user manual single-channel control smx10 · contact form ... bgv berufsgenossenschaftliche...

Alfing Montagetechnik GmbH

Nutrunning Technology

Assembly Machines

Automation

User Manual

Single-Channel Control SMX10 Order No. = 700 6553 (German) Order No. = 700 6554 (English) Rev_14022011_EN Issue | 14.02.2011 ATTENTION! Please read this manual before first operation and keep it for future reference!

2 User Manual Single-Channel Control SMX10 / Rev_14022011_EN

Table of Contents

1 Preface / Important Notes 7 1.1 General Information .................................................................................. 7 1.2 Operating Site ........................................................................................... 7 1.3 Set-Up ....................................................................................................... 7 1.4 Protection of Personnel............................................................................. 8 1.5 Operation .................................................................................................. 8 1.6 Maintenance / Repair ................................................................................ 8 1.7 Transport and Storage .............................................................................. 8 1.8 Disposal .................................................................................................... 9 1.9 Copyright................................................................................................... 9 1.10 Trademarks............................................................................................... 9

2 Safety 13 2.1 Notes and Symbols................................................................................. 13 2.2 Electrical Safety ...................................................................................... 14 2.3 Abbreviations Used................................................................................. 15 2.4 Physical Connections.............................................................................. 15 2.5 Safety and Application Notes.................................................................. 16 2.6 Product Monitoring.................................................................................. 17 2.7 EMC-Conforming Unit Design................................................................. 17

3 Overview 21 3.1 General Information ................................................................................ 21 3.2 Performance Features SMX10 ............................................................... 22 3.3 Parameterisation Software AMT PARA MX............................................ 24

4 Views and Interfaces 27 4.1 Front View............................................................................................... 27 4.2 Top View ................................................................................................. 28 4.3 Bottom View............................................................................................ 30 4.4 Back View – Wall Console ...................................................................... 31 4.5 Back View – Flap Housing ...................................................................... 32

4.5.1 FI................................................................................................. 33 4.5.2 Power X11 (Powercombicon 6pol. 7,62) .................................. 33 4.5.3 LED-Status indication ................................................................. 34 4.5.4 Reset .......................................................................................... 34 4.5.5 ID-Coding Selector (Modul Address).......................................... 35 4.5.6 COM3 X3 (D-Sub09 connector) ................................................ 36 4.5.7 COM1 X1 (D-Sub09 connector); COM2 X2 (D-Sub09 connector); .............................................................................................. 37 4.5.8 ARC IN X14 (RJ45) .................................................................... 38 4.5.9 ARC OUT X15 (RJ45) ............................................................... 39 4.5.10 NET X16 (RJ45) ....................................................................... 39 4.5.11 MC-I/O X17 (8pol. MiniCombiCon 3,81)................................... 40 4.5.12 I²C X18 (4pol. MiniCombicon 3,81) ......................................... 41 4.5.13 CAN IN X12 (RJ45) ................................................................. 41

Table of Contents

Rev_14022011_EN / User Manual Single-Channel Co ntrol SMX10 3

4.5.14 CAN OUT X13 (RJ45) ............................................................. 42 4.5.15 X5 (Handheld nutrunner I/O interface) ................................... 43 4.5.16 X6 (Static program selection PG1)......................................... 43 4.5.17 X7 (WBT interface) ................................................................. 43 4.5.18 X8 Supply ............................................................................... 44 4.5.19 X9 Inputs (10-pole Mini CombiCon 3,81) .............................. 44 4.5.20 X10 Outputs (12pole Mini combiCon 3,81) ........................... 45 4.5.21 TRANSDUCER DIGITAL X19 (D-Sub15HD connector) .......... 46 4.5.22 TRANSDUCER DIGITAL X19.1 (D-Sub09 connector) .......... 47 4.5.23 TRANSDUCER ANALOG X20 (D-Sub09 connector) ............ 48 4.5.24 Hall transducer X21 (D-Sub 15 connector) ........................... 49 4.5.25 Resolver interface X22 (D-Sub15 pin)................................... 50 4.5.26 Motor......................................................................................... 51

4.6 Technical Data ........................................................................................ 52

5 Error Diagnosis 55 5.1 System Errors Displayed by the 7-Segment Display.............................. 55

6 Annex 61 EC Declaration of Conformity............................................................................. 61 Contact Form...................................................................................................... 63


Notes:

Notes

Note Notes

Notizen Anotaciones

Notizen Notes Note


Chapter

1

Preface / Notes

This chapter contains important notes concerning this manual. This chapter contains:

