FEC Handheld Nutrunner HFC3000 User manual

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October 2016 (Preliminary Release)

Thank you for purchasing our Handheld Nutrunner.

This instruction manual describes the procedures for installation, and 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 are subject to change without notice.

prohibited.

It is important for you to 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 use this machine correctly.

Wirings and parameter settings shall be conducted by a professional engineer.

Indicate the following on all instruction manuals that use this equipment.

This equipment is capable of high voltages hazardous to human life.

Never conduct a withstand voltage test or megger t

est

on this equipment.

For the safety of operator and equipment

Please confirm the following when unpacking this equipment.

Confirm that you received the correct model that you had ordered.

Confirm that there are no missing parts, accessories or tools. (Refer to the system structure

specification list.)

Check for any damage caused during transportation.

Points to check when unpacking

Introduction

Warranty Period

The warranty period of this equipment is 1 year from the date of purchase or the date

of delivery to the designated place.

Scope of Warranty

If a malfunction occurs in the equipment in the state of correct use in accordance with

this instruction manual within the warranty period, repair or replacement shall be

performed free of charge. However, accommodations shall be charged accordingly

in the following cases, even within the warranty period.

1. If the cause of a malfunction is a condition, environment, handling, etc., falling

outside that which is indicated in the instruction manual.

2. If a malfunction is due to a modification or repair performed by the customer.

3. If the cause of a malfunction is an apparatus other than this equipment.

4. If a malfunction is due to use outside the specification ranges of this equipment.

5. If the cause of a malfunction is an act of God or other disaster.

The scope of this warranty is limited to the main body of our equipment and damage

induced by a malfunction of this equipment shall be excluded from the warranty.

Warranty

Introduction

Read 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 equipment functions, safety

precautions and instructions.

Safety precautions in this manual are ranked as [Warning] or [Caution].

To prevent danger to the user and other persons as well as property damage, the instructions that must

be fully 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 that are marked with 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 all instructions marked with the symbols.

This instruction manual uses various symbols for instructions that shall be observed.

Warning

This symbol indicates that failure to observe instruction marked with

this symbol may result in severe personal injury or death.

This symbol indicates that failure to observe instruction marked with

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

Warning:

Fire

Ground

Prohibited

Do not

disassemble

Required

Warning:

Electrical shock

Safety Precautions

Caution

Caution: Fire

Caution:

Electrical shock

Caution: High

Temperature

Do not remove the motors and gear cases of tools.

The tool output spindle may rotate and cause injury.

Do not repair, disassemble, or modify the equipment.

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

Never operate the equipment where it is exposed to water or near corrosive atmosphere and

flammable gases. Failure to observe this instruction may cause fire.

Do not touch 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 an electric shock.

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

Failure to observe this instruction may cause an electric shock or injury.

Turn OFF the power when conducting wiring operation and maintenance and inspection.

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

Never damage the cables, apply excessive strength to cables, or squeeze the cables.

Never use damaged power cables.

Failure to observe this instruction may cause an electric shock or fire.

It takes 15 minutes for capacitor discharging. Do not touch the unit and terminals immediatey

after power off.

Be sure to conduct type-3 grounding for the FG terminals.

Failure to observe this instruction may cause electric shock.

In case of abnormal odor, noise, or operation error occurs, stop operation immediately

and turn OFF the power source.

Failure to observe this instruction may cause injury or fire.

Safety Precautions

Warning

Transport the equipment properly according to its weight.

Failure to observe this instruction may cause injury and malfunction.

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

Ambient temperature: -5 C ~ +55 C (Avoid freezing)

Ambient humidity: 50% RH or lower (Avoid moisture)

Package: Tight seal

Do not hold cables and output spindles when transporting the tools.

Failure to observe this instruction may cause injury or malfunction.

The equipment shall be stored under the following conditions.

Ambient temperature: -5 C ~ +55 C (Avoid freezing)

Ambient humidity: 90% RH or lower (Avoid moisture)

Atmosphere: Indoors (Avoid direct sunlight)

No corrosive gases or flammable gases

No oil mist, dust, water, salt, iron powder

Avoid direct vibration or shocks.

Failure to meet the above conditions may cause earth leakage and malfunction.

Caution

Transportation/Storage

Safety Precautions

Installation/Wiring

Install the controller using the specified screws.

