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ELECTRIC SERVO NUTRUNNER

AFC1500 MULTI SYSTEM


MULTI-2 UNIT HARDWARE MANUAL

SECOND Edition March 2009

Automation Systems

51327 Quadrate Drive Phone: (586) 781-2100


Macomb, MI. 48042 Fax: (586) 781-0044
Web: www.fec-usa.com E-mail: sales@fec-usa.com

AFC1500E-HM2-2
WARNING
All applicable national and local codes must be followed when installing and operating the equipment detailed in
this manual.

FAILURE TO ABIDE BY THESE CODES AND THE SPECIFICATIONS DESCRIBED IN THIS MANUAL CAN
RESULT IN SERIOUS INJURY TO PERSONNEL AND/OR DAMAGE TO THE EQUIPMENT!

Any questions regarding the contents of this document or any related matter should be
directed to FEC INC. at (586) 781-2100, faxed to (586) 781-0044 or emailed to support@fec-usa.com.

The information set forth in the following document is the property of FEC INC.

This document shall not be released to or copied for any person and/or organization
without the expressed prior consent of FEC INC.

Unauthorized reproduction or distribution of this manual is strictly prohibited.

Please contact FEC INC. if you require additional copies.

ii
Revision
Revision Revision History
Date
1 04/2008 Initial Release
Revision affecting most chapters including minor fixes, revised
2 3/2009
information and new items – Added Ethernet, Profinet & Toolsnet info.
2.1 2/2010 Chapter 5 only- revised toolsnet version output format pg: 5-74 to 5-83

Manual Numbering Convention

AFC1500E -HM2-2
DSP1500 == Servo
DSP1500 Servo Press
Press Version Number
AFC1500 = Nutrunner
AFC1500 = Nutrunner (Major Revision Level)
FUSION == DC
FUSION DC Hand
Hand Tool
Tool
HS = SAN Unit Hardware
E = English Version
Operation Manual
S = Spanish Version
HM2 = Multi2 / Main Unit
*Japanese Version furnished by DDK Hardware Operation Manual
(uses DDK numbering convention) HM-ENET = Ethernet Manual for
Multi / Main Unit
SW = Software Manual

iii
Introduction

Thank you for purchasing our Electric Servo Nutrunner - AFC1500 System.
This instruction manual describes the procedures for installation, wiring, handling and actions to
be taken in case of any failure.

◆ This instruction manual shall be delivered to the end user who operates the equipment.
◆ Read all instructions before use, and always keep this instruction manual with the equipment.
◆ Items not described in this instruction manual shall be considered “unavailable”.
◆ The product specification and appearance described in this instruction manual is subject to change
without notice.
◆ All rights reserved. Any disclosure, copying, distribution, or use of the information contained herein
for other than its intended purpose is strictly prohibited.

For the safety of operator and equipment

◆ Read all “Safety Precautions” before using the equipment, and understand and observe all
instructions and recommendations included in this manual.
◆ Read all instructions and recommendations included in this manual, understand the functions
and performance of this nutrunner and correctly use this machine.
◆ Wirings and parameter settings shall only be conducted by a qualified professional.
◆ Never conduct a withstand voltage test or insulation resistance test on this equipment.
◆ Only operate this equipment with FEC supplied controllers, tools & cables.
◆ All stated warranties become invalid if other components are used.
◆ This system may be sold as components to a manufacturer (other than FEC) of a complete
system. The manufacturer of the complete system is responsible for adhering to stated
operation and safety brought forth in this manual. It is agreed between the buyer and FEC
that it is the buyer’s responsibility to adhere to this manual.
◆ Indicate the following on all instruction manuals that use this equipment.
“This equipment must be operated in accordance to FEC Supplied Manuals”
”This equipment is capable of high voltages hazardous to human life.”

Points to check when unpacking

Please confirm the followings when unpacking this equipment.

◆ Ensure that you received the correct model as ordered.


◆ Ensure that there are no missing parts.
◆ Check for any damage caused during transportation.

iv
Introduction

Warranty

Warranty Period
FEC Inc. warrants that the equipment manufactured by it and delivered hereunder will be free of defects in
material and workmanship for a period of twelve (12) months from the date of placing the equipment in operation,
or eighteen (18) months from the date of shipment, or 500,000 machine cycles - whichever shall first occur.

Provisions of Warranty
Should any failure to conform to this warranty be reported in writing to the company within said period, the
company shall at its option, correct such nonconformity by suitable repair to such equipment or furnish a
replacement part from FEC or an FEC approved facility, provided the purchaser has stored, installed, maintained
and operated such equipment in accordance with good industry practices and has complied with specific
requirements & recommendations of the company. Accessories or equipment furnished by the company shall not
be liable for any repairs, replacements or adjustments to the equipment or any costs of labor performed by the
purchaser or others without the company's prior written approval.

The effects of corrosion, erosion and normal wear and tear are specifically excluded from the company's
warranty. Performance warranties are limited to those specifically stated within the company's proposal. Unless
responsibility for meeting such performance warranties are limited to specified shop or field tests, the company's
obligation shall be to correct in the manner and for a period of time provided above.

THE COMPANY MAKES NO OTHER WARRANTY OR REPRESENTATION OF ANY KIND WHATSOEVER,


EXPRESSED OR IMPLIED, EXCEPT THAT OF TITLE, AND ALL IMPLIED WARRANTIES, INCLUDING ANY
WARRANTY OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, ARE HEREBY
DISCLAIMED.

Correction by the company of nonconformity's, whether patent or latent in the manner and for the period of time
provided above, shall constitute fulfillment of all liabilities of the company for such nonconformity's, whether based
on contract, warranty negligence, indemnity, strict liability or otherwise with respect to, or arising out of such
equipment.

Non - Warranty Items


The following are defined as non-warranty situations that are outside the scope of warranty provided:

• Product is out of the warranty period as determined by FEC serial number tracking.
• Any cause external to the equipment, including but not limited to any act of God, lighting or power surges, abuse,
negligence, accident or failure to maintain the proper operating environment.
• Use of equipment or adjustments or devices not approved by the manufacturer and FEC.
• Cosmetic damage to unit or any of the parts
• Consumable parts - for example; sockets, rest/wear pads, bushings, etc.
• Physical damage (example - damage caused by dropping, cut cables, etc.)
• Field Service required on a Warranty Part - FEC warranty covers the parts and labor only onsite at FEC.

Extended warranties are available as an addition to the standard warranty period outlined above - for all FEC Inc.
systems. For extended warranties, contact FEC.

v
Safety Precautions
Read
ead all instructions before operating the equipment in order to use this equipment safely and correctly.
Prior to use, read this instruction manual carefully and fully understand the equipments functions, safety
precautions and instructions.. Safety precautions in this manual are marked with two symbols [Warning]
and [Caution].

To prevent danger to the user and other persons as well as property damage
damage, instruction
nstructions that must be
fully
lly observed are marked with the symbols below.

◆ This instruction manual uses the following two symbols according to the degree of damage that may
be caused when the instruction is not observed.

This symbol indicates that failure to observe instruction marked


Warning with this symbol may result in severe personal injury or death.

This symbol indicates that failure to observe instruction marked


Caution with this symbol may result in minor personal injury or material
damage.

Even instructions
nstructions that are marked with Caution may result in severe damage if they are not
observed according to conditions.
Contents marked with the above symbols are very important instructions. For your safety, follow
f all
instructions and especially those marked with the
these symbols.

◆ This instruction manual uses the following additional symbols for instructions
s that shall be observed.

Warning: Warning: Warning:


Electric shock Fire Pinch Point

Caution: Caution: Caution:


Fire Electric shock High Temperature

Prohibited Do not disassemble

Required Ground

vi
Safety Precautions

Warning

Never touch rotating devices or any part of the nutrunner tool while it is rotating.
Make sure that no part of your body gets near any moving part of the tool.
The spindle may rotate unexpectedly, resulting in injury.

Do not remove the motors and gear cases of tools while power is applied.
The tool output spindle may rotate and cause injury.

Do not repair, disassemble, or modify the equipment individual components of the system.
Failure to observe this instruction may cause injury, electric shock, fire and malfunction.

Never operate the equipment where it is exposed to water, near a corrosive atmosphere or
flammable gases. Failure to observe this instruction may cause fire.

Keep fingers away from the connectors while the equipment is turned ON and for a while after
the equipment is turned OFF. Failure to observe this instruction may cause electric shock.
shock

Wiring operation and maintenance work shall be conducted by a qualified professional.


Failure to observe this instruction may cause electric shock and injury.

Turn OFF the power when conducting wiri


wiring operation and maintenance.
Failure to observe this instruction may cause electric shock and injury.

Never damage the cables, apply excess stress to cables, or squeeze the cables.
Never use damaged cables.
Failure to observe this instruction may cause electric shock and fire.

Use type-3
3 grounding of FG terminals.
Failure to observe this instruction may cause electric shock.

In case of an abnormal odor, noise, or operation error occurrence, stop operation immediately
and turn OFF the power source. Failure to observe this instruction may cause injury and fire.

Install a Power shutdown device in order to ensure the safety of equipment.


Failure to observe this instruction may cause injury.

Install an emergency stop circuit on the outside of equipment in order to stop operation
promptly. Failure to observe this instruction may cause injury.

Keep away from the equipment during recovery from a temporary blackout and ensure safety
measures are conducted a after restarting the equipment. The equipment may suddenly restart.
Failure to observe this instruction may cause injury.

vii
Safety Precautions

Transportation / Storage Caution


Transport the equipment properly according to its weight.
Failure to observe this instruction may cause injury and malfunction.

The conditions when transporting the equipment by ship is as below.


◆ Ambient temperature: -5°C~+55°C (Avoid freezing)
◆ Ambient humidity: 5
50% RH or lower (Avoid moisture)
◆ Package: Tight seal
◆ Rust prevention measure: Apply grease or oil on tools.
Failure to observe this instruction may cause earth leakage and malfunction.

Do not hold cables and output spindles when transpo


transporting the tools.
Failure to observe this instruction may cause injury and malfunction.

Do not hold the indictor on the front panel when transporting the AXIS Unit.
The indicator may come off and drop from the front panel.
Failure to observe this instruction may cause injury and malfunction.

The equipment shall be stored under the following conditions.


◆ Ambient temperature: -5°C~+55°C (Avoid freezing)
◆ Ambient humidity: 90% RH or lower (Avoid moisture)
◆ Atmosphere: Indoors (Avoid direct sunlig
sunlight)
No corrosive gases or flammable gases
No oil mist, dust, water, salt, iron powder
◆ Avoid direct vibration or shocks
Failure to observe this instruction may cause earth leakage and malfunction.

viii
Safety Precautions

Installation / Wiring Caution


Install all tools firmly where they can bear the maximum torque during operation.
Failure to observe this instruction may cause injury and malfunction.

Install the AXIS Unit firmly inside the control panel using the specified screws.
Failure to observe this instruction may cause malfunction.

Use the specified tool for the AXIS (SAN) Unit.


Failure to observe this instruction may cause fire and malfunction.

The AXIS (SAN) Unit


nit shall maintain the specified distance from other devices.
Failure to observe this instruction may cause fire and malfunction.

Do not block the ventilation hole of the AXIS (SAN) Unit.


Avoid any foreign body from entering inside the equipment.
Failure to observe this instruction may cause fire and malfunction.

The power source shall be provided with safety measures such as breakers and circuit
protectors. Failure to observe this instruction may cause fire and malfunction.

Do not use tools or AXIS (S


(SAN) Units that are damaged or missing parts.
Failure to observe this instruction may cause fire, injury and malfunction.

Do not get on the top of equipment or do not place heavy objects on the top of equipment.
Failure to observe this instruction may cause injury and malfunction.

Do not subject the equipment to excess shock and impact.


Failure to observe this instruction may cause malfunction.

Apply proper wiring size and firmly tighten all termination points.
Failure to observe this instruction may cause injury, false operation and malfunction.

Operate the equipment within the specified power supply voltage


voltage.
Failure to observe this instruction may cause injury, electric shock, fire and malfunction.

Take sufficient measures to shield the equipment when


hen operating the in the following
conditions:
◆ Location where electrical noise is generated
◆ Location where the equipment is subjected to a strong electric field or magnetic field
◆ Location near a high power wire.
Failure to observe this instruction may cause injury, false operation, and malfunction.

ix
Safety Precautions

Operation / Adjustment Caution


Never operate the equipment with wet hands or while standing in a wet location.
location
Failure to observe this instruction may cause electric shock.

Keep fingers away from the AXIS (SAN) Unit radiating fin and tool motors while the equipment
is turned ON or for a while after the equipment is turned OFF. These parts may become very
hot. Failure to observe this instruction may cause burns.

Use the equipment under the following conditions.


◆ Ambient temperature: 0°C~+45°C (Avoid freezing)
◆ Ambient humidity: 90% RH or lower (Avoid moisture)
◆ Atmosphere: Indoors
rs (Avoid direct sunlight)
No corrosive gases or flammable gases
No oil mist, dust, water, salt, iron powder
◆ Avoid direct vibration or shocks
Failure to observe this instruction may cause earth leakage and malfunction.

Confirm and adjust allll parameters before operation in order to prevent unexpected movement
of the equipment.
Failure to observe this instruction may cause injury, false operation and malfunction.

Never conduct extreme adjustments or setting changes that may cau


cause
se instability of operation.
Failure to observe this instruction may cause injury, false operation and malfunction.

The equipment may restart suddenly when the equipment is reset with the start signal ON.
Always ensure that the start signal is OFF before resetting the equipment.
Failure to observe this instruction may cause injury.

Do not turn the equipment ON and OFF repeatedly.


Failure to observe this instruction may cause malfunction.

Do not use the equipment at torque higher than the maximum torque capacity..
Failure to observe this instruction may shorten equipment life or cause malfunction due to the
high temperature caused by overload.

In case any abnormality occurs, remove the cause and ensure safety before resetting and
restarting the equipment.
Failure to observe this instruction may cause injury.

x
Table of Contents

Chapter 1: Outline
1.1 About this Manual......................................................................................... 1-2
1.2 Functions...............................…..……………………………………………… 1-3
1.3 Safety Precautions……….....…..………………………………………………. 1-4

Chapter 2: Specifications
2.1 Specifications.........................………………………………………………….. 2-2
2.2 Unit Dimensions……….................................…….…………………………… 2-3

Chapter 3: System Description


3.1 System Block Diagram...........………………………………………………….. 3-2
3.2 Unit Description…….....................................…….…………………………… 3-3

Chapter 4: Installation & Wiring


4.1 Installation…….............................................…….…………………………… 4-2
4.2 Power Wiring Reference........………………………………………………….. 4-3
4.3 Input Power Connection........………………………………………………….. 4-4
4.4 RS485 Connection…….........………………………………………………….. 4-4
4.5 User Console Ethernet Connection..………………………………………….. 4-5
4.5.1 Optional Ethernet Port – Data Communication………………………….. 4-6
4.6 Serial Communication Ports..………………………………………………….. 4-7
4.6.1 PC Port………............................………………………………………….. 4-8
4.6.2 Display Port…............................………………………………………….. 4-9
4.6.3 Data-Out (1) Port........................………………………………………….. 4-9
4.6.3.1 Available Output Data...........………………………………………….. 4-10
4.6.3.2 Output Data Format..............………………………………………….. 4-11
4.6.4 Data-Out (2) Port........................………………………………………….. 4-12
4.6.5 Data-In Port…............................………………………………………….. 4-12
4.7 PLC Interface Communication (I/O).………………………………………….. 4-13
4.7.1 Control Interfaces…....……………………………………………………... 4-13
4.7.2 Input Signals………………………………………………………………….. 4-14
4.7.3 Output Signals…………………………………………………………………4-15
4.7.4 Signal Timing Chart…………………………………………………………. 4-18
4.7.5 External DIP Switch Setting……………………………………………….. 4-19
4.8 Setting Default TCP/IP Address – User Console Port……………………….. 4-19
4.9 Firmware Flash Connector……………………………………………………... 4-19

xi
Table of Contents

Chapter 5: Control Interfaces


5.1 Interface Board ……......…….………………………………………………….. 5-2
5.2 Interface Board DIP Switch Setup................…….…………………………… 5-2
5.3 Discrete I/O Interface….........………………………………………………….. 5-3
5.3.1 Sinking Type (NPN)…................………………………………………….. 5-3
5.3.1.1 Discrete Signal Connection (Sinking Type)………………………….. 5-4
5.3.2 Sourcing Type (PNP)..................………………………………………….. 5-5
5.3.2.1 Discrete Signal Connection (Sourcing Type).……………………….. 5-6
5.3.3 Input Signals (PLC-IN)................………………………………………….. 5-7
5.3.4 Output Signals (PLC-OUT).........………………………………………….. 5-8
5.3.4.1 Output Data Banks.…...........………………………………………….. 5-9
5.3.5 Standard I/O Cable – Wire Color Code……………………………………. 5-10
5.4 Interbus S® Interface..…........………………………………………………….. 5-11
5.4.1 Component Descriptions............………………………………………….. 5-13
5.4.2 User Console Software Settings ………………………………………….. 5-14
5.4.3 Input Signals (Reference Layout)..……………………………………….. 5-15
5.4.4 Output Signals (Reference Layout)……………………………………….. 5-16
5.5 DeviceNet® Interface.…........………………………………………………….. 5-17
5.5.1 Component Descriptions...........………………………………………….. 5-19
5.5.2 User Console Software Settings ………………………………………….. 5-20
5.5.3 Input Signals (Reference Layout)..……………………………………….. 5-21
5.5.4 Output Signals (Reference Layout)……………………………………….. 5-22
5.6 Profibus® Interface.……........………………………………………………….. 5-23
5.6.1 Component Descriptions............………………………………………….. 5-25
5.6.2 User Console Software Settings ………………………………………….. 5-26
5.6.3 Input Signals (Reference Layout)..……………………………………….. 5-27
5.6.4 Output Signals (Reference Layout)……………………………………….. 5-28
5.7 Modbus Plus® Interface.........………………………………………………….. 5-29
5.7.1 Component Descriptions............………………………………………….. 5-31
5.7.2 User Console Software Settings ………………………………………….. 5-33
5.7.3 Input Signals (Reference Layout)..……………………………………….. 5-34
5.7.4 Output Signals (Reference Layout)……………………………………….. 5-35
5.8 CC-Link® Interface (Version 1)..……………………………………………….. 5-36
5.8.1 Component Descriptions........... ………………………………………….. 5-38
5.8.3 Input Signals (Reference Layout)..……………………………………….. 5-40
5.8.4 Output Signals (Reference Layout)……………………………………….. 5-41
5.9 CC-Link® Interface (Version 2)..……………………………………………….. 5-42
5.9.1 Component Descriptions............………………………………………….. 5-44
5.9.2 User Console Software Settings ………………………………………….. 5-46
5.9.3 Input Signals (Reference Layout)..……………………………………….. 5-47
5.9.4 Output Signals (Reference Layout)……………………………………….. 5-48
5.10 Allen-Bradley Remote I/O Interface………………………………………….. 5-49
5.10.1 Component Descriptions...........………………………………………….. 5-51
5.10.2 User Console Software Settings .……………………………………….. 5-52
5.10.3 Input Signals (Reference Layout).……………………………………….. 5-53
5.10.4 Output Signals (Reference Layout).…………………………………….. 5-54
xii
Table of Contents

5.11 Ethernet-I/P Interface…........………………………………………………….. 5-55


5.11.1 Component Descriptions...........………………………………………….. 5-56
5.11.2 User Console Software Settings. .……………………………………….. 5-57
5.11.3 Input Signals (Reference Layout).……………………………………….. 5-58
5.11.4 Output Signals (Reference Layout)..…………………………………….. 5-59
5.11.5 PLC Message Transfer Setup Example…..……………………………… 5-61
5.12 Profinet Interface……………………………………………………………….. 5-69
5.12.1 Component Descriptions………………………………………………….. 5-70
5.12.2 User Console Software Settings…………………………………………. 5-71
5.12.3 Input Signals (Reference Layout).……………………………………….. 5-72
5.12.4 Output Signals (Reference Layout)..…………………………………….. 5-73
5.13 Input / Output Signal Layout using Toolsnet Version………………………… 5-74

Chapter 6: Troubleshooting
6.1 Abnormals…………………….………………………………………………….. 6-2

xiii
Blank Page

xiv
Chapter 1: Outline
Chapter 1: Outline
AFC1500 Multi-2 Unit Hardware Manual (Rev. 2)

1.1 About this Multi-2 Unit Manual


This manual details the configuration, specifications and the operation of the AFC1500 Multi-2 Unit.

The following table outlines the contents of each chapter.

Chapter Title Contents


Basic characteristics and requirements of the AFC1500
1 Outline
Multi-2 Unit.
2 Specifications General specifications of the AFC1500 Multi-2 Unit.

3 System Description Description of standard and optional system components.


Mounting requirements, wiring connection references
4 Installation and Wiring
including communication port specifications.
Description of standard Discrete I/O and optional Fieldbus I/O
5 Control Interfaces
PLC Interfaces.
6 Troubleshooting Description of Abnormal conditions.

Any questions regarding the contents of this document or any related matter should be
directed to FEC Inc. at (586) 781-2100 or faxed to (586) 781-0044.

The Information set forth in the following document is the property of FEC Inc. This
document shall not be released to or copied for any person and/or organization without
the expressed prior consent of FEC Inc.
Unauthorized reproduction or distribution of this manual is strictly prohibited. Please
contact FEC Inc. if additional copies are required.

Related Documentation
AFC User Console Manual AFC1500E-SW-*
AFC1500 Operation Manual AFC1500E-HS-*

PAGE 1 - 2
Chapter 1: Outline
AFC1500 Multi-2 Unit Hardware Manual (Rev. 2)

1.2 Functions
The Multi-2 Unit is a complimentary controller device to enhance the AFC1500 SAN Unit capabilities
by providing the communication and the sequence control features required by larger or more
sophisticated multi spindle applications. When a group of AFC1500 Servo Controllers (SAN Units) are
linked to a Multi-2 Unit, the Multi-2 Unit assumes control (over these spindles) of the following
functions:
Input / Output (I/O) connection (including Fieldbus interfaces)
Sequence Control
Parameter Programming
Fastening Data Monitoring & Communication
General Status Indication

♦ Input / Output (I/O) Connection


The Multi-2 Unit assumes control of the control signals (Ex.: STOP, START, REVERSE,
BYPASS, etc.) to all of the AFC1500 Servo (SAN) Controllers connected to it via the RS485
communication port, thus eliminating direct connection & control to the individual spindles
saving costly I/O connection. The control signals for the multi-spindle array can be of
different sources: Signals manually generated by pressing the Control Buttons on the front of
the Multi-2 Unit or I/O (Input/Output) signals from a PLC and / or PC Based Controller.
Additionally, a multitude of (direct connect) Fieldbus interfaces are available when using a
Multi2 Unit.

♦ Sequence Control
The Multi-2 Unit controls the fastening sequencing eliminating the need for external control
devices (PLC) to perform complicated spindle control sequencing. All fastening sequencing is
handled by the Multi-2 Unit. This built in feature allows the Multi-2 Unit to control a variety of
complex sequencing strategies including; incremental fastening steps, spindle grouping,
reject (reverse) strategies, wait timing, multiple starts, etc. Also available are sequence
Input / Output interfaces which allow external control of sequence starting / stopping with
outside automation while in sequence.

♦ Parameter Programming
A Windows® compatible computer running the AFC User Console software package can be
connected to the Multi-2 Unit in order to upload or download the preset data to all the SAN
(Servo) Controllers connected in the multi spindle array. This eliminates the need to program
individual spindles manually.

♦ Fastening Data Monitoring & Communication


The Multi-2 Unit can monitor and process the fastening results collected by the AFC1500 Servo
(SAN) Controllers connected to it. It has four (4) configurable RS232C ports to input and output
fastening data results. Data monitoring / saving is also a function of the AFC User Console
software package.
As an added feature, the Multi-2 Unit stores previous fastening data in RAM (non-volatile) for
uploading at another time. The number of cycles stored is based on the number of spindles
connected (see chart on page 2-2). The data can be uploaded using the AFC User Console
software package.
Additionally, the Multi -2 comes standard with an dedicated ethernet port to connect to a
computer running the AFC User Console Software package making it easier to connect to most
computers without serial convertors. As an option, the Multi - 2E comes with an additional
ethernet port for reporting of resultant fastening data to host systems.

♦ General Status Indication


A set of indicator LED’s provide the status for Power On, Busy, Total Accept, Total Reject and
Abnormal conditions.

PAGE 1 - 3
Chapter 1: Outline
AFC1500 Multi-2 Unit Hardware Manual (Rev. 2)

1.3 Safety Precautions


To ensure the most effective and extended use of all equipment, adhere to the following precautions:

Wiring
• Use only the specified cables for all system connections.
• Do not use a high voltage circuit as a frame ground (FG). Also, the frame ground should be
separate from the power ground. The use of a grounding rod located as close as possible to
the enclosure housing the AFC1500 Multi-2 Unit is preferable.
• Circuit breakers or fuses are required on branch circuit power feeds to the Multi-2 Unit.
• PLC I/O cables must be run separate from any high voltage sources or cabling, and must not
exceed 50 feet.