1 Preface / Notes .........7 1.1 General Information .........7

1.2 Operating Site .........7

1.3 Set-Up .........7

1.4 Protection of Personnel .........8

1.5 Operation .........8

1.6 Maintenance / Repair .........8

1.7 Transport and Storage .........8

1.8 Disposal .........9

1.9 Copyright .........9

1.10 Trademarks .........9


1 Preface / Important Notes

1.1 General Information

This manual describes the nutrunner control SMX10. This manual will help you to use the nutrunner control SMX10 safely and properly. Carefully read all instructions. Adherence to safety notes is the precondition for trouble-free operation and possible filing of warranty claims. Therefore, first read the manual before attempting to operate the unit. This manual contains important notes; be sure to keep it on hand at the unit. All locally applicable legal safety requirements concerning installation, operation and maintenance must be observed at all times. Installation and maintenance work may only be performed by trained specialists. 1.2 Operating Site

If the unit is not specifically designed for it, the following applications are forbidden: • Use in areas with potentially explosive atmosphere • Use in environments with damaging/hazardous oils, acids, gases, steams, dusts,

radiation etc. Keep unauthorised persons (visitors, children etc.) out of the operating site. Observe all local rules for safety and accident prevention. 1.3 Set-Up

• The maximum admissible ambient temperature for operation of the nutsetter controller is +40 °C.

• The controller should be set up so that ambient air can freely circulate around its housing. All connections should be readily accessible.

• Connected peripheral devices should be taken into consideration when determining the space required for installation.

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EN

Preface / Important Notes


1.4 Protection of Personnel

Be sure the components are never exposed to water or humidity. Never misuse the nutrunner control or its components. Keep heat, oil, sharp edged objects etc. away from it. Immediately replace defective components by original spares. Never work when influenced by medication, alcohol or other mind altering substances. Always wear suitable work clothes (e. g. hair net). Before switching the controller on, be sure the tightening tool is switched off. At your workplace be sure to stand safely. Do not use force when using the equipment. Check the components for damage, false adjustment and other errors. Have components serviced or repaired in time. 1.5 Operation

During operation, keep all doors and covers closed. Be sure the main switch is in position “OFF” before connecting the main supply line. 1.6 Maintenance / Repair

Maintenance / repair of the system components may only be performed by qualified technicians. For maintenance / repair exclusively use original spares. 1.7 Transport and Storage

Be sure the system is not subjected to excessive strain. Especially observe the following: • Protection from mechanical damage (transport, handling, etc.)! • Protection from contamination and moisture! • The storage location must be dry and well ventilated! • Outdoor storage is not admissible! • The storage temperature must range between -10 °C a nd +50 °C.


1


1.8 Disposal

Please observe currently applicable regulations. Dispose of materials in accord with their make-up and existing regulations, such as: • Electronic scrap • Plastics • Metals • Copper 1.9 Copyright

Alfing Montagetechnik GmbH. All rights reserved. Printed in Germany. The information contained in this manual is the intellectual property of Alfing Montagetechnik GmbH. Without the prior written consent by Alfing Montagetechnik GmbH neither receipt nor possession of this document entitle the owner to the right of reproduction or publication of the entire document or parts thereof. 1.10 Trademarks

All product names and logos are trademarks or registered trademarks of the respective owners.

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Notes:


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Notizen Anotaciones

Notizen Notes Note

1


Notes:

1

EN


Note Notes

Notizen Anotaciones

Notizen Notes Note


Chapter

2

Safety

This chapter contains the safety notes for installation and use of the nutsetter controller SMX10. This chapter contains:

2 Safety .......13 2.1 Notes and Symbols .......13

2.2 Electrical Safety .......14

2.3 Abbreviations Used .......15

2.4 Physical Connections .......15

2.5 Safety and Application Notes .......16

2.6 Product Monitoring .......17

2.7 EMC-Conforming Unit Design .......17


2 Safety

2.1 Notes and Symbols

The following is a description of the symbols used in this document to highlight information. Technical symbols and characters are deemed familiar.

Signal Word Meaning Consequences Symbol

Warning!

Possibly hazardous situation

Possibly minor or moderate injury

Note! Information!

