Fec FUSIONE-HS-2 User Manual

    

Never operate the equipment with wet handsFailure to observe this instruction may cause electric shock. Properly GROUND all Field Gro

Chapter 6: Fastening Instructions Page 6-4 Two-Step Fastening Two-step fastening will be used primarily for joints that have a requirement to synchro

FEC Fusion Operations Manual Chapter 6: Fastening Instructions (

Chapter 6: Fastening Instructions 6.1.2 Angle Control Method. In Angle Control method, fastening is performed based upon attaining a desired torque v

FEC Fusion Operations Manual Chapter 6: Fastening Instructions (

Chapter 6: Fastening Instructions Two-Step Fastening Two-Step fastening will be used primarily for joints that have a requirement to synchronize with

FEC Fusion Operations Manual FIG. 6-1-2b Angle Control Functions for Two NOTE: When performing

Chapter 6: Fastening Instructions Three-Step Fastening Three-step fastening will be used primarily for joints that have a requirement to synchronize

FEC Fusion Operations Manual NOTE: When performing multiple step Angle control fastening, the rotat

Chapter 6: Fastening Instructions Page 6-12 6.2 Monitoring Functions The Fusion System is user programmable to select and set the monitoring limits

FEC Fusion Operations Manual Chapter 6: Fastening Instructions (

Table of contents i Table of Contents Page Chapter 1: Outline 1-1 1.1 About This operations manual 1-2 1.2 Features 1-3 1.3 Functions. 1-5

Chapter 6: Fastening Instructions Page 6-14 6.2.2Final Torque Monitoring Torque Monitoring is a continuous process whenever the system is operating.

FEC Fusion Operations Manual Chapter 6: Fastening Instructions (

Chapter 6: Fastening Instructions Page 6-16 6.2.3 Angle Monitoring Angle Monitoring commences upon reaching the preset SNUG TORQUE value, and contin

FEC Fusion Operations Manual Chapter 6: Fastening Instructions (

Chapter 6: Fastening Instructions 6.2.4 Point-to-Point Torque Rate MonitoringThe Fusion System is capable of performing 3 torque rate calculations.

FEC Fusion Operations Manual Chapter 6: Fastening Instructions (

Chapter 6: Fastening Instructions Page 6-20 6.2.5 Time Monitoring Time High Limits As outlined in the Fastening Control Methods portion of this chap

FEC Fusion Operations Manual Chapter 6: Fastening Instructions (

Chapter 6: Fastening Instructions Page 6-22 The graphic below describes the ideal relationship between torque and speed. Typically for high mo-tor d

FEC Fusion Operations Manual Chapter 6: Fastening Instructions (

Table of contents ii 4.10 Controller Unit DIP Switch setting. 4-27 4.10.1 Controller Unit DIP switch positions 1 ~ 3 4-27 4.10.2 Controller Un

Chapter 6: Fastening Instructions 6.5 Torque Recovery The Torque Recovery function is used when the potential for joint relaxation and interaction

FEC Fusion Operations Manual Chapter 6: Fastening Instructions (

Chapter 6: Fastening Instructions Page 6-26 6.6.2 Angle Correction An Angle Correction preset is available for correcting angle reading disparitie

FEC Fusion Operations Manual Chapter 6: Fastening Instructions (

Chapter 6: Fastening Instructions Page 6-28 (Blank Page)

FUSION Operations Manual Chapter 7: System Operations (Rev.2) Page 7-1 C

Chapter 7: System Operations Page 7-2 7.1 FUSION Display and Programming unit operation. The FUSION system can be programmed and monitored using the A

FUSION Operations Manual Chapter 7: System Operations (Rev.2) Page 7-3 •

Chapter 7: System Operations Abnormal “A9” Display FIG. 7-1-3 Fastening Displays 7.1.4 Fastening Presetting / Result Display Controls• MODE

FUSION Operations Manual 7.2 Run State Modes.The FUSION system has two operational states that are controlled by “MODE” and “SET” Buttons,

Table of contents iii 7.2 Run State Modes. 7-5 7.2.1 Display indication modes. 7-5 7.2.2 Real-time display indication mode. 7-6 7.2.3 Fasteni

Chapter 7: System Operations 7.2.2 Real-time display indication mode.While the mode is in Real time display modechoose the desired type of data by pr

FUSION Operations Manual Chapter 7: System Operations (Rev.2) Page 7-7 7

Chapter 7: System Operations Page 7-8 7.2.4 Parameter Display Mode The FUSION system can store up to 16 different sets of parameters that can be sele

FUSION Operations Manual Chapter 7: System Operations (Rev.2) Page 7-9 7

Chapter 7: System Operations Page 7-10 Time (Consult FEC be-fore changing these items) 1~16 40 INITIAL TIME Max. 999.9 sec 1~16 41 1ST STEP TIM

FUSION Operations Manual 1) Display operation for Parameter selection FUSION Operations Manual

Chapter 7: System Operations Page 7-12 Special D-No Explanation 2) Torque Unit [WORK]-00, [D-No]-00 00: Nm 02:Kgcm 04:In.Lb.