Installation Environment
• The AFC1500 Multi-2 Unit should be placed in a NEMA 12 enclosure.
• Using the equipment in the following locations may lead to malfunction or breakdown. Avoid
using in these areas or use an air conditioner.
Areas under direct sunlight or if the environmental temperature is out of the 32~122
0~50 ) range.


Areas where relative humidity is out of the 20-90% range, the temperature change is
drastic or where the area is exposed to mist and water drops.
• Do not use at the following locations. (Contact FEC Inc. if necessary for clarification)
Areas where conductive powder, oil, mist, salt or organic solvents exist.
Areas that have corrosive or combustible gases.
Areas that have strong electric or magnetic fields.
Areas where strong vibration or shock could be transmitted directly to a Multi 2 Unit.

Static Electricity
• The AFC1500 Multi-2 Unit incorporates many electronic Surface Mounted Devices (SMD). It
is advisable to strictly adhere to practices for safe electrostatic discharge in order to prevent
damage to the system components when handling them.

Cleaning
• Do not use any organic solvents, such as thinner, to clean a Multi-2 Unit. The solvent could
melt the surface paint, or penetrate inside and cause damage. A cloth dampened with alcohol
or warm water should be used to lightly wipe the components.

Electrical Noise Prevention


• Multi-2 Units must be located a minimum of 600mm from high transient voltage sources such
as transformers, motor starters, AC inverters and AC contactors. If it cannot be avoided, the
unit must be shielded.
• If high powered devices are used inside the enclosure, they must use a surge suppression
device.
• Make sure that the power supply lines and cables for connecting the unit and tool are not run
together inside the same duct.

Handling and Shipping


• It is critical that AFC1500 System components are properly handled and shipped in order to
maintain the system’s integrity. Adhere to the following requirements for shipping and
handling:
Loose AFC1500 Multi-2 Units must be individually packaged and shipped in anti-static
containers or wrap to prevent damage from electrostatic discharge.
If the Multi Unit is to be shipped in an enclosure, tighten all mounting screws to prevent
the unit from being dislodged.
Do not ship or store the unit in environments where the temperature is out of the
23~131 (-5~55 ) range or where the humidity is above 90%.


PAGE 1 - 4
Chapter 2: Specifications
Chapter 2: Specifications
AFC1500 Multi-2 Unit Hardware Manual (Rev.2)

2.1 Specifications

Power Supply Voltage 100 to 220 VAC±15%, 1-phase, 50/60 Hz.


Power Consumption 9 Watt/Hour
In rush current Less than 160 mA
CPU NEC V53A
Data Communication RS232C (User Console PC) (N/A with Ethernet Data Option)
RS232C (Data Output #1 / Data Output)
RS232C (Data Input)
RS232C (Data Output #2) (N/A with Ethernet Data Option)
RS422 (External Remote Display)
RS485 Servo Units Programming/Control
Ethernet - User Console (User Console PC)
Ethernet - Network Communication (OPTIONAL 2E Version Only)
Control Interfaces Discrete I/O (24Vdc Sink)
Discrete I/O (24Vdc Source)
DeviceNet® (Includes data messaging capability)
Profibus®
Profinet IO
Ethernet I/P (Includes data messaging capability)
Mitsubishi CC Link® 1
Allen Bradley Remote I/O 1
Modbus Plus®
CC Link® Version 2 (Includes data messaging capability)
Interbus-S®
M-Net
Additional Interfaces also available:
Contact FEC for special fieldbus requirements

Fastening Sequence 100


Programming Steps (99 plus “End” Step)
Fastening Torque Control / Angle Control
Control Methods Optional Yield Control (Requires SAN Ver. 2.39)
Max. No. of spindles 31 per Multi-2 Unit
Fastening Parameters 16
Fastening Sequences 16
Torque Rate 3
monitoring areas (1st , 2nd and 3rd Rate areas)
# of Stored # of Stored # of Stored # of Stored
Spdls. Cycles Spdls. Cycles Spdls. Cycles Spdls. Cycles
1 7878 9 2288 17 1326 25 936
Data Storage 2 6032 10 2080 18 1248 26 910
(Non-volatile RAM) 3 4888 11 1924 19 1196 27 858
4 4108 12 1794 20 1144 28 832
Based on the number of
spindles connected. 2 5 3536 13 1690 21 1092 29 806
6 3120 14 1586 22 1040 30 780
7 2782 15 1482 23 1014 31 754
8 2496 16 1404 24 962
Installation requirement NEMA12 Enclosure
Operation Temperature 0º to 50 ºC (32 º to 122 ºF)
Operation Humidity 20% to 90%
1) Mitsubishi CC Link & Allen Bradley Remote I/O are proprietary and licensed for use.
2) The number of cycles stored will be reduced if RS232C - DATA IN data is stored with the
fastening data.

PAGE 2 - 2
Chapter 2: Specifications
AFC1500 Multi-2 Unit Hardware Manual (Rev.2)

2.2 Unit Dimensions

Mounting: Top (1) place #8-32 screw


Bottom (2) places #8-32 screw

Weight: 1.4 kg

Note: Unit Dimensions are the same whether a Multi 2 unit (as shown), or a Multi 2E (Ethernet) version.
Chapter 2: Specifications
AFC1500 Multi-2 Unit Hardware Manual (Rev.2)

Blank Page

PAGE 2 - 4
Chapter 3: System Description
Chapter 3: System Description
AFC1500 Multi-2 Unit Hardware Manual (Rev.2)

3.1 System Block Diagram


The diagram below shows how the AFC1500 Multi-2 Unit can be connected to a single unit or combined
in a multiple spindle configuration. The use of a Multi-2 Unit provides one set of PLC I/O for controlling
multiple spindle fastening operations. Along with discrete 24VDC (sinking or sourcing) I/O, various
fieldbus interfaces are also available for direct connection to networks such as Profibus, AB remote I/O,
CCLink, DeviceNet, etc.
The AFC1500 Multi-2 Unit also provides an interface for connection to the User Console PC, serial
printers, barcode readers, display units, etc.

PAGE 3 - 2
Chapter 3: System Description
AFC1500 Multi-2 Unit Hardware Manual (Rev.2)

3.2 Unit Description


AFC MULTI – 2 Standard Version
The standard version of the Multi-2 unit includes both an RS232 port (PC Port) and Ethernet
port (Ethernet U/C Port) for communicating to a computer running the AFC User Console
Software. (Only one may be used at a time)

(RS232C) PC Port

(RS422) Display Port

(RS232C) Data-Out Port #1 Ethernet U/C


Status LED
(RS232C) Data-Out Port #2
Power ON LED
(RS232C) Data-In Port
Busy LED

Accept LED

Reject LED

Interface Board Abnormal LED


Reset Button

Start Button

Reverse Button

Calibration Button

RS485 Port
Power Connector
Ethernet U/C Port

* Discrete I/O Interface Board Shown. (RS232C)Data-Out 2 and (RS422) Data-In are not used.

AFC MULTI – 2E Ethernet Version (Optional)


The optional ethernet version of the Multi – 2 unit adds the functionality of an additional ethernet
port for FASTENING DATA COMMUNICATION protocols to external systems as well as User
Console connectivity. Existing protocols include; QDAS, ToolsNet®, FECNet as well as custom
Protocols. The RS232 PC Port and Data-Out 2 port are removed using this configuration.

Ethernet Network Port


(RS422) Display Port

Ethernet Reset Button Ethernet U/C


(RS232C) Data-Out Port Status LED

(RS232C) Data-In Port

PAGE 3 - 3
Chapter 3: System Description
AFC1500 Multi-2 Unit Hardware Manual (Rev.2)

Multi-2 Unit Panel Description


Power On LED Indicates when power is applied to the Multi-2 Unit.
Busy LED Lights when the unit is performing a self check, return, fastening
operation or is downloading/uploading data to the AFC User Console
software package.
Accept LED Lights if a fastening cycle or a self check test falls within acceptable
parameters. (This LED indicates status for ALL connected spindles)
Reject LED Lights if a fastening cycle or a self check test is outside of acceptable
parameters. (This LED indicates status for ALL connected spindles)
Abnormal LED Lights when a system abnormal condition is detected in the control
system of any connected spindle. (Does NOT indicate a spindle reject).
All operations are halted and cannot be restarted until the Abnormal
condition is corrected. Can be cleared only by the Reset function. (see
AFC1500 Operation Manual for Abnormal Troubleshooting)
RS485 Port RJ45 style connector used to connect to all AFC1500 Servo (SAN)
Units included in the system.
Ethernet U/C Port Communication port for the AFC Software User Console PC.
Red (TX) Transmitting Data
Ethernet U/C Status LEDs Yellow 10/100 Link
Green (RX) Receiving Data
Reset Button Resets all signal and communication buffers to “clear” conditions.
Clears the Abnormal signal and performs the Torque Transducer Zero
Level Check.
Start Button Starts the fastening cycle. Requires a pulse of 0.1 to 0.5 sec. for
“Normal” start selection or must be maintained during complete cycle
for “Deadman” start selection.
Reverse Button Turns the spindles in the opposite direction of the preset fastening
direction while the button is held active.
Cal Button Performs the Torque Transducer shunt calibration test. When pressed,
the Servo (SAN) Units will display either a green accept LED or red
reject LED indicating status of the individual Calibration test.
Power Connector Connects to incoming power: 100 to 220VAC (auto-sensing), Single
phase, 50/60 Hz.
Interface Board (I/O) Allocation socket for input/output signal Interface boards. Options
available are Discrete I/O (Sink or Source), Interbus-S®, DeviceNet®,
Profibus®, CC-Link® (Version 1 or 2), Modbus Plus®, Allen Bradley
Remote I/O (Rockwell License #199906006) or Ethernet-I/P
RS232C – PC Port Communication port for the User Console PC.
RS232C – Data Out Port #1 Communication port for fastening result data output to any external
(RS232C – Data Out Port) device, i.e.: host computer, serial printer, etc. Data output format is
configured using the User Console (AFC) Software package.
RS232C – Data In Port Communication port for ASCII data input from peripheral devices. (Ex:
bar code readers, RF tag, etc.) Allows external ASCII data to be merged
with fastening result data.
RS232C – Data Out Port #2 Not Used
RS422 – Display Port Not Used
® ®
Ethernet Network Port* for network connectivity (Toolsnet , QDAS , SQL, Custom Protocol,
etc.)
Ethernet Reset Button* For resetting the Network Ethernet Port IP address to default setting.
(IP: 192.168.10.40 Subnet Mask: 255.255.255.0 Gateway:
192.168.10.1)
To reset port to default IP address, power down Multi Unit. Depress
reset button and hold it depressed while powering on the Multi Unit until
green Accept LED illuminates.
*On Ethernet Version only.

PAGE 3 - 4
Chapter 4: Installation & Wiring
Chapter 4: Installation & Wiring
AFC1500 Multi-2 Unit Hardware Manual (Rev. 2)

4.3 Input Power Connection


An auto sensing power supply allows for input power in the range of 100 ~ 220VAC single phase,
50/60 hertz. Adequate circuit protection must be provided. Recommended conductor size should be
a minimum of #18AWG.

Wiring Chart

Pin Description
4 4 100 ~ 220VAC +/-15%
3
3 100 ~ 220VAC +/-15%
2 No Connection **
2
1 Frame Ground
1

Mating Connector

Manufacture: Amp
Housing Part No.: 1-178128-4
Contact Part No.: 1-175218-3 (Qty.-3)

** To standardize components, FEC cable part


#FEB-1260 may be used due to the fact that
pin #2 is not connected internally.

4.4 RS485 Connection


The Multi-2 Unit uses an RS485 port to perform the communication operations with the AFC1500
Servo (SAN) Controllers. This port has two channels CH1 and CH2. CH1 is dedicated to handle all
preset data upload and download, fastening results monitoring and collection. Channel CH2 is a high
speed connection to all AFC1500 Servo Controllers. It controls all required commands to perform the
fastening cycle.

RS485 port specifications (RJ45)


Speed 9600, 19200, 38400 baud
Cable Std Cat 5 Ethernet
Maximum number of 31
connected devices
Protocol Proprietary
Operating Voltage RS485 Standard
1
RS485 Wiring
8 NO Signal Name Channel
1 TX+ / RX+ CH1
2 TX- / RX- CH1
3 RX+ CH2
4 TX- CH2
5 TX+ CH2
6 RX- CH2
7 GND
8 GND

PAGE 4 - 4
Chapter 4: Installation & Wiring
AFC1500 Multi-2 Unit Hardware Manual (Rev. 2)

4.5 User Console Ethernet Connection

The “User Console Ethernet” port is a dedicated TCP/IP ethernet port for communicating with the
AFC User Console Software in a Windows® based PC. Similar to the serial RS232 (PC) port
dedicated for the AFC Software connection, this port allows connection in an ethernet environment vs.
using the standard serial port connection in previous versions of the Multi Unit. This port allows the
user to set-up, monitor, save data, display and print fastening data and setup parameters using the
AFC User Console software. The ethernet connection allows connection to multiple Multi-2 units
using an ethernet switch or hub. (Different IP addresses must be configured for multiple connection).

NOTE: An additional ethernet port is available for communicating fastening resultant data to
external data collection systems (ie. QDas , ToolsNet , FECNet , SQL Servers or other
custom protocols). This is an OPTIONAL ethernet port and can be ordered by adding the
E option to the Multi-2 Unit. (Part #1500Multi2E-x)
   

   

The default IP address is set at FEC or it can be configured by the user using the AFC User Console
software. If connection cannot be established using the default IP address, the IP address may
have been changed. The default IP address can be re-established by resetting it. See section
4.8.1 for resetting the IP address back to the default setting. The Multi-2 IP address may also be
uploaded, viewed and modified using the AFC software PC connected serially. (RS232 PC Port or
RS485 SAN UNIT connection) Once the current IP address configuration is verified using a serial
connection, then connection may be attempted using the Ethernet port.

Default IP Address of Multi 2 unit


IP Address: 192.168.10.10
Subnet Mask: 255.255.255.0
Default Gateway: 192.168.10.1

Note: Set-up the TCP/IP properties in the computer that will connect to the Multi-2 unit prior to
attempting ethernet port connection. The actual IP address setup in the computer must be a different
number than the Multi-2 unit IP address. Example: Using the default IP address above, set the PC
IP address to 192.168.10.50. Use the same Subnet & Gateway settings)

Note: Only one AFC Software connection method may be used at any given time whether
serial connection or Ethernet connection. The AFC Software can only be configured for one
connection port at a time. If more than one connection is required at the same time (to
additional Multi Units), additional AFC software may be installed and run at the same time,
each set-up with different communication connections.

The connecting cable is a standard Ethernet Crossover cable if connected directly to a PC (FEC
 

Part #FEB-1331-6). If connected through an Ethernet switch, a standard ethernet CAT5 or CAT5e
may be used (FEC Part Number FEB-1258-6).

Ethernet port specifications (RJ45)


Speed 10/100Mbps (auto select)
Cable Std Cat 5 Ethernet
Protocol Proprietary
Operating Voltage Ethernet Standard

Ethernet Wiring
Pin Signal Name
1 1 Tx+
2 Tx-
8 3 Rx+
4 -
5 -
6 Rx-
7 -
8 -

PAGE 4 - 5
Chapter 4: Installation & Wiring
AFC1500 Multi-2 Unit Hardware Manual (Rev. 2)

4.5.1 Optional Ethernet Port – Data Communication


As an option, an additional ethernet port is available for sending fastening resultant data over an
ethernet TCP/IP connection. This port can be configured using a standard web browser for
communication to Atlas Copco Toolsnet networks, FEC NET or custom protocols. Additionally,
once configured, the AFC User console software can also communicate over this port.

NOTE: Only one ethernet port may be used to communicate to the AFC software. Either the
dedicated User Console Ethernet port (located in the lower right corner of the front face) or the
optional Ethernet port.

Default IP Address of the Multi 2 Optional Ethernet Port


IP Address: 192.168.10.40
Subnet Mask: 255.255.255.0
Default Gateway: 192.168.10.1

If communication cannot be established using these settings, the settings may have been changed
in the Ethernet Port. To reset the setting back to these default settings, press the RESET
pushbutton located beside the ethernet port while powering on the unit.

See the MULTI 2E SETUP PROCEDURE document for more information when using this port.
 

(Contact FEC)

Optional Ethernet Port

Default Reset Button

PAGE 4 - 6
Chapter 4: Installation & Wiring
AFC1500 Multi-2 Unit Hardware Manual (Rev. 2)

4.6 Serial Communication Ports


The Multi-2 Unit has three usable serial RS232C and one RS422 communication ports. All of the
serial port settings and data format are fully configurable with the AFC User Console software.
When the optional “E” ethernet version is used, the PC & DATA-OUT2 ports are removed.

STANDARD VERSION PORT LAYOUT ETHERNET VERSION PORT LAYOUT


(Optional E Version)
 

RS-232C Signal Layout


1 DCD (Data Carrier Detect) Used only for DATA-IN*
2 RXD (Receive Data) Serial Data Input.
3 TXD (Transmit Data) Serial Data Output.
4 DTR (Data Terminal Ready) Output signal; active when the internal device is ready to link.
5 GND (Ground Signal)
Input signal; indicates that the external device is ready to establish a
6 DSR (Data Set Ready)
link. Can be connected directly to DTR for automatic data dump.
Output signal. Active when the internal device is ready to exchange
7 RTS (Request to Send)
data.
Input signal. Indicates that the external device is ready to exchange
8 CTS (Clear to Send) data. Can be connected directly to RTS when no asynchronous data
flow is required.
9 RI (Ring Indicator) Not used
* All Multi-2 serial port connectors are MALE.

PAGE 4 - 7
Chapter 4: Installation & Wiring
AFC1500 Multi-2 Unit Hardware Manual (Rev. 2)

4.6.1 PC Port

The “PC” port is for communicating with the AFC User Console Software PC. The connecting cable
is a standard RS232 Null-Modem cable and can be purchased through FEC (Part #FEB-1301) or
any cable supplier that carries standard 9-Pin Null Modem cables.

Note: This port is removed when using the Ethernet Version (Optional E Version) Multi
   

   

Unit

RS-232 Pin Layout (Male)


1 DCD
2 RXD
3 TXD
4 DTR
Standard Null
5 GND
Modem Cable
6 DSR
7 RTS Front View PC running AFC
8 CTS User Console Software
9 Not Used

RS-232C PC CABLE
(Standard NULL MODEM Cable)

PAGE 4 - 8
Chapter 4: Installation & Wiring
AFC1500 Multi-2 Unit Hardware Manual (Rev. 2)

4.6.2 DISPLAY Port


“DISPLAY” port is currently not used in the US Market.

RS-422 Pin Layout (Male)


1 TX+
2 TX-
3 RX+
4 RX-
5 GND
6 Not Used
7 Not Used
Front View
8 Not Used
9 Not Used

4.6.3 DATA-OUT (1) Port


“DATA-OUT(1)” is an output port for ASCII fastening data communication to external devices.
Information concerning available data and data format is shown in the following sections.

RS-232 Pin Layout (Male)


1 DCD
2 RXD
3 TXD
4 DTR
5 GND
6 DSR
7 RTS
8 CTS Front View
9 Not Used

RS-232C DATA-OUT 1 & 2 CABLE


The following cable diagram shows connection for “dumping” data after a fastening cycle. The
output data configured (using the AFC Software) for the DATA-OUT 1 port will be reported
automatically after the fastening cycle ends.

PAGE 4 - 9
Chapter 4: Installation & Wiring
AFC1500 Multi-2 Unit Hardware Manual (Rev. 2)

4.6.3.1 Available Output Data (From DATA-OUT 1 Port)


The Multi-2 Unit is capable of outputting the fastening results data in an ASCII format to a serial
printer or other serial peripheral devices. The data is sent from the Multi-2 Unit’s RS232C “DATA
OUT - 1” port. The output data string format as well as port configuration can be configured using
the AFC User Console Software. As little as one data item or up to all items can be user
configured. ASCII Control Characters may also be implemented (Ex: Start of Text, End of Text,
etc.). Below is a list of data available and its byte length.

Basic Fastening Data Length in bytes


Peak Torque 6
Final Angle 5
First Time 6
Final Time 6
Cycle Time 5
First Torque Rate 7
Second Torque Rate 7
Third Torque Rate 7
Final Torque 5
Offset Torque 5
Judgment 3
Extended Fastening Data Length in bytes
Current (@ peak torque) 4
Angle (@ peak torque) 4
First Peak Torque 5
Second Peak Torque 5
First Torque Rate Increment Torque 5
First Torque Rate Increment Angle 4
Second Torque Rate Increment Torque 5
Second Torque Rate Increment Angle 4
Third Torque Rate Increment Torque 5
Third Torque Rate Increment Angle 4
Rundown revolutions 4
Cal Voltage Value 5
Zero Voltage Value 5
Judgment 2
Retry Flag 3 (ASCII “RTY”)
Input Data* Length in bytes
RS232C data buffer 1 Up to 128
RS232C data buffer 2 This length is determined by the user and
RS232C data buffer 3 dependent upon the length of data input to
RS232C data buffer 4 these data areas.
System Data Length in bytes
Date 10
Time 8
Spindle Number 2
Sequence Number 2
Parameter Number 2
Cycle Count Number 7

*Input Data is input to the Multi-2 Unit using the RS232C “DATA INPUT” port. This port is
configured through the AFC User Console Software. The data must be ASCII formatted data & is
limited to 128 bytes in (4) separate data buffers. The port must be configured for the input string
which is to be received. The data received can then be married with the resultant fastening data by
selecting the RS232 data in the output format. This function is typically used to marry a part
number with the resultant fastening data for production birth history.

PAGE 4 - 10
Chapter 4: Installation & Wiring
AFC1500 Multi-2 Unit Hardware Manual (Rev. 2)

4.6.3.2 Output Data Format (From DATA-OUT 1 Port)


The example below shows the format of the DATA-OUT (1) port connected to a printer. Actual
data output format may vary depending on the configuration and set-up of this port using the AFC
User Console Software. The data field is selectable from as little as one output field to all available
data (see previous table for available data fields). Headers, footers & ASCII control characters are
all user configurable using the AFC User Console Software.

EXAMPLE ONLY – Actual data will depend on individual user set-up.

2007/09/26 09:17:57 SEQ01 [Input Data from DATA-IN if programmed here]


SP PA TORQUE ANGLE 1RATE 2RATE OFSET JUG Acceptable Fastening
01 01 0.50 2 0.000 0.005 0.00 O

2007/09/26 09:19:36 SEQ01


SP PA TORQUE ANGLE 1RATE 2RATE OFSET JUG Rejected Fastening
01 01 0.17L 0 0.000 0.000 0.00 X

2007/09/26 09:21:16 SEQ01


SP PA TORQUE ANGLE 1RATE 2RATE OFSET JUG Reset Cycle
01 01 0.23L 0 0.000 0.000 0.00 * (Before fastening end)

2007/09/26 09:21:21 SEQ01


SP PA TORQUE ANGLE 1RATE 2RATE OFSET JUG Cycle Stopped
01 01 0.17L 0 0.000 0.000 0.00 ! (Before fastening end)

2007/09/26 09:21:34 SEQ01


SP PA TORQUE ANGLE 1RATE 2RATE OFSET JUG Abnormal
01 01 0.01 0 0.000 0.000 0.00 A05 (Showing abnormal code)

2007/09/26 09:21:21 SEQ01


SP PA TORQUE ANGLE 1RATE 2RATE OFSET JUG Spindle Bypassed
01 00 0. 0. 0. 0. 0.

Index
SEQ: Sequence 1RATE: 1st Rate H: High
SP: Spindle 2RATE: 2nd Rate L: Low
PA: Parameter OFSET: Offset Torque
ANGLE: Final Angle JUG: Judgment

PAGE 4 - 11
Chapter 4: Installation & Wiring
AFC1500 Multi-2 Unit Hardware Manual (Rev. 2)

4.6.4 DATA-OUT 2 Port


“DATA-OUT2” port is currently not used.

RS-232 Pin Layout (Male)


1 DCD
2 RXD
3 TXD
4 DTR
5 GND
6 DSR
7 RTS
8 CTS
9 Not Used Front View

Note: This port is removed when using the Ethernet Version (Optional E Version) Multi
   

   

Unit

4.6.5 DATA-IN Port


The “DATA-IN” port is for inputting ASCII data to the fastening system for marriage to the fastening
data. It is typically used for attaching part serial number(s) to the fastening data for data storage
birth history.

RS-232 Pin Layout (Male)


1 DCD
2 RXD
3 TXD
4 DTR
5 GND
6 Not Used
7 RTS
8 CTS Front View
9 Not Used

RS-232C DATA-IN CABLE

* When using the DATA-IN port, PIN 1 (DCD) must be enabled for data input (Jumper pins 1 & 4).