Application hints and other useful information

Efficient application

Attention! Special information concerning proper performance of operation, maintenance and repair procedures

Possibly damage to the product

Note

This symbol calls attention to currents and voltages

Shield connection in connector

Ground connection

PE connection (protective earthing conductor)

GND / 0 V

2

EN

Safety

1 L S W2 N B L3 P E G N / G E

X 0 1S u p p ly


2.2 Electrical Safety

Do not switch the electric power supply of the controller on unless all connections have been properly made. During installation all national, governmental and local safety and wiring standards must be observed. These standards shall be considered superior to this manual. The controller must be earthed in accordance with the regulations. Exclusively connect the controller to an earthed power socket. Never remove the earthing pin. Do not use adapter plugs, cable drums, multiple power socket rails. If there is reason to doubt that the power socket is earthed properly, immediately contact a qualified electrician. Tightening systems supplied by Alfing Montagetechnik GmbH must not be supplied with galvanically isolated voltages, since this would impair the function of the fault current circuit-breaker. Monthly test the function of the fault current circuit-breaker by pressing the “Test ” button at the fault current circuit-breaker. For details see chapter Back View – Flap Housing page 32. If the system is separated from the power supply due to the test, the cause must be determined before the operation of the unit is resumed. Upon switch-off of the unit, hazardous voltages may still be present in the capacitors of the power section for up to 3 minutes .

Safety

2


2.3 Abbreviations Used

General abbreviations

BGV Berufsgenossenschaftliche Verordnung - German regulation for accident prevention

mark (Communauté Européenne = European Community); confirms conformity of

the products with the relevant EU standards and directives

DIN Deutsches Institut für Normung - German standards institute

EC European Community

EMC Electromagnetic Compatibility

EN European Norm - Standard

EnDat Encoder Data

EEC European Economic Community

IEC International Electrotechnical Commission

MB Megabytes

n.c. not connected

VDE Verband Deutscher Elektrotechniker - German

association of electrical engineers

LED light emitting diode

NTC NTC resistor, negative temperature coefficient

PDS Power Drive Systems (product standard EN 61800-3)

PTC PTC resistor, positive temperature coefficient

VAC alternating current voltage

VDC direct current voltage

2.4 Physical Connections

Physical connections are identified as follows according to their functions:

E Input

A Output

n.c. Vacant input/output (engl. not connected)

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EN

Safety


2.5 Safety and Application Notes

according to: Low Voltage Directive 73/23/EEC Machinery Directive 98/37/EC Electromagnetic Compatibility 89/336/EEC Intended use Since the nutsetter controller is an electric appliance driving tightening tools, the safety requirements set forth in the Machinery Directive (98/37/EC) must be observed. Prior to taking into service it must be ensured that the machine does not present a hazard (e. g. from uncontrolled movements). Conformity with the standard EN 60204-1 / IEC 204-1 must be ensured. Adherence to the limit values for electromagnetic compatibility (EMC) required by law is the responsibility of the manufacturer of the plant equipment or machinery. AMT products are designed to ensure that operation in industrial environments is possible provided the EMC information supplied to machine manufacturers is adhered to. AMT tests all its products in an EMC lab and thereby guarantees that the products conform to the required standards provided they are installed properly. Changes in unit design means that the manufacturer of the plant system or machinery needs to have new tests performed to ensure the requirements of law are satisfied.

Safety

2


2.6 Product Monitoring

We are obligated by law to monitor our products even after they have been delivered. Please let us know any details that may be of interest to us. For instance: • Changed operating data • Experiences made with the system • Recurring errors • Difficulties with this manual 2.7 EMC-Conforming Unit Design

Concerning installation and first operation of all of AMT's units, the EU directives for electromagnetic compatibility (EMC) must be adhered to!

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EN

Safety


Notes:

Safety

Note Notes

Notizen Anotaciones

Notizen Notes Note

2


Notizen:

2

EN

Notizen

Note Notes

Notizen Anotaciones

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Chapter

3

Overview

This chapter informs you about the nutrunner control SMX10. This chapter contains:

3 Overview .......21 3.1 General Information .......21

3.2 Performance Features SMX10 .......22

3.3 Parameterisation Software AMT PARA MX .......24


3 Overview

3.1 General Information

The SMX10 offers the same nutrunning features as the master nutrunner control, without an integrated PC. It was developed especially for use in networks and is generally driven as a “slave” component. An Ethernet interface provides communication capabilities with a plant’s master control (e.g., PC) or an AMT master nutrunner control. In slave mode, the SMX10 receives program requirements from a master, based on target data that is either stored locally or downloaded from a host computer. These are then processed by the SMX10 in a self-sufficient manner. After each fastening operation, rundown results and graphs are reported back to the master. Manual operation Manual operation mode is available with the SMX10 nutrunner control for operation without a master. The control functions in this mode without communication to a master control. This means that it is not possible to form overall part-based quality assessments. Programs are determined by a program selector switch on the operator panel or by a socket tray. If only one program is required, then this can also be permanently set. Enhanced nutrunning and monitoring processes The SMX10 offers programming capabilities for complex nutrunning processes. All torqueand angle-based algorithms are available as base modules. These modules, along with additional commands for process control, can be linked to create complex nutrunning processes. Conditional program statements can be based on rundown results, which enable, for example, loosening operations with or without repeated nutrunning. In addition, the control offers advanced nutrunning and monitoring processes, such as yield control, retrospective nutrunning monitor, and friction measurement. The SMX10 can be programmed with a userfriendly interface that resides on a laptop or master-PC. The modular design of the high power tightening tools allows to connect any hand tool with a reaction torque transducer to the SMX10 nutrunner control.

Overview

3

EN


3.2 Performance Features SMX10

Technische Daten General • Firmware, parameters, and data on removable CompactFlash card Assembly/Dimensions • Four assembly mounting holes in wall console • IP54 protection • Control dimensions: 330x180x316 (HxWxD in mm) • Wall console dimensions: 330x180x63 (HxWxD in mm) • Total dimensions: 330x180x379 (HxWxD in mm) • Weight of control: approx. 9 kg • Weight of wall console: approx. 2 kg Display and Operator Controls • 7-digit display for status and error messages • 4 LEDs to display individual nutrunning and operational status Programming and Parameterization • User-friendly programming software via network • Nutrunning Processes -Torque-controlled tightening -Torque-controlled with angle monitor -Angle-controlled with torque monitor -Yield-controlled tightening -Angle-controlled and torque-controlled loosening -Shutdown based on digital signal with torque and angle monitor -Friction measurement -Retrospective nutrunning monitor -Redundant motor current control -Nutrunning time monito Interfaces • Serial interface for barcode reader • Parallel I/O • Ethernet

3

Overview


Peripheral Equipment • Operator console • Socket tray • Barcode reader Number of Programs • Slave mode -max. 31 tightening programs and 1 loosening program • Manual operation -1 program without operator console or socket tray -max. 8 tightening programs with socket tray -max. 15 tightening programs with operator console and program selection switch -1 loosening program Power Supply • 230 V / 50 Hz

Overview

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EN


3.3 Parameterisation Software AMT PARA MX

The parameterisation software AMT PARA MX is meant for simple configuration, programming and visualisation of the SMX10 nutrunner control on a laptop computer or a central PC. Parameterisation works solely in conjunction with the software AMT Ablauf (sequence). System requirements: Processor: min. Pentium2 or compatible Operating system: Windows 95 V3 or higher, Windows NT, Windows 2000,

Windows XP, Windows XP Service Pack 2 Graphics adapter: Windows compatible, SVGA resolution (800 x 600), Harddisk drive: free harddisk capacity approx. 20 MB Operating memory: min. 128 MB Interfaces: One free serial interface (COM1, COM2, COM3, or COM4)

that is not used by another software (driver) during operation.

User rights: For operating systems based on Windows NT (Windows NT, 2000, XP) administrator rights are required for installation. During operation the user needs minimum rights as a main user.

More information you will find in the software description AMT Para MX.

Overview

3


Notes:

3

EN

Notes

Note Notes

Notizen Anotaciones

Notizen Notes Note


Chapter

4

Views and Interfaces

This chapter presents diverse views and interfaces of the SMX10 nutrunner control. This chapter contains:

4 Views and Interfaces .....27 4.1 Front View .....27

4.2 Top View .....28

4.3 Bottom View .....30

4.4 Back View – Wall Console .....31

4.5 Back View – Flap Housing .....32

4.6 Technical Data .....52


4 Views and Interfaces

4.1 Front View

4

EN


A 7-segment display is located at the front as well 4 LEDs. The mains switch is located in the lower area. Mains on/off

Nok = NOK- fastening Ok = OK- fastening Rdy = Ready Pwr = Power ON 7 segment display = please refer to chapter 5.