Failure to observe this instruction may cause malfunction.

Use the specified combination of the tool and the controller.

Failure to observe this instruction may cause fire and malfunction.

The power input parts must be provided with safety measures such as breakers and

circuit protectors.

Failure to observe this instruction may cause fire and malfunction.

Do not use a tool or a controller that has damages or missing parts.

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

Do not get on the top of equipment or place a heavy object on the top of equipment.

Failure to observe this instruction may cause injury, and malfunction.

Do not subject the equipment to excessive shock or impact.

Failure to observe this instruction may cause malfunction.

Provide proper and firm wiring.

Failure to observe this instruction may cause injury, fault, and malfunction.

Operate the equipment with the specified power supply voltage.

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

When operating the equipment at a location such as the following, take sufficient measures to

shield the equipment.

Location where noise is generated

Location where the equipment is subjected to a strong electric field or magnetic field

Location a power wire is not laid nearby.

Failure to observe this instruction may cause injury, fault, and malfunction.

C

aution

Safety Precautions

Operation/Adjustment

Never operate the equipment with wet hands.

Failure to observe this instruction may cause electric shock.

Use the equipment under the following conditions.

Ambient temperature: 0°C~+45°C (Avoid freezing)

Ambient humidity: 90% RH or lower (Avoid moisture)

Atmosphere: Indoors (Avoid direct sunlight)

No corrosive gases or flammable gases

No oil mist, dust, water, salt, iron powder

Avoid direct vibration or shocks.

Failure to meet these conditions may cause earth leakage and malfunction.

Confirm and adjust all parameters before operation in order to prevent unexpected movement

of the equipment.

Failure to observe this instruction may cause an injury, malfunction, or fault.

Never conduct extreme adjustments or setting change that may cause instability of operation.

Failure to observe this instruction may cause an injury, malfunction, or fault.

Do not turn ON and OFF the equipment repeatedly. Failure to observe this instruction may

cause a malfunction.

Do not use the equipment at a torque higher than the maximum torque.

Failure to observe this instruction may shorten equipment life or cause breakage due to 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.

It is occurred reaction in sudden rise torque in the following cases.

Please attach the reaction jig.

Retightening bolt(nut) which already tighten.

Loosing bolt(nut) which already tighten.