PAGE 4 - 12
Chapter 4: Installation & Wiring
AFC1500 Multi-2 Unit Hardware Manual (Rev. 2)

4.7 PLC Input/Output (I/O) Interface


The Multi-2 Unit is able to operate under different Input/Output control structures through use of a
modular I/O interface board installed in the unit. Besides standard discrete “hardwired” interface
signals, the introduction of “Open” architecture communication networks known as “Fieldbus” made it
necessary for the direct interfacing to these networks. FEC integrated many Fieldbus interfaces
directly into our system through use of a modular I/O board interfacing these networks directly to our
I/O. (See Chapter 5 for available interfaces)

Interface Board

Discrete I/O interface shown above

4.7.1 Control Interfaces


The available I/O interfaces are shown in the chart below. The fieldbus interface boards are integrated
directly to internal I/O signals which eliminate associated I/O wiring thus reducing overall assembly
labor. In fieldbus systems, the communication is typically of the Master/Slave format in which the FEC
unit is a slave to the master CPU. In addition to handling I/O signals, some Fieldbus types allow
resultant fastening data to be sent over the same connection to the host PLC (Described below as I/O
& Messaging)
Base Part
Suffix Description Special Requirements
Number
1500MULTI2(E) -1 Discrete I/O (Sinking Type)
1500MULTI2(E) -2 Discrete I/O (Sourcing Type)
® ®
*1500MULTI2E -3 DeviceNet-S (for Toolsnet ) Hardware V1.09 or later
1500MULTI2(E) -4 Profinet IO (I/O & Messaging)
®
*1500MULTI2E -5 Interbus-S® (for Toolsnet ) Hardware V1.09 or later
®
1500MULTI2(E) -6 Allen Bradley Remote I/O
® ®
*1500MULTI2E -7 Profibus (for Toolsnet ) Hardware V1.09 or later
®
1500MULTI2(E) -8 Modbus Plus
®
1500MULTI2(E) -9 DeviceNet-S (I/O & Messaging)
Hardware V1.12 or later
1500MULTI2(E) -10 Ethernet I/P (I/O & Messaging)
Software V4.16 or later
®
1500MULTI2(E) -11 Interbus-S
®
1500MULTI2(E) -12 Mitsubishi CC-Link Ver. 2 (I/O & Messaging) Software V4.13 or later
®
1500MULTI2(E) -13 Profibus (I/O & Messaging)
®
1500MULTI2(E) -14 Mitsubishi CC-Link Ver. 1 (I/O only)
1500MULTI2(E) -15 M-Net
*Toolsnet Interface available for Multi2E (optional ethernet) version only. See Toolsnet Interface
Manual for set up information. (Other interfaces available – Contact FEC)

PAGE 4 - 13
Chapter 4: Installation & Wiring
AFC1500 Multi-2 Unit Hardware Manual (Rev. 2)

4.7.2 Input Signals


The list below contains a description of the Input signals available on the I/O interface. Further input
mapping can be found in the individual interface information (See Chapter 5).

Signal Contact Description


Emergency Stop Input.
Signal MUST be Active to perform a fastening operation.
Emergency Stop N.C. When this signal is inactive (off), all Multi-2 Unit operation ceases,
all spindles in motion will stop, and all communication ports &
input/outputs will be disabled.
Reset Input.
When active (on), this signal will clear all spindle data and
discrete outputs. A Zero Check of all torque transducers will be
completed. During the Zero Check, the CHECK lamp will
illuminate, the READY signal will turn OFF, and the ACCEPT or
Reset N.O. REJECT lamp will light to indicate the result of the Zero Check. If
the System has been disabled by an Abnormal output, the
System will not return to normal operation until the Abnormal
condition has been corrected, and this signal has been input for
200~500ms. Do not input this signal between cycles as part of an
automatic cycle due to the potential for fastening data loss.
Reverse Spindle Rotation Input.
All spindles will rotate in an opposite direction (of fastening) for as
Reverse N.O. long as this signal is activated (on) and maintained. The Reverse
input functions the same as the reverse pushbutton on the front of
the Multi-2 Unit.
Start Cycle Input.
The Start input automatically resets the previous cycle, clears all
data to zero, and initiates the next fastening cycle. The start input
requires a pulse of 200~500 milliseconds if the Multi-2 Unit is set
Start N.O.
up for AUTOMATIC Start input. If it is set up for DEADMAN
(hand-held operation) input, the Start input must be maintained
"on" for the entire cycle. Typically this signal is held on until
confirmation of the “Busy” signal is received.
Sequence Select 0 N.O. Sequence Select Input.
Sequence Select 1 N.O. These 5 inputs form a binary code which is capable of selecting
Sequence Select 2 N.O. up to 16 different operation sequences. Refer to Table 1. (Can be
Sequence Select 3 N.O. used for part model selection)
Cycle Count Input.
The System cycle counter will increment each time this signal is
input if the CYCLE COUNT UP is set to PLC SIGNAL in the
Cycle Count Up N.O. Multi-2 Unit. The Cycle Count input requires a pulse of 200~500
milliseconds to increment the counter. If the CYCLE COUNT UP
is set to AUTO, the cycle counter increments automatically at the
end of every fastening.
The internal cycle counter is reset when this signal is input.
Cycle Count Clear N.O.
Resetting the counter value requires a 200~500ms pulse.
Disables the Calibration & Zero Level check that automatically is
Self Check Disable N.O.
performed at the start of each cycle
INPORT 1 N.O. External Sequence Input.
INPORT 2 N.O. These four (4) signals are external inputs to the fastening
sequence. When a [PLC INPUT WAIT] instruction is programmed
INPORT 3 N.O. in the fastening sequence, it will stop until the designated external
INPORT 4 N.O. input is active.
BYPASS Spindle No.1 N.O. Bypass’s spindle #1 - Spindle is ignored as if it does not exist.
BYPASS Spindle No.2 N.O. Bypass’s spindle #2 - Spindle is ignored as if it does not exist.
BYPASS Spindle No.3 N.O. Bypass’s spindle #3 - Spindle is ignored as if it does not exist.
BYPASS Spindle No.4 N.O. Bypass’s spindle #4 - Spindle is ignored as if it does not exist.
BYPASS Spindle No.5 N.O. Bypass’s spindle #5 - Spindle is ignored as if it does not exist.
BYPASS Spindle No.6 N.O. Bypass’s spindle #6 - Spindle is ignored as if it does not exist.
BYPASS Spindle No.7 N.O. Bypass’s spindle #7 - Spindle is ignored as if it does not exist.
BYPASS Spindle No.8 N.O. Bypass’s spindle #8 - Spindle is ignored as if it does not exist.
BYPASS Spindle No.9 N.O. Bypass’s spindle #9 - Spindle is ignored as if it does not exist.
BYPASS Spindle No10 N.O. Bypass’s spindle #10 - Spindle is ignored as if it does not exist.
Data Select 0 These 3 inputs form a binary code to select up to 8 Output Data
Data Select 1 N.O. Banks. Used for Digital I/O interfaces. NOTE: Not used for
Data Select 2 Fieldbus interfaces. [See Table 3 on Page 5-12]
Input Signal Power Sink Type +24V
Common for input signal.
Input Signal Power Source Type +0V

PAGE 4 - 14
Chapter 4: Installation & Wiring
AFC1500 Multi-2 Unit Hardware Manual (Rev. 2)

(Continued)

[Table 1 – Sequence Selection]


Sequence Sequence Sequence Sequence
Selected Sequence No.
Select 3 Select 2 Select 1 Select 0
OFF OFF OFF OFF 1
OFF OFF OFF ON 2
OFF OFF ON OFF 3
OFF OFF ON ON 4
OFF ON OFF OFF 5
OFF ON OFF ON 6
OFF ON ON OFF 7
OFF ON ON ON 8
ON OFF OFF OFF 9
ON OFF OFF ON 10
ON OFF ON OFF 11
ON OFF ON ON 12
ON ON OFF OFF 13
ON ON OFF ON 14
ON ON ON OFF 15
ON ON ON ON 16

4.7.3 Output Signals


The list below contains a description of the output signals available on the I/O interface. Further
output mapping can be found in the individual interface information (See Chapter 5). The
Multi-2 Unit is capable of providing over 570 Output signals to indicate the status of the Multi-2
Unit and of all the AFC1500 SAN Controllers connected to it (up to 31 controllers). These
signals are user configurable using the AFC User Console Software and may be programmed
on any designated output bit.

Main Multi Unit Output Signals


Output when the fastening result is a REJECT. Indicates that one or more
Total Reject spindles have failed achieving the fastening limits. This output remains active
until the START signal or RESET signal is input.
Output when the fastening result is a ACCEPT. Indicates all spindles are
Total Accept within fastening limits. This output remains active until the START signal or
RESET signal is input.
Output when an Abnormal condition occurs. This signal indicates that the
System has detected an internal fault, and can no longer proceed. The fault
maybe generated from a connected spindle during a self-check function.
Check the individual spindle status to identify which spindle is reporting the
Abnormal abnormal condition. (see AFC1500 Operation Manual for troubleshooting)
The spindle reporting an abnormal may be bypassed to resume normal
operation, however, the bypassed spindle will be ignored and not run while in
bypass. An Abnormal condition must be corrected before the System will
resume normal operation. The RESET signal clears the abnormal condition.
Output when the system is in the READY condition. Indicates system is ready
Ready to operate, and inputs are enabled. This signal is inactive (off) when the
BUSY output is active (on).
Output after a START signal is received, and active until the fastening cycle is
Busy
complete and the READY signal is output.
Output when a fastening cycle is complete. Remains active until the START,
End
RESET or REVERSE signal is input.
Sequence 0 Output confirmation of SEQUENCE SELECT 0~4 input selections.
Sequence 1 Sequence bits are active according to what sequence is set from the
Sequence 2 sequence select inputs. Used to confirm proper sequence before fastening
Sequence 3 starts. Refer to Table 3.

PAGE 4 - 15
Chapter 4: Installation & Wiring
AFC1500 Multi-2 Unit Hardware Manual (Rev. 2)

Out Port 1
Out Port 2
Out Port 3 These signals will output when the fastening sequence reaches a step that
Out Port 4 has a [PLC OUTPUT] instruction inserted. Used to provide sequence
operation status to external PLC’s and/or control outputs for slide motion,
Out Port 5 lights, & buzzers, etc without the use of a PLC. (The AFC User Console
Out Port 6 Software can set these outputs on and off in the fastening sequence)
Out Port 7
Out Port 8
Signal is active when any of the connected spindles are bypassed either from
Spindle in Bypass
San Unit bypass input signals or from the San Unit bypass switch.
Active when the high current limit has been exceeded. This can be used to
Current Limit Warning identify potential motor failure before total failure occurs by identifying high
current draws over what the typical current draw is for the application.
Can be used to set outputs ON or OFF. Typically used in conjunction with
Always ON / OFF
Bank Outputs to monitor which Bank is selected.

[Table 2 – Sequence Select Output]


Sequence Sequence Sequence Sequence Selected Fastening
Output 3 Output2 Output1 Output0 Sequence No.
OFF OFF OFF OFF 1
OFF OFF OFF ON 2
OFF OFF ON OFF 3
OFF OFF ON ON 4
    

ON ON ON OFF 15
ON ON ON ON 16

PAGE 4 - 16
Chapter 4: Installation & Wiring
AFC1500 Multi-2 Unit Hardware Manual (Rev. 2)

(Output Signals – Continued)

In addition to the main Multi unit output signals, individual spindles that are connected to the Multi unit
report status signals to the Multi Unit. These signals are available on a “per spindle” basis and can
be used or programmed using the AFC User Console software.

Available Individual Spindle Unit Output Signals (Per connected spindle)


Output when the fastening result is a REJECT. Indicates that the spindle has
Reject failed achieving the fastening limits. This output remains active until the
START signal or RESET signal is input.
Output when the fastening result is an ACCEPT. Indicates that the spindle is
Accept within fastening limits. This output remains active until the START signal or
RESET signal is input.
Output when an Abnormal condition occurs. This signal indicates that the
spindle has detected an internal fault and can no longer proceed. The fault
Abnormal maybe generated during a self-check function (see AFC1500 Operation
Manual for troubleshooting). The RESET signal clears the abnormal
condition.
Output when the spindle is in the READY condition. Indicates spindle is
Ready ready to operate and inputs are enabled. This signal is inactive (off) when the
BUSY output is active (on).
Output after a START signal is received, and remains active until the
Busy
fastening cycle is complete and the READY signal is output.
Signal is active when the spindle is bypassed either from San Unit bypass
Bypass
input signal or from the San Unit bypass switch.
Parameter Select 1
Parameter Select 2 Output confirmation of PARAMETER SELECT 1~4 input selections.
Parameter Select bits are active according to what sequence is set from the
Parameter Select 3 sequence select inputs.
Parameter Select 4
st st
Time 1 Low Reject Output when 1 Time result is below the set 1 Time Low Limit value.
Time 1 High Reject Output when 1st Time result is above the set 1st Time High Limit value.
Time 2 Low Reject Output when Final Time result is below the set Final Time Low Limit value.
Time 2 High Reject Output when Final Time result is above the set Final Time High Limit value.
Output when Peak Torque result is below the set Peak Torque Low Limit
Peak Torque Low Reject
value.
Output when Peak Torque result is above the set Peak Torque High Limit
Peak Torque High Reject
value.
Output when Final Torque result is below the set Final Torque Low Limit
Final Torque Low Reject
value.
Output when Final Torque result is above the set Final Torque High Limit
Final Torque High Reject
value.
Angle Low Reject Output when Angle result is below the set Angle Low Limit value.
Angle Low Reject Output when Angle result is above the set Angle High Limit value.
Rate 1 Low Reject Output when Rate 1 result is below the set Rate 1 Low.
Rate 1 High Reject Output when Rate 1 result is above the set Rate 1 High.
Rate 2 Low Reject Output when Rate 2 result is below the set Rate 2 Low.
Rate 2 High Reject Output when Rate 2 result is above the set Rate 2 High.
Rate 3 Low Reject Output when Rate 3 result is below the set Rate 3 Low.
Rate 3 High Reject Output when Rate 3 result is above the set Rate 3 High.
Current Limit Low
Output when the current is below acceptable Limits.
Warning
Current Limit High
Output when the current is above acceptable Limits.
Warning
Used to create “special” outputs formed by using a combination of SAN Unit
Combination Bits 1-8
outputs in “AND / OR” logic.

PAGE 4 - 17
Chapter 4: Installation & Wiring
AFC1500 Multi-2 Unit Hardware Manual (Rev. 2)

4.7.4 Signal Timing Chart


Signal Timing

OFF
STOP ON

OFF
READY ON

OFF
RESET ON A

REVERSE
OFF
START ON
A

Fastening Fastening
FASTENING
Operation Operation
OFF
BUSY ON

OFF
ACCEPT ON

OFF
REJECT ON

OFF
ABNORMAL ON

OFF
END ON

OFF
COUNT UP ON
A

200 ~ 500ms (A)

Because the RESET input clears all fastening data and discrete outputs, it should only be activated
to clear a system Abnormal or to perform a Zero Level Check. The system will automatically reset
with each fastening start. A manual RESET activation between cycles could result in data loss.
The REVERSE signal must be maintained for the duration of the desired REVERSE function.
The STOP input is normally closed and enables all other functions. When open (OFF), all
operations cease and all inputs / outputs become inactive.
The START signal will not operate during RESET, REVERSE or ABNORMAL signal activation. A
pulse of 200~500 milliseconds is required for AUTO START mode. For DEADMAN mode (Used
mainly in handheld applications), the signal must be maintained for the complete fastening cycle
(until BUSY goes low).
When the ABNORMAL signal is activated, the system must be RESET before normal operation will
resume.
REJECT & ACCEPT signals are maintained until the start of the next cycle or on a RESET.
READY indicates when the system is ready to start.
It is recommended when changing sequences that the Sequence Select outputs be used to verify
that the sequence has been changed before issuing a start signal. Delay from Sequence Select
input to Sequence Select output is approximately 5ms.

OFF
Seq. Sel. Bit 0 ON

Seq. Sel. Bit 1 OFF


ON
Sequence Select No. 6
OFF
(Multi-2 Inputs)
Seq. Sel. Bit 2 ON

OFF
Seq. Sel. Bit 3 ON

Allow 20ms to interlock the Sequence Select


Command and the associated result signal.
OFF
Bit 0 Selected ON

OFF
Bit 1 Selected ON
Sequence No. 6 Selected
Bit 2 Selected OFF
ON (Multi-2 Outputs)
OFF
Bit 3 Selected ON
* No bit selected = Sequence No. 1
OFF
START ON

PAGE 4 - 18
Chapter 4: Installation & Wiring
AFC1500 Multi-2 Unit Hardware Manual (Rev. 2)

4.7.5 External DIP Switch 





(Located on bottom of unit)

FRONT
DIP SWITCH (Factory Setting)
No. OFF ON
4 Not Used
3 Not Used
2 Angle resolution: 0.1 Angle resolution: 1
1 EXT. I/O ENABLE EXT. I/O DISABLE

Switch 1: I/O Enable / Disable Test Mode


If Switch No.1 is turned ON, the Input / Output Module
will be bypassed and the STOP signal will be enabled
allowing Manual operations through the front panel
buttons for testing purposes. This is particularly
useful when Fieldbus interfaces are installed and
connection to the master device is not possible.
When finished testing the equipment, be sure to
turn Switch No. 1 OFF.
Do not change Switch No. 3 or 4.

Switch 2 : Angle Resolution


Normal angle resolution is 1.0 degree. Angle
resolution of 0.1 degree is available using this switch.
Note: SAN unit firmware version 3.3x is required and
the function enabled if using the AFC User Console for
monitoring purposes.

(Bottom View) Firmware Flash Connector (CN8)

4.8 Setting Default TCP/IP Address 





User Console Ethernet Port
For Multi-2 units with firmware 1.16 or greater, the IP address for the User Console Ethernet Port can be
reset to the default setting by following the directions below.
1. Turn off power to the unit
2. Turn “ON” DIP Switch no. 1, 2 & 4
3. Depress and HOLD the RESET button (on front of unit) and turn the power back on
4. Hold the RESET button until the green ACC LED turns on solid
5. Turn power off and reset DIP Switch back to original setting

When power is reapplied, the TCP/IP settings will revert to the following default;
IP Address: 192.168.10.10
Subnet Mask: 255.255.255.0
Default Gateway: 192.168.10.1

4.9 Firmware Flash Connector


Upgrades or revisions to firmware are handled easily with the on board Flash Connector located on
the bottom of each Multi-2 Unit. There is no need to remove or disassemble the unit. A flash adapter
(CONTROLLER-ROM) containing the new firmware can be connected to connector CN8 with the
power off to the unit. The power is then cycled on until the ACCEPT LED is blinking indicating the
firmware upload is complete. Turn off power and remove the flash adapter. The firmware update is
now complete.
Note: This connector is for FEC use only and it is not recommended for use other than FEC.

PAGE 4 - 19
Chapter 4: Installation & Wiring
AFC1500 Multi-2 Unit Hardware Manual (Rev. 2)

(Blank Page)

PAGE 4 - 20
Chapter 5: Control Interfaces
Chapter 5: Control
Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2)

5.1 I/O Interface Board


The Multi-2 unit interface board provides the interface between real world control signals and the
AFC1500 Fastening system I/O. Since there are many different I/O control structures in the
industry today, the Multi-2 unit has the ability to adapt to these through use of the I/O interface
board. The interface is available in many Fieldbus or “open architecture” configurations as well as
standard hardwired discrete I/O.

The Multi-2 unit I/O assumes control of the individual SAN unit I/O, thus eliminating the need to wire
to each individual spindle.

All I/O interface motherboards have a DIP Switch SW1 (located at position 7D) which has to be
configured so the Multi-2 Unit can identify the type of interface installed. The table below identifies
the switch set-up for configurable interface boards.

SW1 SW1 SW1 SW1


Interface Type
1 2 3 4
Discrete I/O (Sink Type – active true low ) ON OFF OFF OFF
Discrete I/O (Source Type – active true high) OFF ON OFF OFF
DeviceNet-S® (for Toolsnet®) ON ON OFF OFF
Profinet IO OFF OFF ON OFF
Interbus-S® (for Toolsnet®) ON OFF ON OFF
Allen Bradley Remote I/O OFF ON ON OFF
Profibus® (for Toolsnet®) ON ON ON OFF
Modbus Plus® OFF OFF OFF ON
DeviceNet-S® ON OFF OFF ON
Ethernet I/P OFF ON OFF ON
Interbus-S® ON ON OFF ON
Mitsubishi CC-Link® Version 2 (I/O & Messaging) OFF OFF ON ON
Profibus® ON OFF ON ON
Mitsubishi CC-Link® Version 1 (I/O only) OFF ON ON ON
M-Net ON ON ON ON
(Other interfaces available, contact FEC)

5.2 Interface Board DIP Switch Setup


Throughout this chapter, SW1 settings will be represented as follows:

- Represents switch position

CN3

12 34
22

1
23

13

34 12

22

23 1

13
CN4
Side View – I/O Interface Circuit Board

PAGE 5 - 2
Chapter 5: Control Interfaces
AFC1500 Multi-2 Unit Hardware Manual (Rev2)

5.3 Discrete I/O Interface


The Discrete I/O Interface is commonly used for hardwire direct connect PLC applications. Two
types of Discrete I/O interfaces are available: 24VDC Sinking Type and 24VDC Sourcing Type.
The standard discrete I/O interface is the Sinking Type interface.

5.3.1 Sinking Type (NPN)


The Sinking Type I/O interface is standard with discrete I/O Multi Units. It connects to 24VDC
True Low type (NPN) PLC cards.

- Represents switch position

CN3

12 34
22 CN3

12 34
22

1 1
23 23

13
13 12
34

34 12 22

22
23 1

CN4 13
23 1

CN4 13

Discrete I/O (Sinking Type) Board Specifications


Operating Voltage 24 VDC
Maximum current (outputs) 200 ma
Logic True Low (Sinking)
PLC-IN Connector: Honda #MR-34F
(Cable #FEB-1271) Housing: Honda #MR-34L
Mating Connectors
PLC-OUT Connector: Honda #MR-34M
(Cable #FEB-1272) Housing: Honda #MR-34L

PAGE 5 - 3
Chapter 5: Control
Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2)

5.3.1.1 Discrete Signal Connection (Sinking Type)

AFC1500 MULTI-2 Unit Device PLC

Output

Output

Input

Input

24VDC Power
Source

PAGE 5 - 4
Chapter 5: Control Interfaces
AFC1500 Multi-2 Unit Hardware Manual (Rev2)

5.3.2 Sourcing Type (PNP)


The Sourcing Type I/O interface is optional with discrete I/O Multi Units. It connects to 24VDC
True High type (PNP) PLC cards. (This interface must be specified during ordering)

- Represents switch position

CN3

12 34
22 CN3

12 34
22

1 1
23 23

13
13 12
34

34 12 22

22
23 1

13
CN4
23 1

CN4 13

Discrete I/O (Sourcing Type) Board Specifications


Operating Voltage 24 VDC
Maximum current (outputs) 200 ma
Logic True High (Sourcing)
PLC-IN Connector: Honda #MR-34F
(Cable #FEB-1271) Housing: Honda #MR-34L
Mating Connectors
PLC-OUT Connector: Honda #MR-34M
(Cable #FEB-1272) Housing: Honda #MR-34L

PAGE 5 - 5
Chapter 5: Control
Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2)

5.3.2.1 Discrete Signal Connection (Sourcing Type)

AFC1500 MULTI Unit Device PLC

Output signal

Input signal

PAGE 5 - 6
Chapter 5: Control Interfaces
AFC1500 Multi-2 Unit Hardware Manual (Rev2)

5.3.3 Input Signals (PLC-IN) Connector


The Input Signals are provided on the PLC IN connector. Inputs are assigned in the order as
shown in the table below and cannot be changed. Pins designated as “Not Used” have no
input assigned to them.
NOTE: When using Discrete I/O, “Bypass Spindle” input signals assigned to the PLC IN
connector can only be used for up to 10 individual Spindles (from the Multi-2 Unit). When
using Discrete I/O and you desire to connect this signal from additional spindles, the signal
must be wired from the individual SAN Controllers using the SAN Unit’s PLC connector. (An
alternative to this is to use a fieldbus interface which has control of all spindle bypass signals
from the interface.)

Contac
Pin# Signal Description
t
1 Emergency Stop N.C. Emergency Stop Input
2 Reset N.O. Reset Input
3 Reverse N.O. Reverse Spindle Rotation Input
4 Start N.O. Start Cycle Input
5 Sequence Select 0 N.O.
6 Sequence Select 1 N.O.
Sequence Select Input
7 Sequence Select 2 N.O.
8 Sequence Select 3 N.O.
9 Cycle Count Up N.O. Cycle Count Input
10 Cycle Count Clear N.O.
11 Self Check Disable N.O. Disables automatic self check
12 Sequence Select 4 N.O. Sequence Select Input
13 IN PORT 1 N.O.
14 IN PORT 2 N.O.
External Sequence interface Input
15 IN PORT 3 N.O.
16 IN PORT 4 N.O.
17 BYPASS Spindle No.1 N.O. Bypass’s spindle #1
18 BYPASS Spindle No.2 N.O. Bypass’s spindle #2
19 BYPASS Spindle No.3 N.O. Bypass’s spindle #3
20 BYPASS Spindle No.4 N.O. Bypass’s spindle #4
21 BYPASS Spindle No.5 N.O. Bypass’s spindle #5
22 BYPASS Spindle No.6 N.O. Bypass’s spindle #6
23 BYPASS Spindle No.7 N.O. Bypass’s spindle #7
24 BYPASS Spindle No.8 N.O. Bypass’s spindle #8
25 BYPASS Spindle No.9 N.O. Bypass’s spindle #9
26 BYPASS Spindle No.10 N.O. Bypass’s spindle #10
27 ID Data Clear N.O. Clear ID data from input buffer
28 ID Select Enable N.O. Enable Sequence selection from ID Data table.
29 Not Used
30 Data Select 0
31 Data Select 1 N.O. Output Data Bank Select inputs
32 Data Select 2
33 Input Signal Power Sink Type +24V
Common for input signal.
34 Input Signal Power Source Type +0V
Note) NC: Normal Closed, NO: Normal Open

For Input Signal definition see Section 4.7.2.