4.2 Top View

Nutrunner cable connection top

Compact-Flash-Card

Interlock

Cable feed opening

4



Pin-out of the nutrunner cable connector

XC Connection

Tightening tool

GH Housing (shield) XC 1 TQ +/-5V WH XC 2 CAL GY XC 14 +12V supply RD XC 4 TQ 0V BN XC 5 Data Enable GN XC 7 -12V supply YE XC 13 GND BU GH Housing (shield) XC 11 S1 (Sine) BK XC 10 S4 (Cosine) WH/YE XC 9 R3 (Rotor) WH/GN XC 17 S3 (Sine) VT XC 16 S2 (Cosine) YE/BN XC 18 R1 (Rotor) BN/GN XC 8 PTC_IN RD/BU n.c. PTC_GND GY/PK XC 6 Ready for operation GN XC 3 OK YE XC 15 NOK GY XC A Start WH XC B Backoff BN GH Housing (shield) XC W W 3 XC V V 2 XC U U 1 XC PE PE GN/YE


4

EN


4.3 Bottom View

External USB-Interface

4



4.4 Back View – Wall Console

4

EN

209,0

40,0



4.5 Back View – Flap Housing

4



4.5.1 FI

External residual-current-operated protective device Cable and line protection against overload and short circuit Type: BDI-SF 16 Testen Sie monatlich die Funktion des FI Schutzschalters durch Drücken der Taste “Test “ am FI Schutzschalter. 4.5.2 Power X11 (Powercombicon 6pol. 7,62)

Network supply: Logic: 1*230VAC/50Hz Power: 1*230VAC/50Hz at 40A-nit

3*230VAC/50Hz at 80A-unit 6 L Logic supply 5 N Logic supply 4 PE Ground 3 L3 Power supply 2 L2 Power supply 1 L1 Power supply


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4.5.3 LED-Status indication

LED is off

LED is flashing

LED lis on

LED RUN is off (Measuring card) LED RUN is flashing (Measuring card) LED RUN is on (Measuring card)

LED DATA is on (Measuring card) LED DATA is flashing (Measuring card)

4.5.4 Reset

The LED lights up when the measuring card is ready for operation.

The measuring card is communicating with an action torque sensor.

By pressing the reset button, a reset will be activated on the measuring card.

The LED flashes at a system error of the measuring card.

The LED does not light up when the measuring card is disconnected from the mains.

The measuring card is searching for an action torque sensor or is communicating with a reaction torque sensor.

4



4.5.5 ID-Coding Selector (Modul Address)

If several tightening modules are activated via a RS485 bus system, a different address must be assigned to every tightening module via the ID-coding selector (00 to 99). Each address must only be assigned once. If a new coding has been assigned, the respective device must be turned on and off so that the address is taken over.

Adjust module address Standard = Tightening modul address 00

Example: e.g. module address 8

S1 = 1 er (units digit)

S2 = 10 er (tens digit)

8

0

Example: e.g. module address 24

4

2


4

EN


4.5.6 COM3 X3 (D-Sub09 connector)

Serial interface RS232/RS485

ATTENTION! Pins 1, 4, 6 and 9 not compatible with standard configuration RS232.

Pin Allocation I/O Comment

1 D- E/A RS485 Interface D-

2 RxD E RS232 Interface receive Data

3 TxD A RS232 Interface transmit Data

4 +5V A +5V supply terminal

5 GND A GND signal

6 GND A GND supply terminal

7 RTS A Control line ready to send

8 CTS E Control line clear to send

9 D+ E/A RS485 Interface D+

4



4.5.7 COM1 X1 (D-Sub09 connector); COM2 X2 (D-S ub09 connector);

The two serial interfaces COM1 and COM2 are available as RS232 and RS485. ATTENTION! COM2 (X2) will be used in variante SMX... of measurement card PME60.

The cable shield is connected to the connector shell. WARNING! Consider the position of the ID coding selectors (modul address) of the tightening module if tightening modules are activated via one serial interface.

Pin Bezeichnung E/A Funktion

1 E/A D- RS485-

2 E Rx Daten empfangen (RS232)

3 A Tx Daten senden (RS232)

4 VCC Betriebsspannung +5V

5 GND Masse

6 frei

7 A RTS Sendeteil ein (RS232)

8 E CTS Sendebereitschaft (RS232)

9 E/A D+ RS485+


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4.5.8 ARC IN X14 (RJ45)

Comment: PIN and PIN 2: Standard communication bus ARCNET RS485 between Master-PC and measuring card(s) PME60. PIN 3 and PIN 4: Are connected through from connector X13 to X17, however disconnected from the internal supply of the Arcnet module ArcVcc and GND (ArcVcc) via jumpers. As a standard the jumpers are open. ArcVcc and GND (ArcVcc) are required at the last module for the moving load (resistance network). PIN 7 and PIN 8: Alternative bus interface RS485.


1 D+ E/A Standard communication bus (ARCNET)

2 D - E/A Standard communication bus (RS485 ARCNET)

3 Vcc - Optional useable (only with consultation AMT)

4 GND - Optional useable (only with consultation AMT)

5 - - n.c.

