will continue to use the same message data it receives until new data is sent or the ID Data Clear signal is turned on. Care must be taken so data is not recorded with the same ID data in that case) The Read Tag in the example above is shown happening AFTER the FEC fastening is completed. Once fastening is completed, the MSG Read command can be performed and the fastening result data will be read into the PLC. PAGE 38