PAGE 5 - 7
Chapter 5: Control
Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2)

5.3.4 Ouput Signals (PLC-OUT) Connector


The Multi-2 Unit is capable of providing over 570 Output signals to indicate the status of the
Multi-2 Unit and of all the AFC1500 SAN Controllers connected to it (up to 31 controllers).
These signals are user configurable using the AFC User Console Software and may be
programmed on any designated pin. Up to 8 separate output data “Banks” can be set up,
each with 32 different output signals. The Output “Bank” is then selected using the Data
Select inputs (Data Select 0, Data Select 1, Data Select 2).

FEC Standard* Output Layout


NO Signal Type** Description
1 Total Reject NO Output when the fastening result is a REJECT.
2 Total Accept NO Output when the fastening result is a ACCEPT.
3 Abnormal NO Output when an Abnormal condition occurs.
4 Ready NO Output when the system is in the READY condition.
5 Busy NO System is in cycle
6 End NO Output when a fastening cycle is complete.
7 Sequence Output 0 NO
8 Sequence Output 1 NO
Output confirmation of SEQUENCE SELECT 0~4 input
9 Sequence Output 2 NO
selections.
10 Sequence Output 3 NO
11 Sequence Output 4 NO
12 Out Port 1 NO
13 Out Port 2 NO
14 Out Port 3 NO These signals will output when the fastening sequence
15 Out Port 4 NO reaches a step that has a [PLC OUTPUT] instruction
16 Out Port 5 NO inserted.
17 Out Port 6 NO
18 Out Port 7 NO
19 Spindle in Bypass NO Output when any connected spindle is in Bypass
20 Current Limit Warning NO Active when the high current limit has been exceeded.
21
~ As Configured NO
29
30 Always ON / Always OFF NO See “Output Data Banks” on following page
31 Always ON / Always OFF NO See “Output Data Banks” on following page
32 Always ON / Always OFF NO See “Output Data Banks” on following page
33 Output Signal Power Sink Type +0V
Common for output signal.
34 Output Signal Power Source Type +24V
*This “Standard” layout is only provided as a guide. Any signal may be programmed on any pin
using the AFC Software.
The layout above is programmed standard from FEC. It contains only “Multi” or system signals as shown,
however, individual spindle signals are available and may be programmed (Ex. Individual spindle accept or
reject – See 4.7.3 for complete list of signals that may be programmed on these pins)
** Type: NO = (Normally Open)

For Output Signal definition see Section 4.7.3.

PAGE 5 - 8
Chapter 5: Control Interfaces
AFC1500 Multi-2 Unit Hardware Manual (Rev2)

5.3.4.1 Ouput Data Banks


When working with the Discrete I/O interface, the output signals are programmed into
“Banks” of 32 output signals in up to 8 output “Banks” (Max. 256 outputs). If the required
output signals from the Multi-2 Unit exceed 32 signals, then Bank 2 can be programmed
with additional signals. If over 64 signals are required, Bank 3 can be programmed and
so on. These Output “Banks” can then be selected by the Data Select input signals. The
Data Select input signals 0, 1 & 2 together form a binary code to select up to eight (8)
different Data Banks. (See Table 3 below)

Note: Bank Select inputs do not function with any interface except the Discrete I/O
interface. When using Bank selects, it is recommended that the bank number be
monitored to confirm actual output status of shared discrete output points. This can be
performed by using the “Always On / Always Off” bits set-up in specific discrete output
points when programming the output points with the AFC User Console Software. For
this function, program the “Always On / Always Off” bits to mimic the Data Select input
bits. “Always On” bits will turn on the output in that particular Bank as soon as the bank
is selected. “Always Off” bits will turn off the output in the particular Bank which is
selected. Using different combinations of these bits programmed in an output in each
Bank will allow monitoring of which Bank is selected.
The number of discrete outputs used for this monitoring function depends on how many
Banks are required as shown below:

Number of Discrete Outputs Required


Number of Banks Required
for Monitoring Output Bank Status
1 (32 outputs) 0 or 1
2-4 (64 – 128 outputs) 2
5-8 (160 – 256 outputs) 3

Typically these “Always On / Always Off” bits are programmed in the last output points
(Pins 30 -32 as shown on the previous page).

[Table 3] Output Data (BANK) Selection


Data Select 2 Data Select 1 Data Select 0 Output Data Bank
OFF OFF OFF 0
OFF OFF ON 1
OFF ON OFF 2
OFF ON ON 3
ON OFF OFF 4
ON OFF ON 5
ON ON OFF 6
ON ON ON 7

PAGE 5 - 9
Chapter 5: Control
Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2)

5.3.5 Standard I/O Cable – Wire Color Code


The table below shows the color code of the standard FEC Discrete I/O cable used for I/O
connectors PLC IN and PLC OUT.
(FEC Cable Assemblies #FEB -1271 (PLC IN Cable), #FEB-1272 (PLC OUT Cable))

Pin No. Wire Color


1 Black
2 Brown
3 Red
4 Orange
5 Yellow
6 Green
7 Blue
8 Violet
9 Gray
10 White
11 White/Black
12 White/Brown
13 White/Red
14 White/Orange
15 White/Yellow
16 White/Green
17 White/Blue
18 White/Violet
19 White/Gray
20 White/Black/Brown
21 White/Black/Red
22 White/Black/Orange
23 White/Black/Yellow
24 White/Black/Green
25 White/Black/Blue
26 White/Black/Violet
27 White/Black/Gray
28 White/Brown/Red
29 White/Brown/Orange
30 White/Brown/Yellow
31 White/Brown/Green
32 White/Brown/Blue
33 White/Brown/Violet
34 White/Brown/Gray

PAGE 5 - 10
Chapter 5: Control Interfaces
AFC1500 Multi-2 Unit Hardware Manual (Rev2)

5.4 Interbus S® Interface


InterBus S from Phoenix Contact is an open-ring based, distributed device I/O network. I/O data is
transmitted in frames that provide simultaneous and predictable updates to all devices in the
network. This interface board (S - version) has up to 512 bytes of assigned input data and 512 bytes
of assigned output data* (64bytes default). The 64 bytes of assigned I/O data allow a maximum of
512 inputs and 512 outputs per node. FEC I/O is assigned to the I/O points in these data areas
(some I/O will be designated spare). FEC Inputs match the discrete input layout. FEC Output
locations are programmed using the AFC User Console Software.

* When using Master boards where the PCP channel is NOT supported, the maximum number of
I/O will be 20 input bytes and 20 output bytes.

FEC integrates the Interbus S board manufactured by HMS Fieldbus Systems AB into the Multi-2
Unit modular I/O board. For further technical information on the Interbus S interface go to the HMS
website. (www.hms.se)

- Represents switch position

Daughter board
DB9 Connector (male)
6 1
6 1 1

9 5 5 2
9
RBC BA

5 RBDA/ERR
9
9 5 6 1 3
7
6
4
6 1 5
DB9 Connector
(female)

3 1
4 2

Item Description
1 Application Connector
2 BUS-IN Connector
3 BUS-OUT Connector
4 Baud Rate Jumper
5 Status LEDs (4)
6 UL LED - Green if voltage is OK at Bus
Red - (flashing @ 2Hz) - ASIC and FLASH ROM check fault.
Green (flashing @ 2Hz) - module not initialized.
7 Watchdog LED Green (flashing @ 1Hz) - module initialized and running OK.
Red (flashing @ 1Hz) - RAM check fault.
Red (flashing @ 4Hz) - DPRAM check fault.

PAGE 5 - 11
Chapter 5: Control
Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2)

InterBus Specifications
Baud Rate 500K or 2M bits/sec.
Nodes 256
Distance 400 m
Cable Point to point twisted pair
Packet Size 1-256 words
Communication Type Master/Slave

Interface Specifications
Input data bytes (including free data) 512 (Default: 64 input data*)
Output data bytes (including free data) 512 (Default: 64 output data*)
Interface type Remote bus interface
Operating Voltage +5VDC / 200 ma
Data Width 4 words (1 word PCP, 3 words data)
ID Code F3 Hex
Output objects 6000H through 603FH
Input objects 6040H through 607FH
* Actual Input/Output data length is configurable using the AFC Software package.

PAGE 5 - 12
Chapter 5: Control Interfaces
AFC1500 Multi-2 Unit Hardware Manual (Rev2)

5.4.1 Component Descriptions

Fieldbus Interface Connectors

Bus IN Pin No. Signal Description


Housing PE Protective Earth Ground
1 DO1 Data Output
6 1 2 DI1 Data Input
3 GND Signal Ground
9 4 NC -
5
5 NC -
6 /DO1 Inverted Data Output
7 /DI1 Inverted Data Input
8 NC -
(9 pin male D-sub) 9 NC -

Bus OUT Pin No. Signal Description


Housing PE Protective Earth Ground
1 DO2 Data Output
2 DI2 Data Input
3 GND Signal Ground
9 5
4 NC -
5 GND Signal Ground
6 1 6 /DO2 Inverted Data Output
7 /DI2 Inverted Data Input
8 NC -
(9 pin female D-sub) 9 RBST *

*Always terminate RBST to ground if it is not the last module on the bus. If the RBST is not
connected to ground, the interface will automatically terminate the bus.

Baud Rate Switch

The module supports 2Mbit/s and 500Kbit/s operation. To select the


desired baud rate, just move the jumper cap to the corresponding
location.

Baud rate must be selected before power is on and cannot be changed during operation.

Status LEDs

No. LED Color Description


1 CC/RC Green Cable connection is good & master not in reset
2 BA Green Bus Active
3 RD Yellow Remote Bus Disabled
PCP - Communication active.
4 TR Green
Hold Time = 500ms

PAGE 5 - 13
Chapter 5: Control
Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2)

5.4.2 AFC User Console Software Settings


The Anybus board is set up by sending a Fieldbus Configuration File (*.fcf) containing
initialization messages from the Multi-2 Unit to the board during power up. This string of data
initializes different characteristics required for the board to communicate over the Interbus S
network. In this string are messages which set the length of I/O data as well as other messages.
Since the board is only initialized during power-up, the Multi-2 Unit MUST have the power
cycled OFF/ON after the “fcf” file is downloaded.

To download the fcf file, select “Field Bus Setup” from the “Multi” pull down menu. Select the
appropriate “Bus Type” and click “Browse” to locate the correct fcf file. After the file has been
selected, click “download” to send the file data to the Anybus board.

If no file exists (or if the settings need to be changed), after the Bus Type has been selected
click on the Setup Tab.

Select the desired settings from the pull downs. When finished, go back to the General Tab and
click “download” to send the file data to the Anybus board.

PAGE 5 - 14
Chapter 5: Control Interfaces
AFC1500 Multi-2 Unit Hardware Manual (Rev2)

5.4.3 Input Signals Mapping (CH1 ~ CH16)


Inputs are assigned in the order as shown in the table below and cannot be changed. Bits
designated as “Unused” have no input assigned to them.
NOTE: If Interbus S TOOLSNET version is used – Input/Output Signal layout is different
than shown. See 5.12 for TOOLSNET I/O Layout

FEC Multi-2 FEC Multi-2


CH. No. Bit Signal CH. No. Bit Signal
Bit Bit
0bit Emergency Stop 1 0bit BYPASS SP#1 17
1bit Reset 2 1bit BYPASS SP#2 18
2bit Reverse 3 2bit BYPASS SP#3 19
3bit Start 4 3bit BYPASS SP#4 20
4bit Sequence Select 0 5 4bit BYPASS SP#5 21
5bit Sequence Select 1 6 5bit BYPASS SP#6 22
6bit Sequence Select 2 7 6bit BYPASS SP#7 23
Input CH. Input CH.
7bit Sequence Select 3 8 7bit BYPASS SP#8 24
8bit Cycle Count Up 9 8bit BYPASS SP#9 25
No.01 No.02
9bit Cycle Count Clear 10 9bit BYPASS SP#10 26
10bit Self Check Disable 11 10bit Unused 27
11bit Sequence Select 4 12 11bit Unused 28
12bit INPORT 1 13 12bit Unused 29
13bit INPORT 2 14 13bit Unused 30
14bit INPORT 3 15 14bit Unused 31
15bit INPORT 4 16 15bit Unused 32

FEC Multi-2 FEC Multi-2


CH. No. Bit Signal CH. No. Bit Signal
Bit Bit
0bit BYPASS SP#11 33 0bit BYPASS SP#27 49
1bit BYPASS SP#12 34 1bit BYPASS SP#28 50
2bit BYPASS SP#13 35 2bit BYPASS SP#29 51
3bit BYPASS SP#14 36 3bit BYPASS SP#30 52
4bit BYPASS SP#15 37 4bit BYPASS SP#31 53
5bit BYPASS SP#16 38 5bit 54
6bit BYPASS SP#17 39 6bit 55
Input CH. Input CH.
7bit BYPASS SP#18 40 7bit 56
8bit BYPASS SP#19 41 8bit 57
No.03 No.04
9bit BYPASS SP#20 42 9bit 58
10bit BYPASS SP#21 43 10bit 59
11bit BYPASS SP#22 44 11bit 60
12bit BYPASS SP#23 45 12bit 61
13bit BYPASS SP#24 46 13bit 62
14bit BYPASS SP#25 47 14bit 63
15bit BYPASS SP#26 48 15bit 64

The Channel Number at the Master Unit output side differs according to node address settings.
Please check before operating the unit.

Note: For signal definitions see Section 4.7.2

PAGE 5 - 15
Chapter 5: Control
Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2)

5.4.4 Ouput Signals (CH1 ~ CH16)


The Multi-2 Unit is capable of providing over 570 Output signals to indicate the status of the
Multi-2 Unit and of all the AFC1500 SAN Controllers connected to it (up to 31 controllers).
See Section 4.7.3 for available output signals.

FEC Multi-2
CH. No. Bit Signal Bank Bit
0bit Total Reject 1 1
1bit Total Accept 1 2
2bit Abnormal 1 3 These Output signals are user
3bit Ready 1 4 configurable using the AFC User
4bit Busy 1 5
5bit End 1 6 Console Software and may be
6bit Sequence Output 0 1 7 programmed on any designated
Output CH. 7bit Sequence Output 1 1 8 bit.
No.01 8bit Sequence Output 2 1 9
9bit Sequence Output 3 1 10
10bit Sequence Output 4 1 11 The Output signal mapping
11bit Spindle in Bypass 1 12 shown is only an EXAMPLE.
12bit Current Warning 1 13 The signals may be programmed
13bit 1 14
for placement in ANY bit
14bit 1 15
position.
15bit 1 16
0bit Spindle No.1 Accept 1 17
1bit Spindle No.1 Reject 1 18
2bit Spindle No.1 ABN. 1 19
3bit Spindle No.1 BYP 1 20
4bit Spindle No.2 Accept 1 21
5bit Spindle No.2 Reject 1 22
6bit Spindle No.2 ABN 1 23
Output CH. 7bit Spindle No.2 BYP 1 24
No.02
8bit Spindle No.3 Accept 1 25
9bit Spindle No.3 Reject 1 26
10bit Spindle No.3 ABN 1 27
11bit Spindle No.3 BYP 1 28
12bit Spindle No.4 Accept 1 29
13bit Spindle No.4 Reject 1 30
14bit Spindle No.4 ABN. 1 31
15bit Spindle No.4 BYP 1 32
0bit Spindle No.5 Accept 2 1
1bit Spindle No.5 Reject 2 2
2bit Spindle No.5 ABN. 2 3
3bit Spindle No.5 BYP 2 4
4bit Spindle No.6 Accept 2 5
5bit Spindle No.6 Reject 2 6
6bit Spindle No.6 ABN 2 7
Output CH. 7bit Spindle No.6 BYP 2 8
No.03 8bit Spindle No.7 Accept 2 9
9bit Spindle No.7 Reject 2 10
10bit Spindle No.7 ABN 2 11
11bit Spindle No.7 BYP 2 12
12bit Spindle No.8 Accept 2 13
13bit Spindle No.8 Reject 2 14
14bit Spindle No.8 ABN. 2 15
15bit Spindle No.8 BYP 2 16

CH. No. Bit Signal
0bit 8 1
Output CH.

No.16
15bit 8 32
The CH. No. at the Master input side differs according to node address settings.
Please check before operating the unit.

PAGE 5 - 16
Chapter 5: Control Interfaces
AFC1500 Multi-2 Unit Hardware Manual (Rev2)

5.5 DeviceNet® Interface


The DeviceNet communication interface allows slave connection to an industrial DeviceNet network.
DeviceNet allows industrial devices to be controlled over an open network architecture enabling
device connection at various locations in the field. This “fieldbus” technology reduces hard
wiring/cabling & provides ease of installation. It uses a broadcast-oriented protocol -the CAN
(Controller Area Network)- that can interface to many devices such as limit switches, sensors,
directional valves, motor starters, bar code readers, process sensors, frequency drives, etc. The
network can have up to 64 nodes.
Maximum I/O data is 512 input bytes & 512 output bytes. FEC Inputs match the discrete input
layout. FEC Output location is programmed using the AFC User Console Software.
Note: The DeviceNet interface is implemented according to the ODVA specification for a
communications adapter (profile no.12). It is acting as a “group two only server” on the DeviceNet
network.

FEC integrates the DeviceNet board manufactured by HMS Fieldbus Systems AB into the Multi-Unit
modular I/O board. For further technical information on the DeviceNet interface go to the HMS
website. (www.hms.se)
Further DeviceNet information can be found through the Open DeviceNet Vendors Association
(ODVA). (www.ODVA.org)

- Represents switch position

DEVICENET
CONNECTOR 1
DEVICENET DEVICENET
CONNECTOR CONNECTOR
2

BAUD/MAC ID BAUD/MAC ID
SETTING SETTING
BAUD/MAC ID 3
SETTING
5

LED LED
INDICATORS INDICATORS 4

LED
INDICATORS

Item Description
1 Application Connector
2 DeviceNet Connector
3 Configuration Switches
4 Status LEDs (4)
Red - (flashing @ 2Hz) - ASIC and FLASH ROM check fault.
Green (flashing @ 2Hz) - module not initialized.
5 Watchdog LED Green (flashing @ 1Hz) - module initialized and running OK.
Red (flashing @ 1Hz) - RAM check fault.
Red (flashing @ 4Hz) - DPRAM check fault.

PAGE 5 - 17
Chapter 5: Control
Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2)

DeviceNet Specifications
Speed 125K, 250K and 500K baud
Nodes 64
500 meters at 125K baud
Maximum Distance 250 meters at 250K baud
100 meters at 500K baud
Twisted pair for signal and power
Allen Bradley or equivalent ;
Cable
Thin Cable #1485C-P1-C
Thick Cable # 1485C-P1-A
Communications Type Master/Slave

Interface Board Specifications


Operating Voltage +5V, 200 ma
Output data bytes 512 max.*
Input data bytes 512 max.*
Servers per group 2 Maximum
Interface type Dual Port RAM or Serial Interface
* Typical configuration is 32 Bytes (256 I/O points) but can be altered using the AFC Software
package. (See AnyBus-S Reference at the end of this chapter for I/O Setting example.)

EDS File

Each device on a DeviceNet network is associated with an EDS file containing all necessary
information about the device to be connected. The network configuration program uses this file
during configuration of the network.
The EDS file associated with the FEC device can be downloaded from the FEC website.
www.fec-usa.com (file: abs.eds)
Direct link:www.fec-usa.com/fecusacomnew/support/index.htm
(the file can also be downloaded directly from HMS - www.hms.se)

Note: The FEC system will appear in the network Vendor list as “HMS Fieldbus Systems” and in
the network as “Anybus-S DeviceNet” adapter. This is the manufacturer of the interface board
which is integrated into the Multi-2 Unit.

NOTE: COMPATIBILITY ISSUE


There is a known compatibility issue using with OMRON C200HW-DRM21-V1
PLC’s and the Devicenet interface. This is an OMRON problem.

Omron suggests using CS1-DRM21-V1 PLC in its place.

PAGE 5 - 18
Chapter 5: Control Interfaces
AFC1500 Multi-2 Unit Hardware Manual (Rev2)

5.5.1 Component Descriptions

Fieldbus Interface Connections

Pin No. Signal Wire Color


1 V- Black
2 CAN_L Blue
3 Drain/Shield See “Termination”
4 CAN_H White
5 V+ Red

Termination

Termination of the fieldbus requires a terminating resistor at each end of the fieldbus. These
resistors should have a value of 121 ohms.

Configuration Switches

On a DeviceNet network, each node must be assigned its own unique Mac ID. The Mac ID is a
value between 0 and 63 used to identify each node. The Mac ID and Baud Rate are set using
the DIP switches on the front of the module.
These switches must be set before power is on and cannot be changed during operation.

Baud Rate Settings


Baud Rate SW-1 SW-2
125K OFF OFF
ON 250K OFF ON
1 500K ON OFF
2 Reserved ON ON
3 Mac ID Settings
4 Mac ID SW-3 (MSB) SW-4 SW-5 SW-6 SW-7 SW-8 (LSB)
5 Address 0 OFF OFF OFF OFF OFF OFF
6 Address 1 OFF OFF OFF OFF OFF ON
7 Address 2 OFF OFF OFF OFF ON OFF
8 Address 3 OFF OFF OFF OFF ON ON
… … … … … … …
Address 61 ON ON ON ON OFF ON
Address 62 ON ON ON ON ON OFF
Address 63 ON ON ON ON ON ON

Status LEDs

LED State Description


1 - Reserved - Reserved for future use.
Off Not Powered / Not Online
Green solid Link OK, Online, Connected
2 - Network Status Green flashing Online, Not connected
Red solid Critical Link Failure
Red flashing Connection Timeout
4 1 Off No power to device
3 2 Green solid Device operational
3 - Module Status Green flashing Data size bigger than configured
Red solid Unrecoverable fault
Red flashing Minor fault
4 - Reserved - Reserved for future use.

PAGE 5 - 19
Chapter 5: Control
Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2)

5.5.2 User Console Software Settings


The Anybus board is set up by sending a Fieldbus Configuration File (*.fcf) containing
initialization messages from the Multi-2 Unit to the board during power up. This string of data
initializes different characteristics required for the board to communicate over the DeviceNet
network. In this string are messages which set the length of I/O data as well as other messages.
Since the board is only initialized during power-up, the Multi-2 Unit MUST have the power
cycled OFF/ON after the “fcf” file is downloaded.

To download the fcf file, select “Field Bus Setup” from the “Multi” pull down menu. Select the
appropriate “Bus Type” and click “Browse” to locate the correct fcf file. After the file has been
selected, click “download” to send the file data to the Anybus board.

If no file exists (or if the settings need to be changed), after the Bus Type has been selected
click on the Setup Tab.

Select the desired settings from the pull downs. In I/O SETUP, select the “Input Data Length”
and “Output Data Length” as required by you application. (INPUT & OUTPUT in this screen refer
to PLC side I/O, INPUT = FEC Output size, OUTPUT = FEC Input size) When finished, go back
to the General Tab and click “download” to send the file data to the Anybus board.

The DeviceNet interface also has the ability to transfer fastening results data (message data).
Refer to the AFC1500 User Console Manual for message setup information.

See section 5.11.5 for message set-up example (reference only)

PAGE 5 - 20
Chapter 5: Control Interfaces
AFC1500 Multi-2 Unit Hardware Manual (Rev2)

5.5.3 Input Signals (CH1 ~ CH16)


Inputs are assigned in the order as shown in the table below and cannot be changed. Bits
designated as “Not Used” have no input assigned to them.
Operation Note: The first 16 bits of I/O are used by DeviceNet communication. The first input
must be set “ON” to enable communication.
NOTE: If Devicenet TOOLSNET version is used – Input/Output Signal layout is different
than shown. See 5.12 for TOOLSNET I/O Layout

FEC Multi-2 FEC Multi-2


CH. No. Bit Signal CH. No. Bit Signal
Bit Bit
0bit Emergency Stop 1 0bit BYPASS SP#1 17
1bit Reset 2 1bit BYPASS SP#2 18
2bit Reverse 3 2bit BYPASS SP#3 19
3bit Start 4 3bit BYPASS SP#4 20
4bit Sequence Select 0 5 4bit BYPASS SP#5 21
5bit Sequence Select 1 6 5bit BYPASS SP#6 22
6bit Sequence Select 2 7 6bit BYPASS SP#7 23
Input CH. Input CH.
7bit Sequence Select 3 8 7bit BYPASS SP#8 24
8bit Cycle Count Up 9 8bit BYPASS SP#9 25
No.01 No.02
9bit Cycle Count Clear 10 9bit BYPASS SP#10 26
10bit Self Check Disable 11 10bit Unused 27
11bit Sequence Select 4 12 11bit Unused 28
12bit INPORT 1 13 12bit Unused 29
13bit INPORT 2 14 13bit Unused 30
14bit INPORT 3 15 14bit Unused 31
15bit INPORT 4 16 15bit Unused 32

FEC Multi-2 FEC Multi-2


CH. No. Bit Signal CH. No. Bit Signal
Bit Bit
0bit BYPASS SP#11 33 0bit BYPASS SP#27 49
1bit BYPASS SP#12 34 1bit BYPASS SP#28 50
2bit BYPASS SP#13 35 2bit BYPASS SP#29 51
3bit BYPASS SP#14 36 3bit BYPASS SP#30 52
4bit BYPASS SP#15 37 4bit BYPASS SP#31 53
5bit BYPASS SP#16 38 5bit 54
6bit BYPASS SP#17 39 6bit 55
Input CH. Input CH.
7bit BYPASS SP#18 40 7bit 56
8bit BYPASS SP#19 41 8bit 57
No.03 No.04
9bit BYPASS SP#20 42 9bit 58
10bit BYPASS SP#21 43 10bit 59
11bit BYPASS SP#22 44 11bit 60
12bit BYPASS SP#23 45 12bit 61
13bit BYPASS SP#24 46 13bit 62
14bit BYPASS SP#25 47 14bit 63
15bit BYPASS SP#26 48 15bit 64

The Channel Number at the Master Unit output side differs according to node address settings.
Please check before operating the unit.