6 - - n.c.

7 D+ E/A Optional: RS485 (only with consultation AMT)

8 D - E/A Optional: RS485 (only with consultation AMT)

4



4.5.9 ARC OUT X15 (RJ45)

Identical ARC IN (X14), view 4.5.9 4.5.10 NET X16 (RJ45)

(Optional measuring card PME60 with ethernet)

ATTENTION! Only to be used if the ARCNET communication bus standard is not required. PIN 4, 5, 7,8 Pin assignment per standard Ethernet 10Base


1 TX+ A Transmit data +

2 TX - A Transmit data -

3 RX+ E Receive data +

4 - - n.c.

5 - - n.c.

6 RX- E Receive data -

7 - - n.c.

8 - - n.c.


4

EN


4.5.11 MC-I/O X17 (8pol. MiniCombiCon 3,81)

Parallel I/O interface

ATTENTION! Threshold signal decoupled. External and internal voltage must be supplied to PIN1. IN1 and IN2 decoupled. Internal +12V or +24V or external voltage can be used. When using an external voltage, PIN6 and PIN7 must be bridged.


1 MST+ I External power supply for

MS-Trigger-Signal (5 to 30V)

2 MST - O Opto decoupled MS-Trigger-Signal output (OUT1)

3 IN1 I Opto decoupled input (+12V)

depth1

4 IN2 I Opto decoupled input (+12V)

torsion bar/ depth 2

5 +12V O Internal +12V supply

6 GND O Internal GND

7 EXTGND I External GND

8 +24V O Internal +24V supply

4



4.5.12 I²C X18 (4pol. MiniCombicon 3,81)

I2C bus interface can be used to expand PME60 board, e.g. for additional I/O's. 4.5.13 CAN IN X12 (RJ45)

The cable shield is connected to the connector shell.


1 Data I/O Data line

2 Clock O Tact line

3 +5V O Internal +5V (supply external components)

4 GND O Ground

Pin Designation Additional function

1 CAN_H

2 CAN_L

3 CAN_GND

4 D- RS485- COM1

5 D+ RS485+ COM1

6 CAN_GND

7 CAN_GND

8 CAN_VCC


4

EN


4.5.14 CAN OUT X13 (RJ45)

The cable shield is connected to the connector shell. X4 (Start lock-out) Enables external interruption of start signal. This feature can be prevented by putting a jumper between Pin1 and Pin2.

Pin Designation Additional function

1 CAN_H

2 CAN_L

3 CAN_GND

4 D- RS485- COM1

5 D+ RS485+ COM1

6 CAN_GND

7 CAN_GND

8 CAN_VCC

Pin Allocation

1 Start lock-out

2 Start lock-out

4



4.5.15 X5 (Handheld nutrunner I/O interface)

(Signals handheld tools)

4.5.16 X6 (Static program selection PG1)

(Connection for a fixed selection of program 1)

4.5.17 X7 (WBT interface)


1 Start E Start signal

2 CCW E Anti-clockwise rotation

(direction of rotation)

3 Ready A Ready

4 OK A Tightening OK

5 NOK A Tightening NOK

6 VCC A Supply voltage


1 VCC E Supply voltage

2 PG1 E Program 1


1 Ready A Ready

2 OK A Tightening OK

3 NOK A Tightening NOK

4 Total- OK A Groups IO

5 GND Ground


4

EN


4.5.18 X8 Supply

4.5.19 X9 Inputs (10-pole Mini CombiCon 3,81)

All inputs are operated with a voltage of +10V to +30V




3 GND Ground

4 GND Ground

Pin E/A Comment 6 PG Comment 15 PG

1 E Digital-In 0 Start Start

2 E Digital-In 1 PG 1 Bit 0

3 E Digital-In 2 PG2 Bit 1



6 E Digital-In 5 PG5 Ext. Stop

7 E Digital-In 6 PG6 * Reset counter

8 E Digital-In 7 Loosening Loosening

9 A VCC VCC VCC

10 - 0V / GND Ground Gro


4


4.5.20 X10 Outputs (12pole Mini combiCon 3,81)

1 protected internally with 0.5A self-resetting fuse

The function of the digital outputs OUT1-4 and OUT7 can be specified in the tightening software. The total load for all outputs on the OUT plug is max. 200mA, if there is no external 24V feed. If there is an external 24V feed, then the total load can be increased to max. 500mA.