FUSION Operations Manual Chapter 7: System Operations (Rev.2) Page 7-13

Chapter 7: System Operations Page 7-14 8) Fastening Mode and Fastening Steps [WORK]-1~16, [D-No]-00. The fastening mode is entered into [WORK]-1~16,

FUSION Operations Manual Chapter 7: System Operations (Rev.2) Page 7-15

Table of contents iv 9.4 Tool EEPROM Errors 9-7 9.4.1 Code 3-0 Preamplifier / Tool ID Checksum error 9-7 9.4.2 Code 3-1 Preamplifier / Tool type

Chapter 7: System Operations Page 7-16 Data No.14 Speed Change Torque [Nm, Kgm...] Setting range: 0 ~ [10: Calibration torque] × 1.0 Set the torque v

FUSION Operations Manual Chapter 7: System Operations (Rev.2) Page 7-17

Chapter 7: System Operations Page 7-18 Data No.18 CROS Torque [Nm, Kgm...] Setting range: 0 ~ [10: Calibration torque] × 1.0 2nd stop / synchroniza

FUSION Operations Manual Chapter 7: System Operations (Rev.2) Page 7-19

Chapter 7: System Operations Page 7-20 Data No.20 Low Angle [deg] Data No.21 High Angle [deg] Setting range: 0~9999 Sets the High and Low limits f

FUSION Operations Manual Chapter 7: System Operations (Rev.2) Page 7-21

Chapter 7: System Operations Page 7-22 Data No.55 Not Used Data No.56 Not Used Data No.60 Freerun Revolutions [rev] Setting range: 0 ~ 99.9 S

FUSION Operations Manual Chapter 7: System Operations (Rev.2) Page 7-23

Chapter 7: System Operations 7.2.6 STATUS display Two types of controller STATUS can be displayed, either STOP or ABNORMAL. 1) When the STOP sig

FUSION Operations Manual 7.3 Download / Setup Mode Operation (Bypass Mode Only)The FUSION system has two “MODE” and “SET” Buttons, on the

FEC FUSION Operations Manual Chapter 1: Outline (Rev 2)

Chapter 7: System Operations 7.3.2 Setup Mode selection Depressing the Mode button will initiate the Setup mode. Immediately after the setup mode is

FUSION Operations Manual 7.3.3 Parameter # selectionAll 16 Parameter sets can be setup using the programmer. Data corresponding to the sle

Chapter 7: System Operations 7.3.4 Data # selection The value for digit 1 and 2 of the (blinking) cursor is in the respected position. The [↓↓↓↓] and

FUSION Operations Manual 7.3.5 Data Edit mode operation. FIG. 7-3-3 Setup mode operation When the Torque Unit number (PARM 0 Dchange

Chapter 7: System Operations 7.3.6 Parameter copy. To speed parameter data entry, it may be beneficial to copy from one parameter set to another param

FUSION Operations Manual Chapter 7: System Operations (Rev.2) Page 7-31

Chapter 7: System Operations Page 7-32 7.5 Optional Real Time Clock Module The Fusion system stores 10000 cycles of fastening results in its flash mem

FUSION Operations Manual Chapter 7: System Operations (Rev.2) Page 7-33

Chapter 7: System Operations Page 7-34 7.6.1 Recommended Parameter Set-up for Tubenut Head The following parameters are recommended for setting up t

FUSION Operations Manual Chapter 7: System Operations (Rev.2) Page 7-35

Chapter 1: Outline Page 1-2 1.1 About This operations manual This manual details the configuration, components, specifications, and the operati

Chapter 7: System Operations Page 7-36 (Blank Page)

FUSION Operations Manual Chapter 8: Maintenance and Inspection (Rev. 2)

Chapter 8: Maintenance and Inspection Page 8-2 8.1 Inspection Items A scheduled inspection is recommended to keep the FUSION System in the best co

FUSION Operations Manual Chapter 8: Maintenance and Inspection (Rev. 2)

Chapter 8: Maintenance and Inspection Page 8-4 8.2 Basic Operational Tests WARNING:Follow Lockout/Tagout and other safety precautions when connect

FUSION Operations Manual Chapter 8: Maintenance and Inspection (Rev. 2)