Note: For signal definitions see Section 4.7.2

PAGE 5 - 21
Chapter 5: Control
Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2)

5.5.4 Ouput Signals (CH1 ~ CH16)


The Multi-2 Unit is capable of providing over 570 Output signals to indicate the status of the
Multi-2 Unit and of all the AFC1500 SAN Controllers connected to it (up to 31 controllers).
See Section 4.7.3 for available output signals.

FEC Multi-2
CH. No. Bit Signal Bank Bit
0bit Total Reject 1 1
1bit Total Accept 1 2
2bit Abnormal 1 3 These Output signals are user
3bit Ready 1 4 configurable using the AFC User
4bit Busy 1 5
5bit End 1 6 Console Software and may be
6bit Sequence Output 0 1 7 programmed on any designated
Output CH. 7bit Sequence Output 1 1 8 bit.
No.01 8bit Sequence Output 2 1 9
9bit Sequence Output 3 1 10
10bit Sequence Output 4 1 11 The Output signal mapping
11bit Spindle in Bypass 1 12 shown is only an EXAMPLE.
12bit Current Warning 1 13 The signals may be programmed
13bit 1 14
for placement in ANY bit
14bit 1 15
position.
15bit 1 16
0bit Spindle No.1 Accept 1 17
1bit Spindle No.1 Reject 1 18
2bit Spindle No.1 ABN. 1 19
3bit Spindle No.1 BYP 1 20
4bit Spindle No.2 Accept 1 21
5bit Spindle No.2 Reject 1 22
6bit Spindle No.2 ABN 1 23
Output CH. 7bit Spindle No.2 BYP 1 24
No.02
8bit Spindle No.3 Accept 1 25
9bit Spindle No.3 Reject 1 26
10bit Spindle No.3 ABN 1 27
11bit Spindle No.3 BYP 1 28
12bit Spindle No.4 Accept 1 29
13bit Spindle No.4 Reject 1 30
14bit Spindle No.4 ABN. 1 31
15bit Spindle No.4 BYP 1 32
0bit Spindle No.5 Accept 2 1
1bit Spindle No.5 Reject 2 2
2bit Spindle No.5 ABN. 2 3
3bit Spindle No.5 BYP 2 4
4bit Spindle No.6 Accept 2 5
5bit Spindle No.6 Reject 2 6
6bit Spindle No.6 ABN 2 7
Output CH. 7bit Spindle No.6 BYP 2 8
No.03 8bit Spindle No.7 Accept 2 9
9bit Spindle No.7 Reject 2 10
10bit Spindle No.7 ABN 2 11
11bit Spindle No.7 BYP 2 12
12bit Spindle No.8 Accept 2 13
13bit Spindle No.8 Reject 2 14
14bit Spindle No.8 ABN. 2 15
15bit Spindle No.8 BYP 2 16

CH. No. Bit Signal
0bit 8 1
Output CH.

No.16
15bit 8 32
The CH. No. at the Master input side differs according to node address settings.
Please check before operating the unit.

PAGE 5 - 22
Chapter 5: Control Interfaces
AFC1500 Multi-2 Unit Hardware Manual (Rev2)

5.6 Profibus® Interface


The Profibus-DP communication interface allows slave connection to an industrial Profibus network.
Profibus-DP allows industrial devices to be controlled over an open network architecture enabling
device connection at various locations in the field. This “Fieldbus” technology reduces
hardwiring/cabling & provides ease of installation. It can interface to many devices such as limit
switches, sensors, directional valves, motor starters, bar code readers, process sensors, frequency
drives, etc. The network can have up to 126 nodes. Its maximum communication baud rate is 12M
baud and its minimum baud rate is 9.6K baud.
Node addressing is selectable using the address selection switches. Baud rate is auto detected from
the master and no user setup is required. Module & Network status LED’s provide network
diagnostics. Maximum I/O data is 244 input bytes & 244 output bytes. FEC Inputs match the discrete
input layout. FEC Output location is programmed using the AFC User Console Software.
Note: The Profibus interface is implemented according to the Profibus-DP EN 50 170 (DIN 19245
Part 1) specification.

FEC integrates the Profibus-DP board manufactured by HMS Fieldbus Systems AB into the Multi-
Unit modular I/O board. For further technical information on the Profibus interface go to the HMS
website. (www.hms.se)
Further Profibus information can be found on the Profibus website at www.profibus.com.

- Represents switch position

PROFIBUS
CONNECTOR 1
PROFIBUS PROFIBUS
CONNECTOR CONNECTOR 2

TERMINATION
TERMINATION TERMINATION
SWITCH SWITCH SWITCH 3

ADDRESS ADDRESS 4
SETTING SETTING
ADDRESS
6
SETTING

LED LED
INDICATORS 5
INDICATORS

LED
INDICATORS

Item Description
1 Application Connector
2 Profibus Connector
3 Terminator Switch
4 Address Switches
5 Status LEDs (4)
Red - (flashing @ 2Hz) - ASIC and FLASH ROM check fault.
Green (flashing @ 2Hz) - module not initialized.
6 Watchdog LED Green (flashing @ 1Hz) - module initialized and running OK.
Red (flashing @ 1Hz) - RAM check fault.
Red (flashing @ 4Hz) - DPRAM check fault.

PAGE 5 - 23
Chapter 5: Control
Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2)

Profibus Specifications

Speed 9.6K - 12M baud - auto selected


Nodes 126 Note: Node 126 is reserved for commissioning purposes only
Distance 200m max. at 1.5Mbit/s extendable with repeaters.
Cable Shielded Copper Twisted Pair or fiber optic
Communications Type Master/Slave - EIA RS485
Protocol Version Ver. 1.10
Maximum Cyclic I/O Size 244bytes In, 244 bytes out max. 416 total bytes max.
Data transmission The module only supports cyclic I/O data transmission.

Configuration

FEC Profibus I/O configuration is programmable using the AFC User Console software. I/O can
be set as required by the application according to parameter limits set forth by the GSD
(Profibus) configuration file. The AFC Software allows configuration of the number of I/O in the
Multi Unit. Configuration of the Profibus Master MUST match the configuration of the FEC
Profibus slave. In the Profibus Master setup, input size and output size is set as “byte” ordering.
(Do not use “word” ordering. This will inverse the I/O location) When setting the Profibus Master
configuration, PLC input size refers to FEC output size (ie. Accept, Reject, Busy, etc.) and PLC
output size refers to FEC inputs (ie. Start, Stop, Reset, etc.). FEC will show up as 2 modules.
Module 1 is inputs, module 2 is outputs. (See AnyBus-S Reference at the end of this chapter for
I/O Setting example.)

GSD File

Each device on a Profibus network is associated with a GSD file containing all necessary
information about the device to be connected. The network configuration program uses this file
during configuration of the network.
The GSD file associated with the FEC device can be downloaded from the FEC website.
www.fec-usa.com (File : hms_1003.gsd)
Direct link:www.fec-usa.com/fecusacomnew/support/index.htm
(The file can also be downloaded directly from HMS - www.hms.se)

PAGE 5 - 24
Chapter 5: Control Interfaces
AFC1500 Multi-2 Unit Hardware Manual (Rev2)

5.6.1 Component Descriptions

Fieldbus Interface Connection

Pin No. Signal Description


1 N.C.
2 N.C.
9 5
3 B- Line Positive RxD/TxD according to RS485 Spec.
4 RTS Request to send
6 1
5 GND Bus Isolated GND from RS 485 side
6 +5V Bus Isolated +5V from RS 485 side
7 N.C.
8 A- Line Negative RxD/TxD according to RS485 Spec.
9 N.C.
(9 pin female D-sub) Housing Shield Connected to PE

Termination

Termination of the fieldbus requires a terminating resistor at each end of the


fieldbus. A termination switch is provided on the Profibus-DP interface board.
Set the switch to “ON”, if termination is required. If external terminators are
used, the switch must be in the off position.

Node Address

Before configuring the Profibus-DP module, the node address has to be set.
This is done with two rotary switches on the module which can set the node
address 1-99 in decimal format. The Upper rotary switch (closest to the D-sub)
sets the “tens” digit (10x), and the bottom rotary switch sets the “ones” digit (1x).
Example: To set node 37, place the “tens” digit switch on 3 and the “ones” digit
switch on 7.
This switch must be set before power is on, and cannot be changed
during operation.

Status LEDs

LED Status Description


1 - Not Used
Off Module not on-line
2
Green Module is on-line and data exchange is possible.
Off Module is not off-line
3 Module is off-line and data exchange is not
Red
possible.
Off No diagnostics present.
Error in configuration: IN and/or OUT length set
4 1 Red flashing at 1 during initialization of the module is not equal to
second intervals the length set during configuration of the
3 2 4 network.
Error in user parameter data: The
Fieldbus length/contents of the User Parameter data set
Red flashing at 1/2
Diagnostics during initialization of the module is not equal to
second intervals
the length/contents set during configuration of
the network.
Red flashing at 1/4 Error in initialization of the PROFIBUS
second intervals communication ASIC.

PAGE 5 - 25
Chapter 5: Control
Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2)

5.6.2 User Console Software Settings


The Anybus board is set up by sending a Fieldbus Configuration File (*.fcf) containing
initialization messages from the Multi-2 Unit to the board during power up. This string of data
initializes different characteristics required for the board to communicate over the Profibus
network. In this string are messages which set the length of I/O data as well as other messages.
Since the board is only initialized during power-up, the Multi-2 Unit MUST have the power
cycled OFF/ON after the “fcf” file is downloaded.

To download the fcf file, select “Field Bus Setup” from the “Multi” pull down menu. Select the
appropriate “Bus Type” and click “Browse” to locate the correct fcf file. After the file has been
selected, click “download” to send the file data to the Anybus board.

If no file exists (or if the settings need to be changed), after the Bus Type has been selected
click on the Setup Tab.

Select the desired settings from the pull downs. When finished, go back to the General Tab and
click “download” to send the file data to the Anybus board.

PAGE 5 - 26
Chapter 5: Control Interfaces
AFC1500 Multi-2 Unit Hardware Manual (Rev2)

5.6.3 Input Signals (Word 01 ~ Word 16)


Inputs are assigned in the order as shown in the table below and cannot be changed. Bits
designated as “Unused” have no input assigned to them.
NOTE: If Profibus TOOLSNET version is used – Input/Output Signal layout is different
than shown. See 5.12 for TOOLSNET I/O Layout

FEC Multi-2 FEC Multi-2


CH. No. Bit Signal CH. No. Bit Signal
Bit Bit
0bit Emergency Stop 1 0bit BYPASS SP#1 17
1bit Reset 2 1bit BYPASS SP#2 18
2bit Reverse 3 2bit BYPASS SP#3 19
3bit Start 4 3bit BYPASS SP#4 20
4bit Sequence Select 0 5 4bit BYPASS SP#5 21
5bit Sequence Select 1 6 5bit BYPASS SP#6 22
6bit Sequence Select 2 7 6bit BYPASS SP#7 23
Input Word Input Word
7bit Sequence Select 3 8 7bit BYPASS SP#8 24
8bit Cycle Count Up 9 8bit BYPASS SP#9 25
No.01 No.02
9bit Cycle Count Clear 10 9bit BYPASS SP#10 26
10bit Self Check Disable 11 10bit Unused 27
11bit Sequence Select 4 12 11bit Unused 28
12bit INPORT 1 13 12bit Unused 29
13bit INPORT 2 14 13bit Unused 30
14bit INPORT 3 15 14bit Unused 31
15bit INPORT 4 16 15bit Unused 32

FEC Multi-2 FEC Multi-2


CH. No. Bit Signal CH. No. Bit Signal
Bit Bit
0bit BYPASS SP#11 33 0bit BYPASS SP#27 49
1bit BYPASS SP#12 34 1bit BYPASS SP#28 50
2bit BYPASS SP#13 35 2bit BYPASS SP#29 51
3bit BYPASS SP#14 36 3bit BYPASS SP#30 52
4bit BYPASS SP#15 37 4bit BYPASS SP#31 53
5bit BYPASS SP#16 38 5bit 54
6bit BYPASS SP#17 39 6bit 55
Input Word Input Word
7bit BYPASS SP#18 40 7bit 56
8bit BYPASS SP#19 41 8bit 57
No.03 No.04
9bit BYPASS SP#20 42 9bit 58
10bit BYPASS SP#21 43 10bit 59
11bit BYPASS SP#22 44 11bit 60
12bit BYPASS SP#23 45 12bit 61
13bit BYPASS SP#24 46 13bit 62
14bit BYPASS SP#25 47 14bit 63
15bit BYPASS SP#26 48 15bit 64

Note: For signal definitions see Section 4.7.2

PAGE 5 - 27
Chapter 5: Control
Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2)

5.6.4 Ouput Signals (Word 01 ~ Word 16)


The Multi-2 Unit is capable of providing over 570 Output signals to indicate the status of the
Multi-2 Unit and of all the AFC1500 SAN Controllers connected to it (up to 31 controllers).
See Section 4.7.3 for available output signals.
FEC Multi-2
Word No. Bit Signal Bank Bit
0bit Total Reject 1 1
1bit Total Accept 1 2
2bit Abnormal 1 3 These Output signals are user
3bit Ready 1 4
configurable using the AFC User
4bit Busy 1 5
5bit End 1 6 Console Software and may be
Output 6bit Sequence Output 0 1 7 programmed on any designated
Word 7bit Sequence Output 1 1 8
No.01 bit.
8bit Sequence Output 2 1 9
9bit Sequence Output 3 1 10
10bit Sequence Output 4 1 11 The Output signal mapping
11bit Spindle in Bypass 1 12 shown is only an EXAMPLE.
12bit Current Warning 1 13 The signals may be programmed
13bit 1 14
for placement in ANY bit
14bit 1 15
15bit 1 16 position.
0bit Spindle No.1 Accept 1 17
1bit Spindle No.1 Reject 1 18
2bit Spindle No.1 ABN. 1 19
3bit Spindle No.1 BYP 1 20
4bit Spindle No.2 Accept 1 21
Output 5bit Spindle No.2 Reject 1 22
Word 6bit Spindle No.2 ABN 1 23
No.02 7bit Spindle No.2 BYP 1 24
8bit Spindle No.3 Accept 1 25
9bit Spindle No.3 Reject 1 26
10bit Spindle No.3 ABN 1 27
11bit Spindle No.3 BYP 1 28
12bit Spindle No.4 Accept 1 29
13bit Spindle No.4 Reject 1 30
14bit Spindle No.4 ABN. 1 31
15bit Spindle No.4 BYP 1 32
0bit Spindle No.5 Accept 2 1
1bit Spindle No.5 Reject 2 2
2bit Spindle No.5 ABN. 2 3
3bit Spindle No.5 BYP 2 4
4bit Spindle No.6 Accept 2 5
Output
5bit Spindle No.6 Reject 2 6
Word 6bit Spindle No.6 ABN 2 7
No.03 7bit Spindle No.6 BYP 2 8
8bit Spindle No.7 Accept 2 9
9bit Spindle No.7 Reject 2 10
10bit Spindle No.7 ABN 2 11
11bit Spindle No.7 BYP 2 12
12bit Spindle No.8 Accept 2 13
13bit Spindle No.8 Reject 2 14
14bit Spindle No.8 ABN. 2 15
15bit Spindle No.8 BYP 2 16

CH. No. Bit Signal
0bit 8 1
Output CH.

No.16
15bit 8 32

PAGE 5 - 28
Chapter 5: Control Interfaces
AFC1500 Multi-2 Unit Hardware Manual (Rev2)

5.7 Modbus Plus® Interface


Modbus Plus is a local area network system designed for industrial control and monitoring
applications developed by Modicon Inc. The network enables programmable controllers, host
computers and other devices to communicate throughout the plant. Modbus Plus is normally used in
industrial automation to transfer fast data (up to 1Mbit/sec.) for motor controllers, MMI, I/O units and
other industrial equipment.
This interface board has up to 16 words of assigned input data and 16 words of assigned output
data (256 inputs / 256 outputs). FEC I/O is assigned to the I/O points in these data areas (some I/O
will be designated spare). FEC Inputs match the discrete input layout. FEC Output locations are
programmed using the AFC User Console Software.

FEC integrates the Modbus Plus board manufactured by HMS Fieldbus Systems AB into the Multi-2
Unit’s modular I/O board. For further technical information on the Modbus Plus interface go to the
HMS website. (www.hms.se)

- Represents switch position

Daughter board
DB9 Connector (male)

6 1 1

2
9 5
RBC BA

5 RBDA/ERR
9
3
6 1
4 6

5
DB9 Connector
(female)

Item Description
1 Application Connector
2 Modbus Plus Connector
3 Node ID Switch
4 Source ID Switch
5 Status LEDs (4)
Red - (flashing @ 2Hz) - ASIC and FLASH ROM check fault.
Green (flashing @ 2Hz) - module not initialized.
6 Watchdog LED Green (flashing @ 1Hz) - module initialized and running OK.
Red (flashing @ 1Hz) - RAM check fault.
Red (flashing @ 4Hz) - DPRAM check fault.

PAGE 5 - 29
Chapter 5: Control
Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2)

Modbus Plus Specifications


Baud Rate 1M bits/sec.
Max. Nodes 32 (with repeaters - 64)
Max. Distance 2000m (with repeaters)
Max. Bus Cable Length 500m
Cable RS-485 twisted pair (1-pair + Shield)
Communication Type Master/Slave

Interface Specifications
Input data 16 words (256 bits)*
Output data 16 words (256 bits)*
Interface type token bus interface
Operating Voltage +5VDC / 200 ma
Data Width 8 bits
* Actual Input/Output data length is configurable using the AFC Software package.

PAGE 5 - 30
Chapter 5: Control Interfaces
AFC1500 Multi-2 Unit Hardware Manual (Rev2)

5.7.1 Component Descriptions

Fieldbus Interface Connector

Pin No. Signal Description


Housing PE Protective Earth Ground
1 Shield Cable Shield
9 5 2 MBP Line B Modbus Plus Line B
3 MBP Line A Modbus Plus Line A
4 NC -
6 1
5 NC -
6 NC -
7 NC -
8 NC -
(9 pin female D-sub) 9 NC -

Node ID & Source ID Switches

(S1) Node ID Settings


Function SW-1 (MSB) SW-2 SW-3 SW-4 SW-5 SW-6 (LSB)
Address 1 ON ON ON (LSB
ON ON ON
Address 2 ON ON ON )
ON ON OFF
Address 3 ON ON ON ON OFF ON
Address 4 ON ON ON ON OFF OFF
… … … … … … …
Address 62 OFF OFF OFF OFF ON OFF
Address 63 OFF OFF OFF OFF OFF ON
Address 64 OFF OFF OFF OFF OFF OFF
(S2) Source ID Settings
Function SW-1 (MSB) SW-2 SW-3 SW-4 SW-5 SW-6 (LSB)
Address 1 ON ON ON ON ON ON
Address 2 ON ON ON ON ON OFF
Address 3 ON ON ON ON OFF ON
Address 4 ON ON ON ON OFF OFF
… … … … … … …
Address 62 OFF OFF OFF OFF ON OFF
Address 63 OFF OFF OFF OFF OFF ON
Address 64 OFF OFF OFF OFF OFF OFF

S1 and S2 settings must be made before power is on and cannot be changed during
operation.

PAGE 5 - 31
Chapter 5: Control
Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2)

Status LEDs

LED Status Description


1 - Not Used
2
Red Communication is not OK.
ERROR
Green flashing
Node working normal, receiving and passing
every 160ms; on
token.
80ms; off 80ms
Green flashing at
Node is in MONITOR_OFFLINE state.
1 second intervals
Green - 2 flashes,
on 160ms then off Node is in MAC_IDLE never-getting-token state.
4 1 3
480ms.
MBP
3 2
Active Green - 3 flashes,
on 160ms, off
Node is not hearing any other nodes.
240ms then off
1.6sec.
Green - 4 flashes,
on 160ms, off
Node has detected duplicate node address.
240ms then off
1.2sec.
4
Green Peer interface is initialized.
MBP Init

PAGE 5 - 32
Chapter 5: Control Interfaces
AFC1500 Multi-2 Unit Hardware Manual (Rev2)

5.7.2 User Console Software Settings


The Anybus board is set up by sending a Fieldbus Configuration File (*.fcf) containing
initialization messages from the Multi-2 Unit to the board during power up. This string of data
initializes different characteristics required for the board to communicate over the Modbus Plus
network. In this string are messages which set the length of I/O data as well as other messages.
Since the board is only initialized during power-up, the Multi-2 Unit MUST have the power
cycled OFF/ON after the “fcf” file is downloaded.

To download the fcf file, select “Field Bus Setup” from the “Multi” pull down menu. Select the
appropriate “Bus Type” and click “Browse” to locate the correct fcf file. After the file has been
selected, click “download” to send the file data to the Anybus board.

If no file exists (or if the settings need to be changed), after the Bus Type has been selected
click on the Setup Tab.

Select the desired settings from the pull downs. When finished, go back to the General Tab and
click “download” to send the file data to the Anybus board.

PAGE 5 - 33
Chapter 5: Control
Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2)

5.7.3 Input Signals (Word 01 ~ Word 16)


Inputs are assigned in the order as shown in the table below and cannot be changed. Bits
designated as “Unused” have no input assigned to them.
Since Modbus Plus sends I/O signals 8 bits at a time, and trying to use the data as a
word, all bits and bytes are transferred backwards.