Tightening Module

Pin I/O Allocation Comment

1 A Digital-Out 0 Ready

2 A Digital-Out 1 Bit 0




6 A Digital-Out 5 Tightening OK

7 A Digital-Out 6 Tightening NOK

8 A Digital-Out 7 Total OK

9 A VCC1

10 - 0V / GND

11 E VCC extern

12 E GND-extern


4

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4.5.21 TRANSDUCER DIGITAL X19 (D-Sub15HD connector)

ATTENTION! The signals on PIN1 up to PIN10 are available only in connection with the extension module for analogue measuring transducers. Only PIN11 up to PIN15 are configured as standard. The analogue measuring transducer is connected to the servo interface of the measuring transducer.


1 +5V dig. A Angle encoder supply +5V (digital) option ZKDW

2 0V dig. A GND angle encoder supply (digital) option ZKDW

3 Angle V E Angle A-Impuls TTL-Signal option MEDW / ZKDW

4 Angle N E Angle B-Impuls TTL-Signal option MEDW / ZKDW

5 KAL A Calibration signal TTL-Signal option MEDW / ZKDW

6 -12V A Supply MD-Geber analog option MEDW / 5 / -3

7 +/-5V MD E Torque signal option MEDW-5, HCA etc.

8 M+ E Torque signal M+ option MEDW-1 and ZKDW

9 M - E Torque signal M - option MEDW-1 and ZKDW

10 4-20mA MD E Torque signal 4-20mA (2-18mA) optional MEDW-3

11 +12V A Supply measuring transducer / spindle

12 0V A GND supply MD-Geber

13 D+ E/A RS485-interface, D+, digital measurement transducer

14 D - E/A RS485- interface, D -, digital measurement transducer

15 DIR A Control line measuring transducer

D

I

G

I

T

A

L

4



4.5.22 TRANSDUCER DIGITAL X19.1 (D-Sub09 connecto r)


1 D+ RS485 D+

2 n.c.

3 + 12V A Supply measurement transducer

4 n.c.

5 n.c.

6 D- RS485 D-

7 DIR A Direction

8 n.c.

9 GND A Ground


4

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4.5.23 TRANSDUCER ANALOG X20 (D-Sub09 connector)

The cable shield is connected to the connector shell.

Transducer Tightening Module

Pin E/A Bezeichnung Funktion

1 E MD+ Measuring signal

2 A KAL Calibration signal 5 V active high

3 A VCC+ Supply +12V

4 n.c. n.c.

5 A 5V Supply +5V

6 E MD- 0V torque signal

7 A DE Data-Enable 5V active high

8 A VCC- Supply -12V

9 GND GND


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4.5.24 Hall transducer X21 (D-Sub 15 connector)

The shield must be connected to the metal shell of the 15-pole submin D connector.

Resolver Pin

Designation Function

1 n.c.

2 n.c.

3 SIN+ Sinus+

4 n.c.

5 COS+ Cosinus+

6 n.c.

7 KTY Temperature sensor

8 24V VCC

9 n.c.

10 HALL Aktive tu Pin 8 bridged

11 n.c.

12 SIN- Sinus-

13 n.c.

14 COS- Cosinus-

15 n.c.


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4.5.25 Resolver interface X22 (D-Sub15 pin)

The shield must be connected to the metal shell of the submin D connector

Resolver Pin

Designation Function

1 n.c.

2 n.c.

3 S1 Sinus

4 n.c.

5 S4 Cosinus

6 R3 Rotor

7 PTC Temperature sensor

8 n.c.

9 n.c.

10 n.c.

11 n.c.

12 S3 Sinus

13 R1 Rotor

14 S2 Cosinus

15 n.c.


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4.5.26 Motor

4-pole Power CombiCon Informationen about the shield and ground connectio n Always use shielded motor cables! With respect to the ground connection, one of the following actions must be done: • connect the motor housing to the ground of the machine or • connect the ground terminal of the motor connector to the central ground point

of the machine.

The cable shield must be connected to the connector shell at the motor and to the shield bar at the servo amplifier.