Chapter 8: Maintenance and Inspection Page 8-6 8.2.4Transmission Disassembly and Inspection • The planetary gear transmissions used in the FUSION

FUSION Operations Manual 8.3 Replacements WARNING: DO NOT CONNECT OR DISCONNECT CABLES OR OTHER SYSTEM COMPONENTS WITH POWER APP

Chapter 8: Maintenance and Inspection Page 8-8 8.3.2 Replace Nutrunner (tool). Do not attempt to replace a component of the tool - the tool must b

FUSION Operations Manual Chapter 9: Troubleshooting (Rev. 2) Pa

FEC FUSION Operations Manual Chapter 1: Outline (Rev 2)

Chapter 9: Troubleshooting

FUSION Operations Manual 9.2 Torque Transducer AbnormalsCalibration Error

Chapter 9: Troubleshooting

FUSION Operations Manual Chapter 9: Troubleshooting (Rev. 2) Pa

Chapter 9: Troubleshooting

FUSION Operations Manual Chapter 9: Troubleshooting (Rev. 2) Pa

Chapter 9: Troubleshooting

FUSION Operations Manual Chapter 9: Troubleshooting (Rev. 2) Pa

Chapter 9: Troubleshooting

FUSION Operations Manual Chapter 9: Troubleshooting (Rev. 2) Pa

Chapter 1: Outline Page 1-4 • Motor A permanent magnet High Speed DC motor provides for improved fastening control. The sealed design of the m

Chapter 9: Troubleshooting

FUSION Operations Manual Chapter 9: Troubleshooting (Rev. 2) Pa

Chapter 9: Troubleshooting

FUSION Operations Manual Chapter 9: Troubleshooting (Rev. 2) Pa

FEC FUSION Operations Manual Chapter 1: Outline (Rev 2)

WARNING All applicable national and local codes must be followed when installing and operating the equipment detailed in this manual. FAILURE TO AB

Chapter 1: Outline Page 1-6 1.4 System requirements To ensure the most effective and extended use of all equipment, adhere to the following spec

FEC FUSION Operations Manual Chapter 1: Outline (Rev 2)

Chapter 1: Outline Page 1-8 (Blank Page)

FEC FUSION Operations Manual Chapter 2: Specifications (Rev. 2)

Chapter 2: Specifications Page 2-2 2.1 Main Specifications Power Supply Voltage • Single Phase 100 ~ 230 VAC +/- 10% , 50/60 Hz Auto-Switching

FEC FUSION Operations Manual Chapter 2: Specifications (Rev. 2.1)

Chapter 2: Specifications Page 2-4 2.3 Controller Unit Specifications Controller Model HFC-EC-16 Motor Model RM80, RM50 Controller Supply Vo

FEC FUSION Operations Manual Chapter 2: Specifications (Rev. 2)

Chapter 2: Specifications Page 2-6 2.4.1 Nutrunner Tool Specification Table. TOOL TYPE SERVO TYPE CALIBRATION TORQUE SPEED RPM Weight Sq. Drive L

FEC FUSION Operations Manual Chapter 2: Specifications (Rev. 2)

Revision History Revision date Manual No. Content of Revision 2005/July First Edition Original Operation Manual 2007/August FUSIONE-HS-2 Revision

Chapter 2: Specifications Page 2-8 [Blank Page}

FEC FUSION Operations Manual Chapter 3: System Description (Rev 2)

Chapter 3: System Description Page 3-2 3.1 Controller 3.1.1 Controller Part Number Breakdown HFC-EC-16-[14]-[E]

FEC FUSION Operations Manual Chapter 3: System Description (Rev 2)

Chapter 3: System Description Page 3-4 FRONT PANEL DISPLAY FEATURES ITEM ITEM AS MARKED ON UNIT DESCRIPTION 1 ACCEPT (Green) Lights to in

FEC FUSION Operations Manual Chapter 3: System Description (Rev 2)

Chapter 3: System Description Page 3-6 BACK PANEL CONNECTOR FEATURES ITEM ITEM AS MARKED ON UNIT DESCRIPTION 1 CN1 Twist Lock single conn

FEC FUSION Operations Manual Chapter 3: System Description (Rev 2)

Chapter 3: System Description Page 3-8 3.2.2 FUSION Tool Control, Displays and Connectors Fig. 3.2.2 Tool Description TOOL M

FEC FUSION Operations Manual Chapter 4: System Setup and Wiring (Rev. 2.1) Page 4-1 Chapter 4:

Thank you for purchasing our Electric Servo Nutrunner – FUSION System. This instruction manual describes the procedures for installation, wiring, and