FEC Multi-2 FEC Multi-2


Word No. Bit Signal Word No. Bit Signal
Bank Bit Bank Bit
0bit Sequence Select 3 8 0bit BYPASS SP#8 24
1bit Sequence Select 2 7 1bit BYPASS SP#7 23
2bit Sequence Select 1 6 2bit BYPASS SP#6 22
3bit Sequence Select 0 5 3bit BYPASS SP#5 21
4bit Start 4 4bit BYPASS SP#4 20
5bit Reverse 3 5bit BYPASS SP#3 19
6bit Reset 2 6bit BYPASS SP#2 18
Input Word Input Word
7bit Emergency Stop 1 7bit BYPASS SP#1 17
8bit INPORT 4 16 8bit Unused 32
No.01 No.02
9bit INPORT 3 15 9bit Unused 31
10bit INPORT 2 14 10bit Unused 30
11bit INPORT 1 13 11bit Unused 29
12bit Sequence Select 4 12 12bit Unused 28
13bit Self Check Disable 11 13bit Unused 27
14bit Cycle Count Clear 10 14bit BYPASS SP#10 26
15bit Cycle Count Up 9 15bit BYPASS SP#9 25

FEC Multi-2 FEC Multi-2


Word No. Bit Signal Word No. Bit Signal
Bank Bit Bank Bit
0bit BYPASS SP#18 40 0bit 56
1bit BYPASS SP#17 39 1bit 55
2bit BYPASS SP#16 38 2bit 54
3bit BYPASS SP#15 37 3bit BYPASS SP#31 53
4bit BYPASS SP#14 36 4bit BYPASS SP#30 52
5bit BYPASS SP#13 35 5bit BYPASS SP#29 51
6bit BYPASS SP#12 34 6bit BYPASS SP#28 50
Input Word Input Word
7bit BYPASS SP#11 33 7bit BYPASS SP#27 49
8bit BYPASS SP#26 48 8bit 64
No.03 No.04
9bit BYPASS SP#25 47 9bit 63
10bit BYPASS SP#24 46 10bit 62
11bit BYPASS SP#23 45 11bit 61
12bit BYPASS SP#22 44 12bit 60
13bit BYPASS SP#21 43 13bit 59
14bit BYPASS SP#20 42 14bit 58
15bit BYPASS SP#19 41 15bit 57

Note: For signal definitions see Section 4.7.2

PAGE 5 - 34
Chapter 5: Control Interfaces
AFC1500 Multi-2 Unit Hardware Manual (Rev2)

5.7.4 Ouput Signals (Word 01 ~ Word 16)


The Multi-2 Unit is capable of providing over 570 Output signals to indicate the status of the
Multi-2 Unit and of all the AFC1500 SAN Controllers connected to it (up to 31 controllers).
See Section 4.7.3 for available output signals.
Since Modbus Plus sends I/O signals 8 bits at a time, and trying to use the data as a
word, all bits and bytes are transferred backwards.
FEC Multi-2
Word No. Bit Signal Bank Bit
0bit Sequence Output 1 1 8
1bit Sequence Output 0 1 7
These Output signals are user
2bit End 1 6
3bit Busy 1 5 configurable using the AFC User
4bit Ready 1 4 Console Software and may be
5bit Abnormal 1 3 programmed on any designated
Output 6bit Total Accept 1 2
Word 7bit Total Reject 1 1 bit.
No.01 8bit Spindle No.1 Reject 1 16
9bit Spindle No.1 Accept 1 15 The Output signal mapping
10bit 1 14 shown is only an EXAMPLE.
11bit Current Warning 1 13 The signals may be programmed
12bit Spindle in Bypass 1 12
13bit Sequence Output 4 1 11 for placement in ANY bit
14bit Sequence Output 3 1 10 position.
15bit Sequence Output 2 1 9
0bit Spindle No.3 BYP 1 24
1bit Spindle No.3 ABN. 1 23
2bit Spindle No.3 Reject 1 22
3bit Spindle No.3 Accept 1 21
4bit Spindle No.2 BYP 1 20
Output 5bit Spindle No.2 ABN. 1 19
Word 6bit Spindle No.2 Reject 1 18
No.02 7bit Spindle No.2 Accept 1 17
8bit Spindle No.5 BYP 1 32
9bit Spindle No.5 ABN. 1 31
10bit Spindle No.5 Reject 1 30
11bit Spindle No.5 Accept 1 29
12bit Spindle No.4 BYP 1 28
13bit Spindle No.4 ABN. 1 27
14bit Spindle No.4 Reject 1 26
15bit Spindle No.4 Accept 1 25
0bit Spindle No.7 BYP 2 8
1bit Spindle No.7 ABN. 2 7
2bit Spindle No.7 Reject 2 6
3bit Spindle No.7 Accept 2 5
4bit Spindle No.6 BYP 2 4
Output
5bit Spindle No.6 ABN. 2 3
Word 6bit Spindle No.6 Reject 2 2
No.03 7bit Spindle No.6 Accept 2 1
8bit Spindle No.9 BYP 2 16
9bit Spindle No.9 ABN. 2 15
10bit Spindle No.9 Reject 2 14
11bit Spindle No.9 Accept 2 13
12bit Spindle No.8 BYP 2 12
13bit Spindle No.8 ABN. 2 11
14bit Spindle No.8 Reject 2 10
15bit Spindle No.8 Accept 2 9

CH. No. Bit Signal
0bit 8 1
Output CH.

No.16
15bit 8 32

PAGE 5 - 35
Chapter 5: Control
Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2)

5.8 CC-Link® Interface (Version 1)


The Mitsubishi CC-Link communication interface allows slave connection to an industrial Mitsubishi
CC-Link network. FEC has a partner license with Mitsubishi for the AFC1500 system for connection
on the CC-Link network. Mitsubishi CC-Link allows industrial devices to be controlled over an open
network architecture enabling device connection at various locations in the field. This “Fieldbus”
technology reduces hardwiring/cabling & provides ease of installation. It can interface to many
devices such as limit switches, sensors, directional valves, motor starters, bar code readers,
process sensors, frequency drives, etc. The network can have up to 64 stations. Maximum I/O data
is 128 inputs & 128 outputs (actual usable I/O is 112).

NOTE: The FEC CC-Link module is configured as a “Remote Device Station” when setting up the
parameters in the PLC program.
For detailed information on the Mitsubishi CC-Link Network, see the Mitsubishi User Manual
#13J872 Control & Communication - Link System Master / Local Module.

- Represents switch position

5
OCCUPIED STATION
SETTING
4

Item Description
1 CC-Link Connector
2 Station Number Setting Switch
3 Baud Rate Setting Switch
4 Occupied Station Setting Switch
5 Status LEDs (4)

PAGE 5 - 36
Chapter 5: Control Interfaces
AFC1500 Multi-2 Unit Hardware Manual (Rev2)

CC-Link Specifications
Speed 156K - 10M baud - selectable
Stations 64 Max.
Distance 1200m max. at 156K baud / 50m max. at 10Mbit/s
Cable Shielded Copper Twisted Pair
Mitsubishi BA1SJ61-(m) m=Meters
Belden 8102 or equivalent
Communications Type Master/Slave - EIA RS485
Transmission Format HDLC Standard
Maximum Cyclic I/O Size 128 inputs, 128 outputs max. Size set in groups of 32 I/O
(4 Occupied Stations)
I/O Configuration* I/O addressing set by PLC TO / FROM commands in Logic
* Actual I/O addressing must be assigned in the PLC logic. See the Mitsubishi User Manual
#13J872 Control & Communication - Link System Master / Local Module for logic reference.
(Ref. Section 10)

Configuration

Configuration of the CC-Link system is done in the PLC Logic. It is essential that this
configuration matches the Dip Switch settings of the FEC CC-Link slave. FEC is considered a
“Remote Device” in the PLC configuration. The number of “Occupied Stations” set in the PLC
must also match the Dip Switch set-up. (Note: The last 16 output addresses are used by the CC-
Link communication & cannot be used by the user) .

PAGE 5 - 37
Chapter 5: Control
Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2)

5.8.1 Component Descriptions

Fieldbus Interface Connection

Pin 1 DA Communication Line See


“Termination”
Pin 2 DB Communication Line
Pin 3 DG Digital Ground
Pin 4 SHIELD Connect cable shield
Pin 5 FG Field Ground

Mating Connector: Allows in-line “series” connection


Manufacturer:Phoenix Contact
Model Name :TMSTBP 2.5/5-ST-5.08

*Connector is attached.

Wiring of the CC-Link network should be performed by using the cable listed in the CC-Link
Specifications. The three twisted conductors should be wired in series to each CC-Link device,
using a terminating resistor at the Master end and on the last Remote/Local device between the
DA & DB terminals.

Termination

Termination of the CC-Link requires a terminating resistor at each end of the fieldbus. Connect
120 ohm resistor between the DA & DB terminals if this is the last connection. (Remember that
the CC-Link master also needs to be terminated)

Station Number Setting (SW1)

Station Number switch sets the address in the CC-Link network. Max. number of stations is 64.
No two devices may share the same address. Switch setting format is Binary Coded Decimal
(BCD) Switch 1-4 is Least Significant Byte (LSB). Switch 5-8 is Most Significant Byte (MSB).

SW-1 SW-2 SW-3 SW-4 SW-5 SW-6 SW-7 SW-8 Station #


ON
1 ON OFF OFF OFF OFF OFF OFF OFF 1
2 OFF ON OFF OFF OFF OFF OFF OFF 2
3 . . . . . . . . .
4
OFF OFF OFF OFF ON OFF OFF OFF 10
5
. . . . . . . . .
6
7 ON ON ON OFF OFF OFF ON OFF 47
8 . . . . . . . . .
OFF OFF ON OFF OFF ON ON OFF 64
This switch must be set before power is on and cannot be changed during operation.

Baud Rate Setting (SW2)

Baud rate SW-1 SW-2 SW-3 SW-4


ON
1 156K OFF OFF OFF OFF
2 625K ON OFF OFF OFF
3 2.5M OFF ON OFF OFF
4 5M ON ON OFF OFF
10M OFF OFF ON OFF
This setting MUST match the setting of the Master module. This switch must be set
before power is on and cannot be changed during operation.
PAGE 5 - 38
Chapter 5: Control Interfaces
AFC1500 Multi-2 Unit Hardware Manual (Rev2)

Number of Occupied Stations (SW3)

Occupied Stations setting determines the number of 32 bit station buffer memory locations that
will be allocated for this station in the Master buffer memory. This sets the number of total I/O
available for the station. Each memory bit has a designated input AND output buffer. So a
setting of (1) 32 station actually allocates 32 input & 32 output locations for a total of 64 total
points. This switch must be set before power is on, and cannot be changed during operation.
NOTE: See FEC Electrical Controls drawings for actual setting required as this may vary per
application.

ON
Number of Stations SW-1 SW-2 SW-3 SW-4
1
1 (32 In/32 Out) ON ON ON OFF
2
2 (64 In/64 Out) ON OFF ON OFF
3
4 3 (96 In/96 Out) OFF ON ON OFF
4 (128 In/128 Out) OFF OFF ON OFF

Status LEDs

RUN OFF Watchdog Timer error


ON Module is Normal - Running
ERR OFF Normal
ON - Steady Communication error at all
Stations
ON - Flashing Communication error at Station
SD Send Data Module Sending Data
RD Read Data Module Reading Data

PAGE 5 - 39
Chapter 5: Control
Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2)

5.8.2 Input Signals


Inputs are assigned in the order as shown in the table below and cannot be changed. Bits
designated as “Unused” have no input assigned to them.

FEC Multi-2 FEC Multi-2


Address Signal Address Signal
Bank Bit Bank Bit
RY(n+0)0 Emergency Stop 1 RY(n+1)0 BYPASS SP#1 17
RY(n+0)1 Reset 2 RY(n+1)1 BYPASS SP#2 18
RY(n+0)2 Reverse 3 RY(n+1)2 BYPASS SP#3 19
RY(n+0)3 Start 4 RY(n+1)3 BYPASS SP#4 20
RY(n+0)4 Sequence Select 0 5 RY(n+1)4 BYPASS SP#5 21
RY(n+0)5 Sequence Select 1 6 RY(n+1)5 BYPASS SP#6 22
RY(n+0)6 Sequence Select 2 7 RY(n+1)6 BYPASS SP#7 23
RY(n+0)7 Sequence Select 3 8 RY(n+1)7 BYPASS SP#8 24
RY(n+0)8 Cycle Count Up 9 RY(n+1)8 BYPASS SP#9 25
RY(n+0)9 Cycle Count Clear 10 RY(n+1)9 BYPASS SP#10 26
RY(n+0)A Self Check Disable 11 RY(n+1)A Unused 27
RY(n+0)B Sequence Select 4 12 RY(n+1)B Unused 28
RY(n+0)C INPORT 1 13 RY(n+1)C Unused 29
RY(n+0)D INPORT 2 14 RY(n+1)D Unused 30
RY(n+0)E INPORT 3 15 RY(n+1)E Unused 31
RY(n+0)F INPORT 4 16 RY(n+1)F Unused 32

FEC Multi-2 FEC Multi-2


Address Signal Address Signal
Bank Bit Bank Bit
RY(n+2)0 BYPASS SP#11 33 RY(n+3)0 BYPASS SP#27 49
RY(n+2)1 BYPASS SP#12 34 RY(n+3)1 BYPASS SP#28 50
RY(n+2)2 BYPASS SP#13 35 RY(n+3)2 BYPASS SP#29 51
RY(n+2)3 BYPASS SP#14 36 RY(n+3)3 BYPASS SP#30 52
RY(n+2)4 BYPASS SP#15 37 RY(n+3)4 BYPASS SP#31 53
RY(n+2)5 BYPASS SP#16 38 RY(n+3)5 Unused 54
RY(n+2)6 BYPASS SP#17 39 RY(n+3)6 Unused 55
RY(n+2)7 BYPASS SP#18 40 RY(n+3)7 Unused 56
RY(n+2)8 BYPASS SP#19 41 RY(n+3)8 Unused 57
RY(n+2)9 BYPASS SP#20 42 RY(n+3)9 Unused 58
RY(n+2)A BYPASS SP#21 43 RY(n+3)A Unused 59
RY(n+2)B BYPASS SP#22 44 RY(n+3)B Unused 60
RY(n+2)C BYPASS SP#23 45 RY(n+3)C Unused 61
RY(n+2)D BYPASS SP#24 46 RY(n+3)D Unused 62
RY(n+2)E BYPASS SP#25 47 RY(n+3)E Unused 63
RY(n+2)F BYPASS SP#26 48 RY(n+3)F Unused 64

Note: For signal definitions see Section 4.7.2

PAGE 5 - 40
Chapter 5: Control Interfaces
AFC1500 Multi-2 Unit Hardware Manual (Rev2)

5.8.4 Output Signals


The Multi-2 Unit is capable of providing over 570 Output signals to indicate the status of the
Multi-2 Unit and of all the AFC1500 SAN Controllers connected to it (up to 31 controllers).
See Section 4.7.3 for available output signals.
FEC Multi-2
Address Signal Bank Bit
RX(n+0)0 Total Reject 1 1
RX(n+0)1 Total Accept 1 2
RX(n+0)2 Abnormal 1 3
RX(n+0)3 Ready 1 4
RX(n+0)4 Busy 1 5 These Output signals are user
RX(n+0)5 End 1 6 configurable using the AFC User
RX(n+0)6 Sequence Output 0 1 7 Console Software and may be
RX(n+0)7 Sequence Output 1 1 8
programmed on any designated
RX(n+0)8 Sequence Output 2 1 9
RX(n+0)9 Sequence Output 3 1 10 bit.
RX(n+0)A Sequence Output 4 1 11
RX(n+0)B Spindle in Bypass 1 12 The Output signal mapping
RX(n+0)C Current Warning 1 13
shown is only an EXAMPLE.
RX(n+0)D 1 14
RX(n+0)E 1 15 The signals may be programmed
RX(n+0)F 1 16 for placement in ANY bit
RX(n+1)0 Spindle No.1 Accept 1 17 position.
RX(n+1)1 Spindle No.1 Reject 1 18
RX(n+1)2 Spindle No.1 ABN. 1 19
RX(n+1)3 Spindle No.1 BYP 1 20
RX(n+1)4 Spindle No.2 Accept 1 21
RX(n+1)5 Spindle No.2 Reject 1 22
RX(n+1)6 Spindle No.2 ABN 1 23
RX(n+1)7 Spindle No.2 BYP 1 24
RX(n+1)8 Spindle No.3 Accept 1 25
RX(n+1)9 Spindle No.3 Reject 1 26
RX(n+1)A Spindle No.3 ABN 1 27
RX(n+1)B Spindle No.3 BYP 1 28
RX(n+1)C Spindle No.4 Accept 1 29
RX(n+1)D Spindle No.4 Reject 1 30
RX(n+1)E Spindle No.4 ABN. 1 31
RX(n+1)F Spindle No.4 BYP 1 32
RX(n+2)0 Spindle No.5 Accept 2 1
RX(n+2)1 Spindle No.5 Reject 2 2
RX(n+2)2 Spindle No.5 ABN. 2 3
RX(n+2)3 Spindle No.5 BYP 2 4
RX(n+2)4 Spindle No.6 Accept 2 5
RX(n+2)5 Spindle No.6 Reject 2 6
RX(n+2)6 Spindle No.6 ABN 2 7
RX(n+2)7 Spindle No.6 BYP 2 8
RX(n+2)8 Spindle No.7 Accept 2 9
RX(n+2)9 Spindle No.7 Reject 2 10
RX(n+2)A Spindle No.7 ABN 2 11
RX(n+2)B Spindle No.7 BYP 2 12
RX(n+2)C Spindle No.8 Accept 2 13
RX(n+2)D Spindle No.8 Reject 2 14
RX(n+2)E Spindle No.8 ABN. 2 15
RX(n+2)F Spindle No.8 BYP 2 16

Address Signal Description
For RX(n+x)0 Unusable The last 16 bits are reserved for CC-Link
CC-Link
… … Communication only, regardless of how many
Comm.
RX(n+x)F Unusable stations are set.
Only

PAGE 5 - 41
Chapter 5: Control
Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2)

5.9 CC-Link® Interface (Version 2)

FEC integrates the CC-Link board (Version 2 setting) manufactured by HMS Fieldbus Systems AB
into the Multi-2 Unit’s modular I/O board when CC-link must send both I/O and Message Data. For
further technical information on the CC-Link (Version 2) interface go to the HMS website.
(www.hms.se)

NOTE: The FEC CC-Link (V2) module is configured as a “Remote Device Station” when setting up
the parameters in the PLC program.
For detailed information on the Mitsubishi CC-Link Network, see the Mitsubishi User Manual #
13J872 Control & Communication - Link System Master / Local Module.

- Represents switch position

Daughter board
DB9 Connector (male)

6 1 1

9 5 2

RBC BA

5 RBDA/ERR 3
9
4
6 1
6

5
DB9 Connector
(female)

Item Description
1 Application Connector
2 CC-Link Connector
3 Baud Rate Setting Switch
4 Station Number Setting Switches (2)
5 Status LEDs (4)
Red - (flashing @ 2Hz) - ASIC and FLASH ROM check fault.
Green (flashing @ 2Hz) - module not initialized.
6 Watchdog LED Green (flashing @ 1Hz) - module initialized and running OK.
Red (flashing @ 1Hz) - RAM check fault.
Red (flashing @ 4Hz) - DPRAM check fault.

PAGE 5 - 42
Chapter 5: Control Interfaces
AFC1500 Multi-2 Unit Hardware Manual (Rev2)

CC-Link Specifications
Speed 156K - 10M baud - selectable
Stations 64 Max.
Distance 1200m max. at 156K baud / 50m max. at 10Mbit/s
Cable Shielded Copper Twisted Pair
Mitsubishi BA1SJ61-(m) m=Meters
Belden 8102 or equivalent
Communications Type Master/Slave - EIA RS485
Transmission Format HDLC Standard
Maximum Cyclic I/O Size 896 inputs, 896 outputs max. Size set in groups of 256 I/O
(Occupied Stations)
I/O Configuration* I/O addressing set by PLC TO / FROM commands in Logic
* Actual I/O addressing must be assigned in the PLC logic. See the Mitsubishi User Manual #
13J872 Control & Communication - Link System Master / Local Module for logic reference. (Ref.
Section 10)

Configuration

Configuration of the CC-Link system is done in the PLC Logic. It is essential that this
configuration matches the Dip Switch settings of the FEC CC-Link slave. FEC is considered a
“Remote Device” in the PLC configuration. The number of “Occupied Stations” set in the PLC
must also match the settings in the AFC User Console set-up. (Note: The last 16 output
addresses are used by the CC-Link communication & cannot be used by the user)

FEC CC-Link (Version 2) I/O configuration is programmable using the AFC User Console
software. I/O can be set as required by the application according to parameter limits set forth by
the CC-Link System Profile (CSP file). The AFC Software allows configuration of the number of
Occupied Stations and Extended Cyclic Settings in the Multi Unit. Configuration of the CC-Link
Master MUST match the configuration of the FEC CC-Link slave.

CSP File

To simplify network configuration, CC-Link devices may be associated with a CC-Link System
Profile, also known as a CSP-file. This file contains a description of the device and can be used
by some CC-Link system utilities to simplify the configuration process.
The CSP file associated with the FEC device can be downloaded directly from HMS -
www.hms.se.

PAGE 5 - 43
Chapter 5: Control
Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2)

5.9.1 Component Descriptions

Fieldbus Interface Connection

Pin 1 DA Communication Line See


Pin 2 DB Communication Line “Termination”
Pin 3 DG Digital Ground
Pin 4 SHIELD Connect cable shield
Pin 5 FG Field Ground

Mating Connector: Allows in-line “series” connection


Manufacturer:Phoenix Contact
Model Name :TMSTBP 2.5/5-ST-5.08

*Connector is attached.

Wiring of the CC-Link network should be performed by using the cable listed above in the CC-
Link Specifications. The three twisted conductors should be wired in series to each CC-Link
device, using a terminating resistor at the Master end and on the last Remote/Local device
between the DA & DB terminals.

Termination

Termination of the CC-Link requires a terminating resistor at each end of the fieldbus. Connect
120 ohm resistor between the DA & DB terminals if this is the last connection. (Remember that
the CC-Link master also needs to be terminated)

Baud Rate Switch

This rotary switch is used to specify the baud rate of the module.
This can also be specified in the FB_INIT mailbox command. In
this case, the switch must be set to “9”.
This setting MUST match the setting of the Master module.
This switch must be set before power is on and cannot be
changed during operation.

Station Number Switches

These two rotary switches are used to specify the station number of the module
(Two digit decimal). The Upper rotary switch (closest to the Baud Rate Switch)
sets the “tens” digit (10x), and the bottom rotary switch sets the “ones” digit (1x).
Valid settings range from 1 up to 641.
Example: To set station number 24, place the “tens” digit switch on 2 and the
“ones” digit switch on 4.
This can also be specified in the FB_INIT mailbox command. In this case, the
switches must be set to “99”.
This switch must be set before power is on, and cannot be changed
during operation.

1) If more than one station is occupied by the module, the highest possible station number is
reduced by the number of occupied stations minus one.

PAGE 5 - 44
Chapter 5: Control Interfaces
AFC1500 Multi-2 Unit Hardware Manual (Rev2)

Status LEDs

LED Color State Description


ON Normal Operation
1
Green Network non-participating or timeout status
(RUN) OFF
No power on module
CRC error detection
ON
2 Illegal station number or illegal baud rate selected
Red
(ERRL) Normal Operation
OFF
4 1
No power on module
ON Data being received
3 2 3
Green No data reception
(RDLED) OFF
No power on module
ON Data being transmitted
4
Green No data transmission
(SDLED) OFF
No power on module

PAGE 5 - 45
Chapter 5: Control
Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2)

5.9.2 User Console Software Settings


The Anybus board is set up by sending a Fieldbus Configuration File (*.fcf) containing
initialization messages from the Multi-2 Unit to the board during power up. This string of data
initializes different characteristics required for the board to communicate over the CC-Link
network. In this string are messages which set the length of I/O data as well as other messages.
Since the board is only initialized during power-up, the Multi-2 Unit MUST have the power cycled
OFF/ON after the “fcf” file is downloaded.

To download the fcf file, select “Field Bus Setup” from the “Multi” pull down menu. Select the
appropriate “Bus Type” and click “Browse” to locate the correct fcf file. After the file has been
selected, click “download” to send the file data to the Anybus board.

If no file exists (or if the settings need to be changed), after the Bus Type has been selected
click on the Setup Tab.

Select the desired settings from the pull downs. When finished, go back to the General Tab and
click “download” to send the file data to the Anybus board.

The CC-Link (Version 2) interface also has the ability to transfer message data. Refer to the
AFC1500 User Console Manual for message setup information.

PAGE 5 - 46
Chapter 5: Control Interfaces
AFC1500 Multi-2 Unit Hardware Manual (Rev2)

5.9.3 Input Signals


Inputs are assigned in the order as shown in the table below and cannot be changed. Bits
designated as “Unused” have no input assigned to them.

