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Automation Systems
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.
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
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.
◆ 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.”
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.
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.
• 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.
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.
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
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 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
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.
viii
Safety Precautions
Install the AXIS Unit firmly inside the control panel using the specified screws.
Failure to observe this instruction may cause 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 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.
Apply proper wiring size and firmly tighten all termination points.
Failure to observe this instruction may cause injury, false operation and malfunction.
ix
Safety Precautions
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.
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.
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 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
xi
Table of Contents
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)
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
♦ 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.
PAGE 1 - 3
Chapter 1: Outline
AFC1500 Multi-2 Unit Hardware Manual (Rev. 2)
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.
PAGE 1 - 4
Chapter 2: Specifications
Chapter 2: Specifications
AFC1500 Multi-2 Unit Hardware Manual (Rev.2)
2.1 Specifications
PAGE 2 - 2
Chapter 2: Specifications
AFC1500 Multi-2 Unit Hardware Manual (Rev.2)
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)
PAGE 3 - 2
Chapter 3: System Description
AFC1500 Multi-2 Unit Hardware Manual (Rev.2)
(RS232C) PC Port
Accept LED
Reject LED
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.
PAGE 3 - 3
Chapter 3: System Description
AFC1500 Multi-2 Unit Hardware Manual (Rev.2)
PAGE 3 - 4
Chapter 4: Installation & Wiring
Chapter 4: Installation & Wiring
AFC1500 Multi-2 Unit Hardware Manual (Rev. 2)
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)
PAGE 4 - 4
Chapter 4: Installation & Wiring
AFC1500 Multi-2 Unit Hardware Manual (Rev. 2)
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.
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 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)
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.
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)
PAGE 4 - 6
Chapter 4: Installation & Wiring
AFC1500 Multi-2 Unit Hardware Manual (Rev. 2)
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-232C PC CABLE
(Standard NULL MODEM Cable)
PAGE 4 - 8
Chapter 4: Installation & Wiring
AFC1500 Multi-2 Unit Hardware Manual (Rev. 2)
PAGE 4 - 9
Chapter 4: Installation & Wiring
AFC1500 Multi-2 Unit Hardware Manual (Rev. 2)
*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)
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)
Note: This port is removed when using the Ethernet Version (Optional E Version) Multi
Unit
* 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)
Interface Board
PAGE 4 - 13
Chapter 4: Installation & Wiring
AFC1500 Multi-2 Unit Hardware Manual (Rev. 2)
PAGE 4 - 14
Chapter 4: Installation & Wiring
AFC1500 Multi-2 Unit Hardware Manual (Rev. 2)
(Continued)
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.
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)
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.
PAGE 4 - 17
Chapter 4: Installation & Wiring
AFC1500 Multi-2 Unit Hardware Manual (Rev. 2)
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
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
OFF
Seq. Sel. Bit 3 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)
(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
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
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)
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.
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)
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
PAGE 5 - 3
Chapter 5: Control
Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2)
Output
Output
Input
Input
24VDC Power
Source
PAGE 5 - 4
Chapter 5: Control Interfaces
AFC1500 Multi-2 Unit Hardware Manual (Rev2)
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
PAGE 5 - 5
Chapter 5: Control
Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2)
Output signal
Input signal
PAGE 5 - 6
Chapter 5: Control Interfaces
AFC1500 Multi-2 Unit Hardware Manual (Rev2)
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
PAGE 5 - 7
Chapter 5: Control
Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2)
PAGE 5 - 8
Chapter 5: Control Interfaces
AFC1500 Multi-2 Unit Hardware Manual (Rev2)
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:
Typically these “Always On / Always Off” bits are programmed in the last output points
(Pins 30 -32 as shown on the previous page).
PAGE 5 - 9
Chapter 5: Control
Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2)
PAGE 5 - 10
Chapter 5: Control Interfaces
AFC1500 Multi-2 Unit Hardware Manual (Rev2)
* 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)
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)
*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 must be selected before power is on and cannot be changed during operation.
Status LEDs
PAGE 5 - 13
Chapter 5: Control
Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2)
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)
The Channel Number at the Master Unit output side differs according to node address settings.
Please check before operating the unit.
PAGE 5 - 15
Chapter 5: Control
Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2)
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)
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)
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
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.