Chapter 4: System Setup and Wiring Page 4-2 4.1 Design and Build Procedure Review Chapters 1 and 2 prior to designing a System. If the require

FEC FUSION Operations Manual Chapter 4: System Setup and Wiring (Rev. 2.1) Page 4-3 4.2 Compo

Chapter 4: System Setup and Wiring Page 4-4 4.3 Unit Arrangement ** See preceding page for actual unit width FIG. 4

FEC FUSION Operations Manual Chapter 4: System Setup and Wiring (Rev. 2.1) Page 4-5 4.4 Nutru

Chapter 4: System Setup and Wiring 4.4.2 Right Angle Tool FIG. 4-4 HFT-TYPE TORQUE SPEED A 015M50-A1 1.5KgM 1215 rpm 381 025M8

FEC FUSION Operations Manual 4.4.3 Pistol Tools The FEC Pistol tool is available in two configuratitol style. Th

Chapter 4: System Setup and Wiring “P” Type Pistol Tool The “P” type pistol tool is mainly used for handan optional mounting bracket. If held i

FEC FUSION Operations Manual 4.5 Connection DiagramA basic layout of Systemence drawings can WARNING: Follow Lock

Chapter 4: System Setup and Wiring 4.6 Power Requirements and Connections 4.6.1 Controller Unit The Controller uses a standard “computer” powe

FEC FUSION Operations Manual 4.7 Wiring PLC I/O All interface devices must accommodate active true low logic for c

Warranty Period The standard warranty period is one year from the date of purchase or one year from delivery to the designated End User (not to exceed

Chapter 4: System Setup and Wiring Page 4-12 4.7.1 Explanation of CONTROLLER Unit I/O INPUT SIGNALS Pin # SIGNAL NAME DESCRIPTION A1 RE

FEC FUSION Operations Manual Chapter 4: System Setup and Wiring (Rev. 2.1) Page 4-13 OUTPUT SI

Chapter 4: System Setup and Wiring Page 4-14 4.7.3 Bank Select Table Bank Select inputs are used to “multiplex” the output signals allowing up

FEC FUSION Operations Manual Chapter 4: System Setup and Wiring (Rev. 2.1) Page 4-15 BANK SEL.

Chapter 4: System Setup and Wiring Page 4-16 4.7.4 Bank Output Servo Error Table The Bank Servo Error Table defines the type of servo error (f

FEC FUSION Operations Manual Chapter 4: System Setup and Wiring (Rev. 2.1) Page 4-17 4.7.5 PL

Chapter 4: System Setup and Wiring 4.8 RS-232 Data communication ports.The FUSION system programming and Industrial based system. Communication

FEC FUSION Operations Manual 4.8.2 Rear Panel DB9 Connector: DB-9P (Male)Mating Connector: DB PIN 1 2 3 4 5 6 7 8

Chapter 4: System Setup and Wiring Page 4-20 4.8.3 Rear Panel RS232 Standard Communication Protocol Communication protocol from the rear panel

FEC FUSION Operations Manual Chapter 4: System Setup and Wiring (Rev. 2.1) Page 4-21 Byte

Read all instructions before operating the correctly. Prior to use, read this instructionments functions, safety precautions and marked with two symbo

Chapter 4: System Setup and Wiring Page 4-22 Rear Panel RS232 Standard Communication Protocol (Continued) 1Judgment Flag The Judgment Flag us

FEC FUSION Operations Manual Chapter 4: System Setup and Wiring (Rev. 2.1) Page 4-23 Rear Pan

Chapter 4: System Setup and Wiring Page 4-24 4.8.4 Rear Panel RS232 Abbreviated Communication Protocol The RS232C output format can be switched

FEC FUSION Operations Manual Chapter 4: System Setup and Wiring (Rev. 2.1) Page 4-25 4.8.5 Re

Chapter 4: System Setup and Wiring Page 4-26 4.9 T/A MON. DB9 Connector - External Torque/Angle/Current/Speed Output This auxiliary connector is

FEC FUSION Operations Manual 4.10 Controller Unit DIP Switch In a multiple controller uzational purposes. The numbe

Chapter 4: System Setup and Wiring 4.10.2 Controller Unit DIP Switch positions 4 ~ 8 DIP switch positions 4 ~ 8 are used for setting the descr

FEC FUSION Operations Manual 4.11 Tool Cable Connection• Tools are connected to the ducer preamp, motor andficatio

Chapter 4: System Setup and Wiring Page 4-30 4.11.1 Cable Installation Guidelines Improper installation of cables can reduce cable life expect