FEC Multi-2 FEC Multi-2


Address Signal Address Signal
Bank Bit Bank Bit
RY(n+0)0 Emergency Stop 1 RY(n+1)0 BYPASS SP#1 17
RY(n+0)1 Reset 2 RY(n+1)1 BYPASS SP#2 18
RY(n+0)2 Reverse 3 RY(n+1)2 BYPASS SP#3 19
RY(n+0)3 Start 4 RY(n+1)3 BYPASS SP#4 20
RY(n+0)4 Sequence Select 0 5 RY(n+1)4 BYPASS SP#5 21
RY(n+0)5 Sequence Select 1 6 RY(n+1)5 BYPASS SP#6 22
RY(n+0)6 Sequence Select 2 7 RY(n+1)6 BYPASS SP#7 23
RY(n+0)7 Sequence Select 3 8 RY(n+1)7 BYPASS SP#8 24
RY(n+0)8 Cycle Count Up 9 RY(n+1)8 BYPASS SP#9 25
RY(n+0)9 Cycle Count Clear 10 RY(n+1)9 BYPASS SP#10 26
RY(n+0)A Self Check Disable 11 RY(n+1)A Unused 27
RY(n+0)B Sequence Select 4 12 RY(n+1)B Unused 28
RY(n+0)C INPORT 1 13 RY(n+1)C Unused 29
RY(n+0)D INPORT 2 14 RY(n+1)D Unused 30
RY(n+0)E INPORT 3 15 RY(n+1)E Unused 31
RY(n+0)F INPORT 4 16 RY(n+1)F Unused 32

FEC Multi-2 FEC Multi-2


Address Signal Address Signal
Bank Bit Bank Bit
RY(n+2)0 BYPASS SP#11 33 RY(n+3)0 BYPASS SP#27 49
RY(n+2)1 BYPASS SP#12 34 RY(n+3)1 BYPASS SP#28 50
RY(n+2)2 BYPASS SP#13 35 RY(n+3)2 BYPASS SP#29 51
RY(n+2)3 BYPASS SP#14 36 RY(n+3)3 BYPASS SP#30 52
RY(n+2)4 BYPASS SP#15 37 RY(n+3)4 BYPASS SP#31 53
RY(n+2)5 BYPASS SP#16 38 RY(n+3)5 54
RY(n+2)6 BYPASS SP#17 39 RY(n+3)6 55
RY(n+2)7 BYPASS SP#18 40 RY(n+3)7 56
RY(n+2)8 BYPASS SP#19 41 RY(n+3)8 57
RY(n+2)9 BYPASS SP#20 42 RY(n+3)9 58
RY(n+2)A BYPASS SP#21 43 RY(n+3)A 59
RY(n+2)B BYPASS SP#22 44 RY(n+3)B 60
RY(n+2)C BYPASS SP#23 45 RY(n+3)C 61
RY(n+2)D BYPASS SP#24 46 RY(n+3)D 62
RY(n+2)E BYPASS SP#25 47 RY(n+3)E 63
RY(n+2)F BYPASS SP#26 48 RY(n+3)F 64

Note: For signal definitions see Section 4.7.2

PAGE 5 - 47
Chapter 5: Control
Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2)

5.9.4 Ouput Signals


The Multi-2 Unit is capable of providing over 570 Output signals to indicate the status of the
Multi-2 Unit and of all the AFC1500 SAN Controllers connected to it (up to 31 controllers).
See Section 4.7.3 for available output signals.
FEC Multi-2
Address Signal Bank Bit
RX(n+0)0 Total Reject 1 1
RX(n+0)1 Total Accept 1 2
RX(n+0)2 Abnormal 1 3
RX(n+0)3 Ready 1 4
RX(n+0)4 Busy 1 5
RX(n+0)5 End 1 6 These Output signals are user
RX(n+0)6 Sequence Output 0 1 7 configurable using the AFC User
RX(n+0)7 Sequence Output 1 1 8
Console Software and may be
RX(n+0)8 Sequence Output 2 1 9
RX(n+0)9 Sequence Output 3 1 10 programmed on any designated
RX(n+0)A Sequence Output 4 1 11 bit.
RX(n+0)B Spindle in Bypass 1 12
RX(n+0)C Current Warning 1 13
The Output signal mapping
RX(n+0)D 1 14
RX(n+0)E 1 15 shown is only an EXAMPLE.
RX(n+0)F 1 16 The signals may be programmed
RX(n+1)0 Spindle No.1 Accept 1 17 for placement in ANY bit
RX(n+1)1 Spindle No.1 Reject 1 18 position.
RX(n+1)2 Spindle No.1 ABN. 1 19
RX(n+1)3 Spindle No.1 BYP 1 20
RX(n+1)4 Spindle No.2 Accept 1 21
RX(n+1)5 Spindle No.2 Reject 1 22
RX(n+1)6 Spindle No.2 ABN 1 23
RX(n+1)7 Spindle No.2 BYP 1 24
RX(n+1)8 Spindle No.3 Accept 1 25
RX(n+1)9 Spindle No.3 Reject 1 26
RX(n+1)A Spindle No.3 ABN 1 27
RX(n+1)B Spindle No.3 BYP 1 28
RX(n+1)C Spindle No.4 Accept 1 29
RX(n+1)D Spindle No.4 Reject 1 30
RX(n+1)E Spindle No.4 ABN. 1 31
RX(n+1)F Spindle No.4 BYP 1 32
RX(n+2)0 Spindle No.5 Accept 2 1
RX(n+2)1 Spindle No.5 Reject 2 2
RX(n+2)2 Spindle No.5 ABN. 2 3
RX(n+2)3 Spindle No.5 BYP 2 4
RX(n+2)4 Spindle No.6 Accept 2 5
RX(n+2)5 Spindle No.6 Reject 2 6
RX(n+2)6 Spindle No.6 ABN 2 7
RX(n+2)7 Spindle No.6 BYP 2 8
RX(n+2)8 Spindle No.7 Accept 2 9
RX(n+2)9 Spindle No.7 Reject 2 10
RX(n+2)A Spindle No.7 ABN 2 11
RX(n+2)B Spindle No.7 BYP 2 12
RX(n+2)C Spindle No.8 Accept 2 13
RX(n+2)D Spindle No.8 Reject 2 14
RX(n+2)E Spindle No.8 ABN. 2 15
RX(n+2)F Spindle No.8 BYP 2 16

Bit Signal Description
For RX(n+x)0 Unusable The last 16 bits are reserved for CC-Link
CC-Link
… … Communication only regardless of how many
Comm.
RX(n+x)F Unusable stations are set.
Only

PAGE 5 - 48
Chapter 5: Control Interfaces
AFC1500 Multi-2 Unit Hardware Manual (Rev2)

5.10 Allen-Bradley Remote I/O Interface


The Allen Bradley (AB) Remote I/O communication interface allows slave connection to an AB
Remote I/O network. FEC has licensed (Lic. #199906006) the use of the AB Remote I/O interface
board (through HMS Fieldbus Systems). AB Remote I/O is a proprietary Fieldbus of Allen Bradley.
AB - RIO allows industrial devices to be controlled over a network architecture enabling device
connection at various locations in the field. This “Fieldbus” technology reduces hardwiring/cabling &
provides ease of installation. The network can have up to 240 nodes with valid rack addresses of
0-59. Maximum I/O data is 128 inputs & 128 outputs (Full Rack). 1/4, 1/2, 3/4 & Full rack
configuration is supported. (Default config. is 1/2 Rack 64In/64Out)

FEC integrates the AB Remote I/O board manufactured by HMS Fieldbus Systems into the Multi-
Unit modular I/O board. For further technical information on the AB Remote I/O interface see the
AnyBus -DT reference found at the end of this chapter or go to the HMS website. (www.hms.se)
Further AB Remote I/O information can be found through Allen Bradley’s website. (www.ab.com)

- Represents switch position

BAUD/ADDRESS
SETTING 1
3
BAUD/ADDRESS BAUD/ADDRESS
SETTING SETTING

LED LED LED


5
INDICATION INDICATION INDICATION

TERMINATION TERMINATION
SWITCH SWITCH 4

TERMINATION
SWITCH REMOTE I/O REMOTE I/O
6
CONNECTOR CONNECTOR 2

REMOTE I/O
CONNECTOR

Item Description
1 Application Connector
2 Remote I/O Connector
3 Baud Rate / Station Number Setting Switch
4 Terminator Switch
5 Status LEDs (3)
Red - (flashing @ 2Hz) - ASIC and FLASH ROM check fault.
Green (flashing @ 2Hz) - module not initialized.
6 Watchdog LED Green (flashing @ 1Hz) - module initialized and running OK.
Red (flashing @ 1Hz) - RAM check fault.
Red (flashing @ 4Hz) - DPRAM check fault.

PAGE 5 - 49
Chapter 5: Control
Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2)

AB Remote I/O Specifications


Speed 57.6, 115, 230K baud - Selectable
Rack Addresses 0-59
Nodes up to 240 1/4 racks
Rack Configuration supported* 1/4, 1/2 (Default), 3/4, Full
Distance 57.6k - 3048 meter
115K - 1524 meter
230K - 762 meter
Cable 78 ohm Twinax
Belden #9463 or equivalent
Communications Type Master/Slave
*Rack Config. set by AFC User Console software. Contact FEC for other setting.

PAGE 5 - 50
Chapter 5: Control Interfaces
AFC1500 Multi-2 Unit Hardware Manual (Rev2)

5.10.1 Component Descriptions

Fieldbus Interface Connection

Pin No. Color Description


1 Blue COM Line
2 Clear Ground
3 Shield COM Line

Termination

Termination of the RIO network requires a terminating resistor at each end of


the network. A termination switch is provided on the front of the interface board.
Set the switch to “ON”, if termination is required. If external terminators are
used, the switch must be in the off position.

Configuration Switches

On an A-B Remote I/O network, each node must be assigned its own unique Rack Address. The
Rack Address is a value between 0 and 59 used to identify each node. The Rack Address and
Baud Rate are set using the DIP switches on the front of the module.
These switches must be set before power is on and cannot be changed during operation.

Baud Rate Settings


Baud Rate SW-1 SW-2
57.6K OFF OFF
ON 115K ON OFF
1 230K OFF ON
2 Reserved ON ON
3 Rack Address Settings
4 Rack
SW-3 (MSB) SW-4 SW-5 SW-6 SW-7 SW-8 (LSB)
5 Address
6 Address 0 OFF OFF OFF OFF OFF OFF
7 Address 1 ON OFF OFF OFF OFF OFF
8 Address 2 OFF ON OFF OFF OFF OFF
Address 3 ON ON OFF OFF OFF OFF
… … … … … … …
Address 57 ON OFF OFF ON ON ON
Address 58 OFF ON OFF ON ON ON
Address 59 ON ON OFF ON ON ON

Status LEDs

LED State Description


Error OFF Normal Operation
ON - Red Bus off / Error
Active OFF No Communication
ON - Green Communication Active
Power OFF Power Off
ON - Green Power On

PAGE 5 - 51
Chapter 5: Control
Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2)

5.10.2 User Console Software Settings


The Anybus board is set up by sending a Fieldbus Configuration File (*.fcf) containing
initialization messages from the Multi-2 Unit to the board during power up. This string of data
initializes different characteristics required for the board to communicate over the Allen-Bradley
Remote I/O network. In this string are messages which set the length of I/O data as well as other
messages. Since the board is only initialized during power-up, the Multi-2 Unit MUST have the
power cycled OFF/ON after the “fcf” file is downloaded.

To download the fcf file, select “Field Bus Setup” from the “Multi” pull down menu. Select the
appropriate “Bus Type” and click “Browse” to locate the correct fcf file. After the file has been
selected, click “download” to send the file data to the Anybus board.

If no file exists, (or if the settings need to be changed) after the Bus Type has been selected
click on the Setup Tab.

Select the desired settings from the pull downs. When finished, go back to the General Tab and
click “download” to send the file data to the Anybus board.

PAGE 5 - 52
Chapter 5: Control Interfaces
AFC1500 Multi-2 Unit Hardware Manual (Rev2)

5.10.3 Input Signals (CH1 ~ CH16)


Inputs are assigned in the order as shown in the table below and cannot be changed. Bits
designated as “Not Used” have no input assigned to them.

FEC Multi-2 FEC Multi-2


CH. No. Bit Signal CH. No. Bit Signal
Bank Bit Bank Bit
0bit Emergency Stop 1 0bit BYPASS SP#1 17
1bit Reset 2 1bit BYPASS SP#2 18
2bit Reverse 3 2bit BYPASS SP#3 19
3bit Start 4 3bit BYPASS SP#4 20
4bit Sequence Select 0 5 4bit BYPASS SP#5 21
5bit Sequence Select 1 6 5bit BYPASS SP#6 22
6bit Sequence Select 2 7 6bit BYPASS SP#7 23
Input CH. Input CH.
7bit Sequence Select 3 8 7bit BYPASS SP#8 24
8bit Cycle Count Up 9 8bit BYPASS SP#9 25
No.01 No.02
9bit Cycle Count Clear 10 9bit BYPASS SP#10 26
10bit Self Check Disable 11 10bit Unused 27
11bit Sequence Select 4 12 11bit Unused 28
12bit INPORT 1 13 12bit Unused 29
13bit INPORT 2 14 13bit Unused 30
14bit INPORT 3 15 14bit Unused 31
15bit INPORT 4 16 15bit Unused 32

FEC Multi-2 FEC Multi-2


CH. No. Bit Signal CH. No. Bit Signal
Bank Bit Bank Bit
0bit BYPASS SP#11 33 0bit BYPASS SP#27 49
1bit BYPASS SP#12 34 1bit BYPASS SP#28 50
2bit BYPASS SP#13 35 2bit BYPASS SP#29 51
3bit BYPASS SP#14 36 3bit BYPASS SP#30 52
4bit BYPASS SP#15 37 4bit BYPASS SP#31 53
5bit BYPASS SP#16 38 5bit 54
6bit BYPASS SP#17 39 6bit 55
Input CH. Input CH.
7bit BYPASS SP#18 40 7bit 56
8bit BYPASS SP#19 41 8bit 57
No.03 No.04
9bit BYPASS SP#20 42 9bit 58
10bit BYPASS SP#21 43 10bit 59
11bit BYPASS SP#22 44 11bit 60
12bit BYPASS SP#23 45 12bit 61
13bit BYPASS SP#24 46 13bit 62
14bit BYPASS SP#25 47 14bit 63
15bit BYPASS SP#26 48 15bit 64

The Channel Number at the Master Unit output side differs according to rack address settings.
Please check before operating the unit.

PAGE 5 - 53
Chapter 5: Control
Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2)

5.10.4 Ouput Signals (CH1 ~ CH16)


The Multi-2 Unit is capable of providing over 570 Output signals to indicate the status of the
Multi-2 Unit and of all the AFC1500 SAN Controllers connected to it (up to 31 controllers).
See Section 4.7.3 for available output signals.
FEC Multi-2
CH. No. Bit Signal Bank Bit
0bit Total Reject 1 1
1bit Total Accept 1 2
2bit Abnormal 1 3
3bit Ready 1 4 These Output signals are user
4bit Busy 1 5 configurable using the AFC User
5bit End 1 6
Console Software and may be
Output CH. 6bit Sequence Output 0 1 7
7bit Sequence Output 1 1 8 programmed on any designated
No.01
8bit Sequence Output 2 1 9 bit.
9bit Sequence Output 3 1 10
10bit Sequence Output 4 1 11
The Output signal mapping
11bit Spindle in Bypass 1 12
12bit Current Warning 1 13 shown is only an EXAMPLE.
13bit 1 14 The signals may be programmed
14bit 1 15 for placement in ANY bit
15bit 1 16 position.
0bit Spindle No.1 Accept 1 17
1bit Spindle No.1 Reject 1 18
2bit Spindle No.1 ABN. 1 19
3bit Spindle No.1 BYP 1 20
4bit Spindle No.2 Accept 1 21
Output CH. 5bit Spindle No.2 Reject 1 22
No.02 6bit Spindle No.2 ABN 1 23
7bit Spindle No.2 BYP 1 24
8bit Spindle No.3 Accept 1 25
9bit Spindle No.3 Reject 1 26
10bit Spindle No.3 ABN 1 27
11bit Spindle No.3 BYP 1 28
12bit Spindle No.4 Accept 1 29
13bit Spindle No.4 Reject 1 30
14bit Spindle No.4 ABN. 1 31
15bit Spindle No.4 BYP 1 32
0bit Spindle No.5 Accept 2 1
1bit Spindle No.5 Reject 2 2
2bit Spindle No.5 ABN. 2 3
3bit Spindle No.5 BYP 2 4
4bit Spindle No.6 Accept 2 5
5bit Spindle No.6 Reject 2 6
Output CH. 6bit Spindle No.6 ABN 2 7
No.03 7bit Spindle No.6 BYP 2 8
8bit Spindle No.7 Accept 2 9
9bit Spindle No.7 Reject 2 10
10bit Spindle No.7 ABN 2 11
11bit Spindle No.7 BYP 2 12
12bit Spindle No.8 Accept 2 13
13bit Spindle No.8 Reject 2 14
14bit Spindle No.8 ABN. 2 15
15bit Spindle No.8 BYP 2 16

CH. No. Bit Signal
0bit 8 1
Output CH.

No.16
15bit 8 32

The CH. No. at the Master input side differs according to rack address settings.
Please check before operating the unit.

PAGE 5 - 54
Chapter 5: Control Interfaces
AFC1500 Multi-2 Unit Hardware Manual (Rev2)

5.11 Ethernet-I/P Interface


The Ethernet-I/P communication interface allows slave connection to PLC networks that support
Ethernet communication via TCP/IP.
Maximum I/O data is 256 input bits & 256 output bits. FEC Inputs match the discrete input layout.
FEC Output location is programmed using the AFC User Console Software. Communication speeds
of 10/100M baud (auto-selectable) are supported.

FEC integrates the Ethernet-I/P board manufactured by HMS Fieldbus Systems AB into the
Multi-2 Unit’s modular I/O board. For further technical information on the Ethernet-I/P interface go to
the HMS website. (www.hms.se)

- Represents switch position

1
DEVICENET
CONNECTOR
2

BAUD/MAC ID
SETTING
3

LED
INDICATORS
4

Item Description
1 Application Connector
2 Ethernet Connector
3 Configuration Switches
4 Status LEDs (4)
Red - (flashing @ 2Hz) - ASIC and FLASH ROM check fault.
Green (flashing @ 2Hz) - module not initialized.
5 Watchdog LED Green (flashing @ 1Hz) - module initialized and running OK.
Red (flashing @ 1Hz) - RAM check fault.
Red (flashing @ 4Hz) - DPRAM check fault.

PAGE 5 - 55
Chapter 5: Control
Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2)

5.11.1 Component Descriptions

Fieldbus Interface Connections

Pin Signal Note


1 TD+
2 TD-
3 RD+
4 - Normally left unused; to ensure signal integrity, these pins are tied
5 - together and terminated to PE via a filter circuit in the module.
6 RD-
7 - Normally left unused; to ensure signal integrity, these pins are tied
8 - together and terminated to PE via a filter circuit in the module.

Configuration DIP Switch

This switch is not used for FEC IP configuration and should be set to
all OFF. The IP address is set-up using the AFC Software (see
5.11.2 below) “Fieldbus Configuration” feature.

Status LEDs

LED State Description


Off No Link Established
1 - Link
On Link Established
Off Not Powered / Not Online
Green solid Controlled by scanner in run state
Green flashing Not configured or scanner in idle state
2 - Module Status A major unrecoverable fault has been
4 1 Red solid
detected.
3 2 A minor recoverable fault has been
Red flashing
detected.
No power to device or no IP address
Off
has been set.
Online. One or more connections
Green solid
established.
3 - Network Status
Green flashing Data size bigger than configured.
Red solid Duplicate IP address. Fatal error.
Red flashing One or more connections timed out.
Green / Red Self test in progress
Flashes each time a packet is
4 - Activity Green
transmitted or received.

PAGE 5 - 56
Chapter 5: Control Interfaces
AFC1500 Multi-2 Unit Hardware Manual (Rev2)

5.11.2 User Console Software Settings


The Anybus board is set up by sending a Fieldbus Configuration File (*.fcf) containing
initialization messages from the Multi-2 Unit to the board during power up. This string of data
initializes different characteristics required for the board to communicate over the Ethernet-I/P
network. In this string is data which set the length of I/O data as well as length of messages
(Resultant Fastening data). Since the board is only initialized during power-up, the Multi-2 Unit
MUST have the power cycled OFF/ON after the “fcf” file is downloaded.

To download the fcf file, select “Field Bus Setup” from the “Multi” pull down menu. Select the
appropriate “Bus Type” and click “Browse” to locate the correct fcf file. After the file has been
selected, click “download” to send the file data to the Anybus board.

If no file exists, (or if the settings need to be changed) after the Bus Type has been selected
click on the Setup Tab.

In NETWORK SETUP, input all of the IP settings required by the host PLC. In I/O SETUP, select
the “Input Data Length” and “Output Data Length” as required by you application. (INPUT &
OUTPUT in this screen refer to PLC side I/O, INPUT = FEC Output size, OUTPUT = FEC Input
size) Data lengths MUST MATCH the PLC’s same I/O length setup otherwise connection will
not be possible.

The Ethernet-I/P interface also has the ability to transfer resultant fastening data using the
message data. Set the MESSAGE INPUT (AFC1500 to PLC) settings according to the PLC
settings. MESSAGE OUTPUT is currently not used. Refer to Page 5.11.5 for message setup
information.

See section 5.11.5 for message set-up example (reference)

PAGE 5 - 57
Chapter 5: Control
Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2)

5.11.3 Input Signals (CH1 ~ CH16)


Inputs are assigned in the order as shown in the table below and cannot be changed. Bits
designated as “Unused” have no input assigned to them.

FEC Multi-2 FEC Multi-2


CH. No. Bit Signal CH. No. Bit Signal
Bank Bit Bank Bit
0bit Emergency Stop 1 0bit BYPASS SP#1 17
1bit Reset 2 1bit BYPASS SP#2 18
2bit Reverse 3 2bit BYPASS SP#3 19
3bit Start 4 3bit BYPASS SP#4 20
4bit Sequence Select 0 5 4bit BYPASS SP#5 21
5bit Sequence Select 1 6 5bit BYPASS SP#6 22
6bit Sequence Select 2 7 6bit BYPASS SP#7 23
Input CH. Input CH.
7bit Sequence Select 3 8 7bit BYPASS SP#8 24
8bit Cycle Count Up 9 8bit BYPASS SP#9 25
No.01 No.02
9bit Cycle Count Clear 10 9bit BYPASS SP#10 26
10bit Self Check Disable 11 10bit Unused 27
11bit Sequence Select 4 12 11bit Unused 28
12bit INPORT 1 13 12bit Unused 29
13bit INPORT 2 14 13bit Unused 30
14bit INPORT 3 15 14bit Unused 31
15bit INPORT 4 16 15bit Unused 32

FEC Multi-2 FEC Multi-2


CH. No. Bit Signal CH. No. Bit Signal
Bank Bit Bank Bit
0bit BYPASS SP#11 33 0bit BYPASS SP#27 49
1bit BYPASS SP#12 34 1bit BYPASS SP#28 50
2bit BYPASS SP#13 35 2bit BYPASS SP#29 51
3bit BYPASS SP#14 36 3bit BYPASS SP#30 52
4bit BYPASS SP#15 37 4bit BYPASS SP#31 53
5bit BYPASS SP#16 38 5bit 54
6bit BYPASS SP#17 39 6bit 55
Input CH. Input CH.
7bit BYPASS SP#18 40 7bit 56
8bit BYPASS SP#19 41 8bit 57
No.03 No.04
9bit BYPASS SP#20 42 9bit 58
10bit BYPASS SP#21 43 10bit 59
11bit BYPASS SP#22 44 11bit 60
12bit BYPASS SP#23 45 12bit 61
13bit BYPASS SP#24 46 13bit 62
14bit BYPASS SP#25 47 14bit 63
15bit BYPASS SP#26 48 15bit 64

The Channel Number at the Master Unit output side differs according to node address settings.
Please check before operating the unit.

PAGE 5 - 58
Chapter 5: Control Interfaces
AFC1500 Multi-2 Unit Hardware Manual (Rev2)

5.11.4 Ouput Signals (CH1 ~ CH16)


The Multi-2 Unit is capable of providing over 570 Output signals to indicate the status of the
Multi-2 Unit and of all the AFC1500 SAN Controllers connected to it (up to 31 controllers).
See Section 4.7.3 for available output signals.
FEC Multi-2
CH. No. Bit Signal Bank Bit
0bit Total Reject 1 1
1bit Total Accept 1 2
2bit Abnormal 1 3
These Output signals are user
3bit Ready 1 4
4bit Busy 1 5 configurable using the AFC User
5bit End 1 6 Console Software and may be
Output CH. 6bit Sequence Output 0 1 7 programmed on any designated
No.01 7bit Sequence Output 1 1 8
8bit Sequence Output 2 1 9 bit.
9bit Sequence Output 3 1 10
10bit Sequence Output 4 1 11 The Output signal mapping
11bit Spindle in Bypass 1 12
shown is only an EXAMPLE.
12bit Current Warning 1 13
13bit 1 14 The signals may be programmed
14bit 1 15 for placement in ANY bit
15bit 1 16 position.
0bit Spindle No.1 Accept 1 17
1bit Spindle No.1 Reject 1 18
2bit Spindle No.1 ABN. 1 19
3bit Spindle No.1 BYP 1 20
4bit Spindle No.2 Accept 1 21
Output CH. 5bit Spindle No.2 Reject 1 22
No.02 6bit Spindle No.2 ABN 1 23
7bit Spindle No.2 BYP 1 24
8bit Spindle No.3 Accept 1 25
9bit Spindle No.3 Reject 1 26
10bit Spindle No.3 ABN 1 27
11bit Spindle No.3 BYP 1 28
12bit Spindle No.4 Accept 1 29
13bit Spindle No.4 Reject 1 30
14bit Spindle No.4 ABN. 1 31
15bit Spindle No.4 BYP 1 32
0bit Spindle No.5 Accept 2 1
1bit Spindle No.5 Reject 2 2
2bit Spindle No.5 ABN. 2 3
3bit Spindle No.5 BYP 2 4
4bit Spindle No.6 Accept 2 5
5bit Spindle No.6 Reject 2 6
Output CH. 6bit Spindle No.6 ABN 2 7
No.03 7bit Spindle No.6 BYP 2 8
8bit Spindle No.7 Accept 2 9
9bit Spindle No.7 Reject 2 10
10bit Spindle No.7 ABN 2 11
11bit Spindle No.7 BYP 2 12
12bit Spindle No.8 Accept 2 13
13bit Spindle No.8 Reject 2 14
14bit Spindle No.8 ABN. 2 15
15bit Spindle No.8 BYP 2 16

CH. No. Bit Signal
0bit 8 1
Output CH.

No.16
15bit 8 32
The CH. No. at the Master input side differs according to node address settings.
Please check before operating the unit.

PAGE 5 - 59
Chapter 5: Control
Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2)

5.11.5 PLC Message Transfer Setup Example


This example procedure is written using Rockwell Automation RXLogix5000 V15.02.00 and
Allen-Bradley Compact Logix L32E. Please contact your PLC manufacturer for specific setup
and configuration information.
Note: Allen-Bradley Control Logix configures up to 400 bytes per block with a maximum of 5
blocks of data for a total of 2000 bytes.

Configuration

1. Register the Multi-2 Unit to the network.

In the I/O configuration, right click on “Ethernet Port Local ENB” and select “New Module”.

Select “Generic Ethernet Module” from the “Module” list and click the OK button.