Connector Designation

Shield bar

at the

tightening module Shield

W

Motor phase W

V

Motor phase V

U

Motor phase U

PE

Protective

conductor

Ground the motor housing in the machine


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4.6 Technical Data

Weight: approx. 11 kg Lackierung: Wall console RAL 7016 (coal gray)

Housing RAL 9006 (white aluminium) Front RAL 7016 (coal gray) Enclosure type: IP54 Supply power connection: line voltage

230 Volt (200-240) Total dimensions: (H x B x T) in mm 330 x 180 x 379


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Chapter

5

Error Diagnosis

This chapter describes error diagnosis in the SMX10 nutrunner control. This chapter contains:

5 Error Diagnosis .......55 5.1 System Errors Displayed by the 7-Segment Display .......55


5 Error Diagnosis

5.1 System Errors Displayed by the 7-Segment Displa y

Error messages are indicated by the 7-segment display. The messages are displayed in sequences of four steps. The interval between the sequences is 0.5 s. The first sequence generally is 8 (7-segment display OFF), in the last (fourth) sequence the decimal point is displayed additionally. The last two sequences indicate the actual code. If the sequence is 8Exx. the error has occurred during operation of the nutrunner control. The error will be reset by the next start signal, provided the cause of the error has been resolved. If the sequence is 88xx. the error has occurred in the idling condition. A reset is not required. The display will be reset as soon as the cause of the error has been resolved. An error code is assigned to each error message, allowing evaluation and display of the error with the highest error code.

7-Segment display

Error Diagnosis

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Designation Cause Reaction (in tight. operation)

Nutsetter is ready Output section is off.

Nutsetter is ready.

Output section is on.

Tightening operation.

Power supply

No power supply or voltage too low (intermediate circuit voltage too low).

The tightening module brakes with the parameter emergency ramp, then the output section is shut-off.

Motor temperature (NTC / PTC)

The motor temperature is too high (thermal contact NTC or PTC tripped).

The tightening module brakes for 100ms, then the output section is shut-off.

Heat sink temperature

The heat sink temperature of the output section of the tightening module is too high.


Bus system

Communication error in bus system (CAN-Bus etc.).

The tightening module brakes with the parameter emergency ramp, then the output section is shut-off.

I²t monitoring

The I²t monitoring of the output section or the nutsetter has tripped. Thermal overload of output section or nutsetter.


Too high speed

The motor speed has exceeded the limit for too high speed (limit value for speed control).

The output section is shutoff immediately.

Resolver

The resolver is defective. Cable broken or not plugged in.


Motor phases

One or several motor phases are interrupted. Cable broken or motor cable not plugged in.


Undervoltage intermediate circuit

The voltage in the intermediate circuit has dropped below the undervoltage limit.


Overvoltage intermediate circuit

The voltage in the intermediate circuit has risen above the overvoltage limit.


Overcurrent output section

The current has exceeded the current limit of the output section.


Power supply unit not OK

Short-circuit, overvoltage or overloading of power supply unit.

The tightening module can not be started.

Programming error

No parameters present or parameters incompatible with hardware.


Error torque sensor

Calibratrion error or faulty transducer data. Cable broken or not plugged in. Tightening tool may have to be replaced


Firmware not active (Display flashes right and left alternately.)

Power-up initialisation or download of system software (firmware etc.) or parameters.


static

static

Error code

Error Diagnosis

5


The measuring board only outputs 3 messages at the 7-segment display of the servo. The messages always begin with an “H”. 1. H - A Reading spindle data

This message is output upon power-up and reset of the measuring board. Additionally, the spindle data is read if the system detects during operation that a spindle has been disconnected and then reconnected, since it is immediately read out upon detection.

2. H - E-C Error spindle data (Error Constants)

This message is output upon reading of spindle data if an error has been found while comparing with the locally saved spindle data and a new spindle has thus been detected. The message is also output if data could not be read from a spindle.

3. H - D-A Duplicate address (Double Address)

This message is output if a tightening module detects that at least 1 further tightening module has the same bus address. In this case, check the bus addresses of the respective tightening modules.

Error Diagnosis

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Notes

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Chapter

6

Annex

This chapter contains the EC declaration by AMT for this machine/system as well as a contact form. This chapter contains:

6 Annex .......61 EC Declaration of Conformity .....61

Contact Form .....63


6 Annex

EC Declaration of Conformity


Contact Form

Please complete and fax to: 07361 / 501 2709 Your address: _______________________________________________________________________________________ Date: Signature / Company stamp Person to c ontact

Contact Form

Company

Name

Department

Street

City

Telephone

Fax

E-Mail

I need general descriptive literature.

I am interested in a detailed discussion. Please call to make an appointment.

Please call me.

I need descriptive literature concerning:

Hand tools Built-in nutsetters Assembly systems Automation


Notizen:

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Notes:

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AMT Alfing Montagetechnik GmbH Auguste-Kessler-Straße 20 D-73433 Aalen Tel. +49 7361 501-2701 Fax +49 7361 501-2709 [email protected] www.alfing.de

Alfing Montagetechnik GmbH

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