FEC FUSION Operations Manual Chapter 4: System Setup and Wiring (Rev. 2.1) Page 4-31 4.11.2 C

Do not remove the motorThe tool output spindle may rotate and cause injury.Do not repair, disassemble, or modify the equipmentFailure to observe Neve

Chapter 4: System Setup and Wiring Page 4-32 4.11.5 Tool Cable - Preamplifier Pins. The preamplifier connection links the controller to the tool

FEC FUSION Operations Manual Chapter 4: System Setup and Wiring (Rev. 2.1) Page 4-33 4.12 Firm

Chapter 4: System Setup and Wiring Page 4-34 4.13 SYNC Connector The Sync connector is provided for a means to synchronize more than one spind

FEC FUSION Operations Manual Chapter 4: System Setup and Wiring (Rev. 2.1) Page 4-35 4.14 Opt

Chapter 4: System Setup and Wiring Page 4-36 4.14.1 Ethernet Set-up of PC to Communicate to Ethernet Module The PC used to configure the Eth

FEC FUSION Operations Manual Chapter 4: System Setup and Wiring (Rev. 2.1) Page 4-37 4.14.2

Chapter 4: System Setup and Wiring Page 4-38 4.15 Options – Fieldbus Interfaces The Fusion controller is able to operate under different Input/

FEC FUSION Operations Manual Chapter 4: System Setup and Wiring (Rev. 2.1) Page 4-39 PROFIBUSC

Chapter 4: System Setup and Wiring Page 4-40 Termination Termination of the fieldbus requires a terminating resistor at each end of the fieldb

FEC FUSION Operations Manual Chapter 4: System Setup and Wiring (Rev. 2.1) Page 4-41 Profi

Transport the equipment properly according to its weight. Failure to observe this instruction may causeThe conditions when transporting the equipment

Chapter 4: System Setup and Wiring Page 4-42 Profibus Signal I/O Map From Fusion to PLC : 8 Words (16 Bytes – 128 Bits) Word Byte Bit No. Signal

FEC FUSION Operations Manual Chapter 4: System Setup and Wiring (Rev. 2.1) Page 4-43 Profibus

Chapter 4: System Setup and Wiring Page 4-44 BAUD/ADDRESSSETTINGLEDINDICATIONTERMINATIONSWITCHREMOTE I/OCONNECTOR4.15.2 Fieldbus Interfaces –

FEC FUSION Operations Manual Chapter 4: System Setup and Wiring (Rev. 2.1) Page 4-45 Termina

Chapter 4: System Setup and Wiring Page 4-46 Dip Switch Setting Address setting (DIP switch) SW-3 (LSB) SW-4 SW-5 SW-6 SW-

FEC FUSION Operations Manual Chapter 4: System Setup and Wiring (Rev. 2.1) Page 4-47 I/O Signa

Chapter 4: System Setup and Wiring Page 4-48 4.15.3 Fieldbus Interfaces – DeviceNet® DeviceNet® Interface The DeviceNet communication interfac

FEC FUSION Operations Manual Chapter 4: System Setup and Wiring (Rev. 2.1) Page 4-49 DeviceNe

Chapter 4: System Setup and Wiring Page 4-50 Configuration FEC DeviceNet I/O is pre-configured according to the I/O Signal Map (See below). Con

FEC FUSION Operations Manual Chapter 4: System Setup and Wiring (Rev. 2.1) Page 4-51 Configur

Install or provide torque reaction for operation. Failure to observeMake sure controller is firmly mounted and will not come lose or fall during oper

Chapter 4: System Setup and Wiring Page 4-52 DeviceNet Signal I/O Map From Fusion to PLC : 8 Words (16 Bytes – 128 Bits) Data Bit No. Signal Des

FEC FUSION Operations Manual Chapter 4: System Setup and Wiring (Rev. 2.1) Page 4-53 DeviceNet

Chapter 4: System Setup and Wiring Page 4-54 (Blank Page)

FEC FUSION Operations Manual Chapter 5: Power Up and Initial Checks (Rev. 2)

Chapter 5: Power Up and Initial Checks 5.1 Before Powering On WARNING:Follow Lockout / disconnecting cabling, wiring, and equipment. Each item belo

FEC FUSION Operations Manual Chapter 5: Power Up and Initial Checks (Rev. 2)

Chapter 5: Power Up and Initial Checks Page 5-4 (Blank Page)

FEC Fusion Operations Manual Chapter 6: Fastening Instructions (

Chapter 6: Fastening Instructions 6.1 Fastening Control. The Fusion system is user programmable to select from two different fastening methods, rfer

FEC Fusion Operations Manual Chapter 6: Fastening Instructions (