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Chapter 5: Control Interfaces
AFC1500 Multi-2 Unit Hardware Manual (Rev2)

Specify the “Name” (FEC AFC1500), “IP address”, and “Connection Parameters” that match
the parameters set to the Multi2 unit using the AFC software.

Click on the “Connection” tab and set connection setup as below.

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Chapter 5: Control
Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2)

When the MULTI-2 unit is added to the I/O configuration, the data table will be added to the
controller tags automatically.

AFC1500_2:I
Input signals from MULTI-2 unit. (MULTI-2 -> PLC)
AFC1500_2:O
Output signals to MULTI-2 unit (PLC -> MULTI-2)
AFC1500_2:C
Message communication data from the MULTI-2 unit (MULTI-2 -> PLC for fastening result
data). An additional program/command needs to be added for retrieving the data.

2. Set up the Multi-2 Unit’s Fieldbus Message to transfer data using the MSG function.

Before the MESSAGE function can be setup to transfer data, the AFC1500 Software first
must be configure for the data type and format of the data to be transferred to the PLC.

AFC1500 Fieldbus Message Setup

Configure the field bus message through the AFC User Console software by selecting “Field
Bus Message Setup” from the “Multi” pulldown menu.

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Chapter 5: Control Interfaces
AFC1500 Multi-2 Unit Hardware Manual (Rev2)

Select the DATA TYPE format (BCD or ASCII).


Data from the Multi-2 and Axis (Spindle) must be configured in the table below each tab. The
MULTI FORMAT contains the “Header” data (such as Date, Time, Sequence #, Cycle Count,
etc. – aka data that comes from the Multi-2 Unit) The AXIS FORMAT contains the actual
spindle fastening data (such as Torque, Angle, Time, Rate, etc.) Right click on the table and
select the item that you wish to be transferred from the pop up window.

(Example of Multi format selection shown above)


Note: Selecting “Null” deletes the item from the list.

(Example of Axis format selection shown above – this format will be for EACH spindle
connected in the system)

When the system has more than 1 spindle, the data will be mapped as shown below.
Data from MULTI-2 controller
Data from SPINDLE 1 nutrunner
Data from SPINDLE 2 nutrunner
Data from SPINDLE 3 nutrunner
Data from SPINDLE 4 nutrunner
Data from SPINDLE 5 nutrunner….up to 31
spindles

PAGE 5 - 63
Chapter 5: Control
Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2)

After the fastening result data has been selected, download the configuration to the MULTI-2
controller. The setup for this configuration is part of the “PLC SIGNAL OUTPUT FORMAT”.

PLC Program

Read_Tag needs be added to the “Controller Tags” for message transfer


This data tag contains the configuration of the message transfer.
Each MSG command needs to have its own Read_ tag.

The MSG command is used for transferring the fastening result.

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Chapter 5: Control Interfaces
AFC1500 Multi-2 Unit Hardware Manual (Rev2)

Property of the MSG command is shown below. (Right Click in MSG command)

Message Type CIP Generic


Service Type Get Attribute Single
Service Code E
Class B0
Instance 1
Attribute 1~5
Destination The controller tag “C” should be
selected

Note: Each message command can only handle 400 bytes. If more than 400 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 attribute
as 2 (and so on up to a maximum of 5 for up to 2000 bytes of message data).

PAGE 5 - 65
Chapter 5: Control
Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2)

At the communication tab screen, select “Path”. The MULTI-2 controller can be browsed as
shown below.

PAGE 5 - 66
Chapter 5: Control Interfaces
AFC1500 Multi-2 Unit Hardware Manual (Rev2)

An example of a message transfer program is shown below.

This program transfers up to 800 bytes of fastening result data.


The first MSG command has “1” as attribute and is sending the data into AFC1500:C memory
block. The second MSG command has “2” as attribute and sending the data into another data
memory block that would have been manually added when the second Read_tag was added.

Note: The above information contained in this procedure are meant for REFERENCE ONLY
when configuring an FEC Ethernet I/P interface using FEC AFC User Console Software, FEC
AFC1500 Multi Nutrunner System, Rockwell Automation RSlogix 5000 software and Allen-
Bradley CompactLogix L32E hardware. Actual application configuration may differ from this
set-up.

PAGE 5 - 67
Chapter 5: Control
Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2)

Message Data Example written to AFC1500:C Data Read Tag

AFC User Console


MONITOR Screen for
above data

PAGE 5 - 68
Chapter 5: Control Interfaces
AFC1500 Multi-2 Unit Hardware Manual (Rev2)

5.12 Profinet Interface


The Profinet communication interface allows slave connection to PLC networks that support Profinet
communication via TCP/IP.
Maximum I/O data is 512 input bits & 512 output bits. FEC Inputs match the discrete input layout.
FEC Output location is programmed using the AFC User Console Software.

FEC integrates the Profinet board manufactured by HMS Fieldbus Systems AB into the Multi-2
Unit’s modular I/O board. For further technical information on the Ethernet-I/P interface go to the
HMS website. (www.hms.se)

- Represents switch position

1
DEVICENET
CONNECTOR
2

BAUD/MAC ID
SETTING
3

LED
INDICATORS
4

Item Anybus Board Description


1 Application Connector
2 Ethernet Connector
3 Anybus Watchdog LED (Factory Use Only)
4 Status LEDs (4)

5.12.1 Component Descriptions

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Chapter 5: Control
Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2)

Fieldbus Interface Connections

Pin Signal Note


1 TD+
2 TD-
3 RD+
4 - Normally left unused; to ensure signal integrity, these pins are tied
5 - together and terminated to PE via a filter circuit in the module.
6 RD-
7 - Normally left unused; to ensure signal integrity, these pins are tied
8 - together and terminated to PE via a filter circuit in the module.

Status LEDs

LED State Description


Green Link Established
1 – Link/Activity Green, Flashing Receiving/Transmitting data
Off No Link Established or power off
Off Offline
Online, Run
Green solid - Connection established
4 1
2 - Communication
- IO controller in RUN
Status
3 2 Online, Stop
Green, 1 flash - Connection Established
- IO controller in STOP
Off No power or not initialized
Green solid Initialized, no error
Green, 1 flash Diagnostic data available
Green, 2 flashes Blink. Factory ID tool
Configuration Error
- Too many modules
3 - Module Status - I/O from IO controller config.
Red, 1 flash
Too large
- Configuration Mismatch (no
module, wrong module)
No station name or no IP address
Red 3 flashes
assigned
Red, 4 flashes Internal error
4 – Not Used

PAGE 5 - 70
Chapter 5: Control Interfaces
AFC1500 Multi-2 Unit Hardware Manual (Rev2)

5.12.2 User Console Software Settings


The Anybus board is set up by sending a Fieldbus Configuration File (*.fcf) containing
initialization messages from the Multi-2 Unit to the board during power up. This string of data
initializes different characteristics required for the board to communicate over the Ethernet-I/P
network. In this string is data which set the length of I/O data as well as length of messages
(Resultant Fastening data). Since the board is only initialized during power-up, the Multi-2 Unit
MUST have the power cycled OFF/ON after the “fcf” file is downloaded.

To download the fcf file, select “Field Bus Setup” from the “Multi” pull down menu. Select the
appropriate “Bus Type” and click “Browse” to locate the correct fcf file. After the file has been
selected, click “download” to send the file data to the Anybus board.

If no file exists, (or if the settings need to be changed) after the Bus Type has been selected
click on the Setup Tab.

In NETWORK SETUP, input all of the IP settings required by the host PLC. In I/O SETUP, select
the “Input Data Length” and “Output Data Length” as required by you application. (INPUT &
OUTPUT in this screen refer to PLC side I/O, INPUT = FEC Output size, OUTPUT = FEC Input
size) Data lengths MUST MATCH the PLC’s same I/O length setup otherwise connection will
not be possible.

The Ethernet-I/P interface also has the ability to transfer resultant fastening data using the
message data. Set the MESSAGE INPUT (AFC1500 to PLC) settings according to the PLC
settings. MESSAGE OUTPUT is currently not used. Refer to Page 5.11.5 for message setup
information.

PAGE 5 - 71
Chapter 5: Control
Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2)

5.12.3 Input Signals (CH1 ~ CH16)


Inputs are assigned in the order as shown in the table below and cannot be changed. Bits
designated as “Unused” have no input assigned to them.

FEC Multi-2 FEC Multi-2


CH. No. Bit Signal CH. No. Bit Signal
Bank Bit Bank Bit
0bit Emergency Stop 1 0bit BYPASS SP#1 17
1bit Reset 2 1bit BYPASS SP#2 18
2bit Reverse 3 2bit BYPASS SP#3 19
3bit Start 4 3bit BYPASS SP#4 20
4bit Sequence Select 0 5 4bit BYPASS SP#5 21
5bit Sequence Select 1 6 5bit BYPASS SP#6 22
6bit Sequence Select 2 7 6bit BYPASS SP#7 23
Input CH. Input CH.
7bit Sequence Select 3 8 7bit BYPASS SP#8 24
8bit Cycle Count Up 9 8bit BYPASS SP#9 25
No.01 No.02
9bit Cycle Count Clear 10 9bit BYPASS SP#10 26
10bit Self Check Disable 11 10bit Unused 27
11bit Sequence Select 4 12 11bit Unused 28
12bit INPORT 1 13 12bit Unused 29
13bit INPORT 2 14 13bit Unused 30
14bit INPORT 3 15 14bit Unused 31
15bit INPORT 4 16 15bit Unused 32

FEC Multi-2 FEC Multi-2


CH. No. Bit Signal CH. No. Bit Signal
Bank Bit Bank Bit
0bit BYPASS SP#11 33 0bit BYPASS SP#27 49
1bit BYPASS SP#12 34 1bit BYPASS SP#28 50
2bit BYPASS SP#13 35 2bit BYPASS SP#29 51
3bit BYPASS SP#14 36 3bit BYPASS SP#30 52
4bit BYPASS SP#15 37 4bit BYPASS SP#31 53
5bit BYPASS SP#16 38 5bit 54
6bit BYPASS SP#17 39 6bit 55
Input CH. Input CH.
7bit BYPASS SP#18 40 7bit 56
8bit BYPASS SP#19 41 8bit 57
No.03 No.04
9bit BYPASS SP#20 42 9bit 58
10bit BYPASS SP#21 43 10bit 59
11bit BYPASS SP#22 44 11bit 60
12bit BYPASS SP#23 45 12bit 61
13bit BYPASS SP#24 46 13bit 62
14bit BYPASS SP#25 47 14bit 63
15bit BYPASS SP#26 48 15bit 64

The Channel Number at the Master Unit output side differs according to node address settings.
Please check before operating the unit.

PAGE 5 - 72
Chapter 5: Control Interfaces
AFC1500 Multi-2 Unit Hardware Manual (Rev2)

5.12.4 Ouput Signals (CH1 ~ CH16)


The Multi-2 Unit is capable of providing over 570 Output signals to indicate the status of the
Multi-2 Unit and of all the AFC1500 SAN Controllers connected to it (up to 31 controllers).
See Section 4.7.3 for available output signals.
FEC Multi-2
CH. No. Bit Signal Bank Bit
0bit Total Reject 1 1
1bit Total Accept 1 2
2bit Abnormal 1 3
These Output signals are user
3bit Ready 1 4
4bit Busy 1 5 configurable using the AFC User
5bit End 1 6 Console Software and may be
Output CH. 6bit Sequence Output 0 1 7 programmed on any designated
No.01 7bit Sequence Output 1 1 8
8bit Sequence Output 2 1 9 bit.
9bit Sequence Output 3 1 10
10bit Sequence Output 4 1 11 The Output signal mapping
11bit Spindle in Bypass 1 12
shown is only an EXAMPLE.
12bit Current Warning 1 13
13bit 1 14 The signals may be programmed
14bit 1 15 for placement in ANY bit
15bit 1 16 position.
0bit Spindle No.1 Accept 1 17
1bit Spindle No.1 Reject 1 18
2bit Spindle No.1 ABN. 1 19
3bit Spindle No.1 BYP 1 20
4bit Spindle No.2 Accept 1 21
Output CH. 5bit Spindle No.2 Reject 1 22
No.02 6bit Spindle No.2 ABN 1 23
7bit Spindle No.2 BYP 1 24
8bit Spindle No.3 Accept 1 25
9bit Spindle No.3 Reject 1 26
10bit Spindle No.3 ABN 1 27
11bit Spindle No.3 BYP 1 28
12bit Spindle No.4 Accept 1 29
13bit Spindle No.4 Reject 1 30
14bit Spindle No.4 ABN. 1 31
15bit Spindle No.4 BYP 1 32
0bit Spindle No.5 Accept 2 1
1bit Spindle No.5 Reject 2 2
2bit Spindle No.5 ABN. 2 3
3bit Spindle No.5 BYP 2 4
4bit Spindle No.6 Accept 2 5
5bit Spindle No.6 Reject 2 6
Output CH. 6bit Spindle No.6 ABN 2 7
No.03 7bit Spindle No.6 BYP 2 8
8bit Spindle No.7 Accept 2 9
9bit Spindle No.7 Reject 2 10
10bit Spindle No.7 ABN 2 11
11bit Spindle No.7 BYP 2 12
12bit Spindle No.8 Accept 2 13
13bit Spindle No.8 Reject 2 14
14bit Spindle No.8 ABN. 2 15
15bit Spindle No.8 BYP 2 16

CH. No. Bit Signal
0bit 8 1
Output CH.

No.16
15bit 8 32
The CH. No. at the Master input side differs according to node address settings.
Please check before operating the unit.

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Chapter 5: Control
Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2)

5.13 Input / Output Signal Layout using Toolsnet Version


InterBus-S, Devicenet & Profibus interfaces can be configured to be connected to the Atlas
Copco Toolsnet Network. If this setting is selected, the I/O signal mapping changes according
to the tables below. (If the Toolsnet version is selected during the interface board set-up (5.1),
this I/O mapping will be automatically set)

Input Signals

Byte No. Bit Signal Byte No. Bit Description


0bit Start 16bit BYPASS SP#1
1bit Emergency Stop 17bit BYPASS SP#2
2bit Reverse 18bit BYPASS SP#3
3bit INPORT 1 19bit BYPASS SP#4
Byte 0 Byte 2
4bit INPORT 2 20bit BYPASS SP#5
5bit INPORT 3 21bit BYPASS SP#6
6bit INPORT 4 22bit BYPASS SP#7
7bit Reset 23bit BYPASS SP#8
8bit Sequence Select 0 24bit BYPASS SP#9
9bit Sequence Select 1 25bit BYPASS SP#10
10bit Sequence Select 2 26bit Unused
11bit Sequence Select 3 27bit Unused
Byte 1 Byte 3
12bit Sequence Select 4 28bit Unused
13bit Cycle Count Up 29bit Unused
14bit Cycle Count Clear 30bit Unused
15bit Self Check Disable 31bit Unused

Byte No. Bit Signal Byte No. Bit Description


32bit BYPASS SP#11 48bit BYPASS SP#27
33bit BYPASS SP#12 49bit BYPASS SP#28
34bit BYPASS SP#13 50bit BYPASS SP#29
35bit BYPASS SP#14 51bit BYPASS SP#30
Byte 4 Byte 6
36bit BYPASS SP#15 52bit BYPASS SP#31
37bit BYPASS SP#16 53bit
38bit BYPASS SP#17 54bit
39bit BYPASS SP#18 55bit
40bit BYPASS SP#19 56bit
41bit BYPASS SP#20 57bit
42bit BYPASS SP#21 58bit
43bit BYPASS SP#22 59bit
Byte 5 Byte 7
44bit BYPASS SP#23 60bit
45bit BYPASS SP#24 61bit
46bit BYPASS SP#25 62bit
47bit BYPASS SP#26 63bit

Byte No. Bit Signal Byte No. Bit Description


64bit VIN NUMBER BYTE 0 80bit VIN NUMBER BYTE 2
65bit 81bit
66bit 82bit
67bit 83bit
Byte 8 Byte 10
68bit 84bit
69bit 85bit
70bit 86bit
71bit 87bit
72bit VIN NUMBER BYTE 1 88bit VIN NUMBER BYTE 3
73bit 89bit
74bit 90bit
75bit 91bit
Byte 9 Byte 11
76bit 92bit
77bit 93bit
78bit 94bit
79bit 95bit

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Chapter 5: Control Interfaces
AFC1500 Multi-2 Unit Hardware Manual (Rev2)

Input Signals (Toolsnet Version - Continued)

Byte No. Bit Signal Byte No. Bit Description


96bit VIN NUMBER BYTE 4 112bit VIN NUMBER BYTE 6
97bit 113bit
98bit 114bit
99bit 115bit
Byte 12 Byte 14
100bit 116bit
101bit 117bit
102bit 118bit
103bit 119bit
104bit VIN NUMBER BYTE 5 120bit VIN NUMBER BYTE 7
105bit 121bit
106bit 122bit
107bit 123bit
Byte 13 Byte 15
108bit 124bit
109bit 125bit
110bit 126bit
111bit 127bit

Byte No. Bit Signal Byte No. Bit Description


128bit VIN NUMBER BYTE 8 144bit VIN NUMBER BYTE 10
129bit 145bit
130bit 146bit
131bit 147bit
Byte 16 Byte 18
132bit 148bit
133bit 149bit
134bit 150bit
135bit 151bit
136bit VIN NUMBER BYTE 9 152bit VIN NUMBER BYTE 11
137bit 153bit
138bit 154bit
139bit 155bit
Byte 17 Byte 19
140bit 156bit
141bit 157bit
142bit 158bit
143bit 159bit

Byte No. Bit Signal Byte No. Bit Description


160bit VIN NUMBER BYTE 12 176bit VIN NUMBER BYTE 14
161bit 177bit
162bit 178bit
163bit 179bit
Byte 20 Byte 22
164bit 180bit
165bit 181bit
166bit 182bit
167bit 183bit
168bit VIN NUMBER BYTE 13 184bit VIN NUMBER BYTE 15
169bit 185bit
170bit 186bit
171bit 187bit
Byte 21 Byte 23
172bit 188bit
173bit 189bit
174bit 190bit
175bit 191bit

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Chapter 5: Control
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Input Signals (Toolsnet Version - Continued)

Byte No. Bit Signal Byte No. Bit Description


192bit VIN NUMBER BYTE 16 209bit VIN NUMBER BYTE 18
193bit 210bit
194bit 211bit
195bit 212bit
Byte 24 Byte 26
196bit 213bit
198bit 214bit
199bit 215bit
200bit 216bit
201bit VIN NUMBER BYTE 17 217bit VIN NUMBER BYTE 19
202bit 218bit
203bit 219bit
204bit 220bit
Byte 25 Byte 27
205bit 221bit
206bit 222bit
207bit 223bit
208bit 224bit

Byte No. Bit Signal Byte No. Bit Description


225bit VIN NUMBER BYTE 20 241bit VIN NUMBER BYTE 22
226bit 242bit
227bit 243bit
228bit 244bit
Byte 28 Byte 30
229bit 245bit
230bit 246bit
231bit 247bit
232bit 248bit
233bit VIN NUMBER BYTE 21 249bit VIN NUMBER BYTE 23
234bit 250bit
235bit 251bit
236bit 252bit
Byte 29 Byte 31
237bit 253bit
238bit 254bit
239bit 255bit
240bit 256bit

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Chapter 5: Control Interfaces
AFC1500 Multi-2 Unit Hardware Manual (Rev2)

Output Signals (Toolsnet Version)

Byte No. Bit Signal Byte No. Bit Description


0bit Total Reject 16bit Spindle #1 Accept
1bit Total Accept 17bit Spindle #1 Reject
2bit N/R Abnormal 18bit Spindle #1 Abnormal
3bit Ready 19bit Spindle #1 Bypass
Byte 0 Byte 2
4bit Busy 20bit Spindle #2 Accept
5bit End 21bit Spindle #2 Reject
6bit 22bit Spindle #2 Abnormal
7bit 23bit Spindle #2 Bypass
8bit Sequence Select 0 24bit Spindle #3 Accept
9bit Sequence Select 1 25bit Spindle #3 Reject
10bit Sequence Select 2 26bit Spindle #3 Abnormal
11bit Sequence Select 3 27bit Spindle #3 Bypass
Byte 1 Byte 3
12bit Output Port 1 28bit Spindle #4 Accept
13bit Output Port 2 29bit Spindle #4 Reject
14bit Output Port 3 30bit Spindle #4 Abnormal
15bit Output Port 4 31bit Spindle #4 Bypass

Byte No. Bit Signal Byte No. Bit Description


32bit Spindle #5 Accept 48bit Spindle #9 Accept
33bit Spindle #5 Reject 49bit Spindle #9 Reject
34bit Spindle #5 Abnormal 50bit Spindle #9 Abnormal
35bit Spindle #5 Bypass 51bit Spindle #9 Bypass
Byte 4 Byte 6
36bit Spindle #6 Accept 52bit Spindle #10 Accept
37bit Spindle #6 Reject 53bit Spindle #10 Reject
38bit Spindle #6 Abnormal 54bit Spindle #10 Abnormal
39bit Spindle #6 Bypass 55bit Spindle #11 Bypass
40bit Spindle #7 Accept 56bit Spindle #11Accept
41bit Spindle #7 Reject 57bit Spindle #11Reject
42bit Spindle #7 Abnormal 58bit Spindle #11Abnormal
43bit Spindle #7 Bypass 59bit Spindle #11 Bypass
Byte 5 Byte 7
44bit Spindle #8 Accept 60bit Spindle #12Accept
45bit Spindle #8 Reject 61bit Spindle #12Reject
46bit Spindle #8 Abnormal 62bit Spindle #12Abnormal
47bit Spindle #8 Bypass 63bit Spindle #12Bypass

Byte No. Bit Signal Byte No. Bit Description


64bit Network Connected 80bit Spdl.1 Torque Low Limit
65bit Data Buffer Full 81bit Upper Byte
66bit 82bit
67bit 83bit
Byte 8 Byte 10
68bit 84bit
69bit 85bit
70bit 86bit
71bit 87bit
72bit 88bit Spdl.1 Torque Low Limit
73bit 89bit Lower Byte
74bit 90bit
75bit 91bit
Byte 9 Byte 11
76bit 92bit
77bit 93bit
78bit 94bit
79bit 95bit

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Chapter 5: Control
Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2)

Output Signals (Toolsnet Version-Continued)

Byte No. Bit Signal Byte No. Bit Description


96bit Spdl.1 Torque 112bit Spdl.1 Torque High Limit
97bit Upper Byte 113bit Upper Byte
98bit 114bit
99bit 115bit
Byte 12 Byte 14
100bit 116bit
101bit 117bit
102bit 118bit
103bit 119bit
104bit Spdl.1 Torque 120bit Spdl.1 Torque High Limit
105bit Lower Byte 121bit Lower Byte
106bit 122bit
107bit 123bit
Byte 13 Byte 15
108bit 124bit
109bit 125bit
110bit 126bit
111bit 127bit

Byte No. Bit Signal Byte No. Bit Description


128bit Spdl.1 Angle Low Limit 144bit Spdl.1 Angle
129bit Upper Byte 145bit Upper Byte
130bit 146bit
131bit 147bit
Byte 16 Byte 18
132bit 148bit
133bit 149bit
134bit 150bit
135bit 151bit
136bit Spdl.1 Angle Low Limit 152bit Spdl.1 Angle
137bit Upper Byte 153bit Lower Byte
138bit 154bit
139bit 155bit
Byte 17 Byte 19
140bit 156bit
141bit 157bit
142bit 158bit
143bit 159bit

Byte No. Bit Signal Byte No. Bit Description


160bit Spdl.1 Angle High Limit 176bit Spdl.2 Torque Low Limit
161bit Upper Byte 177bit Upper Byte
162bit 178bit
163bit 179bit
Byte 20 Byte 22
164bit 180bit
165bit 181bit
166bit 182bit
167bit 183bit
168bit Spdl.1 Angle High Limit 184bit Spdl.2 Torque Low Limit
169bit Upper Byte 185bit Lower Byte
170bit 186bit
171bit 187bit
Byte 21 Byte 23
172bit 188bit
173bit 189bit
174bit 190bit
175bit 191bit

Continues through Byte 249 for up to 18 spindles

PAGE 5 - 78
Chapter 6: Troubleshooting
Chapter 6: Troubleshooting
AFC1500 Multi-2 Unit Hardware Manual (Rev. 2)

6.1 Abnormals
The Multi-2 Unit is capable of giving unit fault status to the AFC 1500 User Console in the form of a
code number. This number can be read and displayed by the User Console software. (See the User
Console Software Manual for more information on where to access this function)

Abnormal
Description
Number
1 An Axis unit was not in Ready status when the Multi-2 Unit
attempted to start - confirm all axis status
2 The connected spindles do not match with spindles called
from fastening sequence - confirm fastening sequence
3 Fastening sequence does not have spindle numbers
assigned - confirm fastening sequence
4 Fastening sequence selected does not exist - confirm
fastening sequence.
5 No End command in the fastening sequence
6 Fastening sequence abnormal
7 An Axis unit was not in Ready status when the Multi-2 Unit
attempted to send 1st step command - confirm all axis
status
8 An Axis unit was not in Ready status when the Multi-2 Unit
attempted to send 2nd step command - confirm all axis
status
9 Input / Output port number error - input port number over 4
or Output port number over 8 is set

PAGE 6 - 2

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