PAGE 5 - 18
Chapter 5: Control Interfaces
AFC1500 Multi-2 Unit Hardware Manual (Rev2)
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.
Status LEDs
PAGE 5 - 19
Chapter 5: Control
Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2)
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.
PAGE 5 - 20
Chapter 5: Control Interfaces
AFC1500 Multi-2 Unit Hardware Manual (Rev2)
The Channel Number at the Master Unit output side differs according to node address settings.
Please check before operating the unit.
PAGE 5 - 21
Chapter 5: Control
Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2)
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)
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.
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
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)
Termination
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
PAGE 5 - 25
Chapter 5: Control
Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2)
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)
PAGE 5 - 27
Chapter 5: Control
Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2)
PAGE 5 - 28
Chapter 5: Control Interfaces
AFC1500 Multi-2 Unit Hardware Manual (Rev2)
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)
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)
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)
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
PAGE 5 - 32
Chapter 5: Control Interfaces
AFC1500 Multi-2 Unit Hardware Manual (Rev2)
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)
PAGE 5 - 34
Chapter 5: Control Interfaces
AFC1500 Multi-2 Unit Hardware Manual (Rev2)
PAGE 5 - 35
Chapter 5: Control
Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2)
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.
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)
*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 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).
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
PAGE 5 - 39
Chapter 5: Control
Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2)
PAGE 5 - 40
Chapter 5: Control Interfaces
AFC1500 Multi-2 Unit Hardware Manual (Rev2)
PAGE 5 - 41
Chapter 5: Control
Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2)
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.
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)
*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)
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.
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
PAGE 5 - 45
Chapter 5: Control
Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2)
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.
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Chapter 5: Control Interfaces
AFC1500 Multi-2 Unit Hardware Manual (Rev2)
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Chapter 5: Control
Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2)
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Chapter 5: Control Interfaces
AFC1500 Multi-2 Unit Hardware Manual (Rev2)
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)
BAUD/ADDRESS
SETTING 1
3
BAUD/ADDRESS BAUD/ADDRESS
SETTING SETTING
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.
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Chapter 5: Control Interfaces
AFC1500 Multi-2 Unit Hardware Manual (Rev2)
Termination
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.
Status LEDs
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Chapter 5: Control
Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2)
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.
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Chapter 5: Control Interfaces
AFC1500 Multi-2 Unit Hardware Manual (Rev2)
The Channel Number at the Master Unit output side differs according to rack address settings.
Please check before operating the unit.
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Chapter 5: Control
Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2)
The CH. No. at the Master input side differs according to rack address settings.
Please check before operating the unit.
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Chapter 5: Control Interfaces
AFC1500 Multi-2 Unit Hardware Manual (Rev2)
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)
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.
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Chapter 5: Control
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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
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Chapter 5: Control Interfaces
AFC1500 Multi-2 Unit Hardware Manual (Rev2)
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.
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Chapter 5: Control
Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2)
The Channel Number at the Master Unit output 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)
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Chapter 5: Control
Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2)
Configuration
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.
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Chapter 5: Control
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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.
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)
(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
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Chapter 5: Control
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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
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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)
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).
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Chapter 5: Control
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At the communication tab screen, select “Path”. The MULTI-2 controller can be browsed as
shown below.
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Chapter 5: Control Interfaces
AFC1500 Multi-2 Unit Hardware Manual (Rev2)
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.
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Chapter 5: Control
Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2)
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Chapter 5: Control Interfaces
AFC1500 Multi-2 Unit Hardware Manual (Rev2)
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)
1
DEVICENET
CONNECTOR
2
BAUD/MAC ID
SETTING
3
LED
INDICATORS
4
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Chapter 5: Control
Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2)
Status LEDs
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Chapter 5: Control Interfaces
AFC1500 Multi-2 Unit Hardware Manual (Rev2)
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)
The Channel Number at the Master Unit output 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)
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Chapter 5: Control
Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2)
Input Signals
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Chapter 5: Control Interfaces
AFC1500 Multi-2 Unit Hardware Manual (Rev2)
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Chapter 5: Control
Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2)
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Chapter 5: Control Interfaces
AFC1500 Multi-2 Unit Hardware Manual (Rev2)
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Chapter 5: Control
Interfaces AFC1500 Multi-2 Unit Hardware Manual (Rev2)
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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