Caution

Safety Precautions

Table of Contents

Chapter 1 Outline

1-1 How to Use This Instruction Manual 1-2

1-2 Features 1-3

1-3 Usage Precautions 1-5

Chapter 2 Specifications

2-1 System Specifications 2-2

2-1-1 Duty Cycle Calculation 2-2

2-1-2 Unit Specifications 2-2

2-2 Performance 2-3

2-2-1 Fastening Performance 2-3

2-2-2 Unit 2-3

2-3 Functions 2-4

2-3-1 Main Functions 2-4

2-3-2 Fastening Methods 2-5

Chapter 3 Part Names

3-1 Unit 3-2

3-1-1 Unit Front Panel 3-2

3-1-2 Unit Rear Panel 3-3

3-2 Tools 3-4

3-2-1 Angle Tool 3-4

3-2-2 Pistol Tool 3-5

Chapter 4 Installation

4-1 Installation Procedure 4-2

4-2 Unit Outer Shape and Installation Dimensions 4-3

4-3 Input Power Source Connection 4-4

4-4 Tool Cable Specifications 4-5

4-5 External Control Signal Connection 4-6

4-5-1 Unit I/O Signals [BANK SELECT=OFF] 4-7

4-5-2 Unit I/O Signals [BANK SELECT=ON] 4-8

4-5-3

Input and Output Circuit Specifications and Recommended Connection Circuit

4-9

4-5-4 Description of I/O Signals 4-10

4-5-5 Timing Chart 4-16

4-6 External Monitoring Device Signal 4-18

4-7 RS-232C Interface Signal 4-19

4-7-1 RS232C Specification (RS232C-1) 4-20

4-7-2 Data Format (RS232C-1) 4-21

4-8 Ethernet Interface 4-23

Table of Contents

Chapter 5: Power Activation and Operational Tests

5-1 Items to be Checked Before Power Activation 5-2

5-2 Items to be Checked When Activating the Equipment 5-3

5-3 Input Initial Setting Data 5-4

5-4 Items to be Checked After Activation 5-4

Chapter 6 Description of Operations

6-1 Changing between RUN and PROGRAM Modes 6-2

6-2 RUN Mode 6-5

6-2-1 Changing Modes in the RUN Mode 6-6

6-2-2 Indications in the RUN Mode (Real Time Mode) 6-7

6-2-3 Indications in the RUN Mode (Fastening Result Mode) 6-10

6-2-4 Indications in the RUN Mode (Parameter Setting Mode) 6-12

6-2-5 Indications in the RUN Mode (System Setting Mode) 6-13

6-2-6 Indications in the RUN Mode (Operation View) 6-14

6-3 PROGRAM Mode 6-16

6-3-1 Changing Modes in the PROGRAM Mode 6-16

6-3-2 Indications in the PROGRAM Mode (Set Value Selection Mode) 6-17

6-3-3 Indications in the PROGRAM Mode (Set Value Editing Mode) 6-19

6-4

Copying of Parameters/Erasure of the Fastening Result Record/Formatting of the CF Card

6-21

6-5 Fastening NG (Failure) Result Indications 6-23

6-5-1 Example of Fastening NG item indication 6-24

6-5-2 NG Judgment 6-26

6-6 Parameter Structure 6-36

Chapter 7 Troubleshooting

7-1 Abnormal State Display 7-2

7-2 Abnormality Details/Causes and Recovery Methods 7-3

7-3 Axis Judgment: Checking the Contents of the REJECT 7-9

7-4 Ethernet Communication 7-10

7-5 RTC 7-12

Chapter 8 Options

8-1 CompactFlash (CF) Card 8-2

8-2 Expansion RS232C Interface 8-7

Chapter 9: External Interface

9-1 Common specifications 9-2

9-2 EtherNet/IP 9-7

9-3 CC-Link 9-12

9-4 PROFIBUS DP-V1 9-19

9-5 DeviceNet 9-24

9-6 PROFINET IO 9-29

Table of Contents

Chapter 10 Warranty and Servicing

10-1 Warranty 10-2

10-1-1 Warranty Period 10-2

10-1-2 Scope of Warranty 10-2

10-2 Servicing System 10-3

Appendix: List of Tool Models

Revision History

Revision

date Manual No. Content of revision Page

Jan, 2016 HFC3000E-HW-1

1

st

Edition

(SupportingV1.000) – Release from DDK (S0140185-C)

Manual Numbering Convention

HFC3000E-HW-1

HW = Hardware Operation Manual

SW = Software Manual

DSP1500 = Servo Press

AFC3000 =

Nutrunner

FUSION = DC Hand

Tool

HFC3000 = DC Hand

Tool

E = English Version

S = Spanish Version

*Japanese Version furnished by DDK

uses DDK numbering convention.

Version Number

(Major Revision Level)

Notes

Chapter 1 Outline

PAGE 1-1

Chapter 1 Outline

1

Chapter 1 Outline

PAGE 1-2

1-1 How to Use This Instruction Manual

This manual describes the system structure, specifications, handling method, etc., of the Handheld

Nutrunner System.

These are described in the following order in this manual:

Chapter

Items

Contents

Chapter 1

Outline

Description of functions and precautions.

Chapter 2

Specifications

General specifications of the Hand System.

Chapter 3

Names of Parts

Names and functions of the respective parts of the controller

and the tools.

Chapter 4

Installation

Installation procedure

Chapter 5

Power Activation and

Operational Tests

Items to be checked before power activation and procedures

for operational tests.

Chapter 6

Description of

Operations

Descriptions of items displayed on the panel and instructions

for setting the fastening set values.

Chapter 7

Troubleshooting

Descriptions of abnormal operation indications during

operation and corrective actions.

Chapter 8

Options

Optional functions

Chapter 9

Fieldbus

Fieldbus setting and functions

Chapter 10

Warranty and Servicing

Warranty period and servicing system

Chapter 1 Outline

PAGE 1-3

1-2 Features

The Handheld Nutrunner is a flexible fastening tool equipped with a compact, high-performance

servomotor developed especially for this product. Like the usual high-performance nutrunner system, it

is designed to accommodate various tool models and provide useful functions for error proofing, data

management, data communication, etc.

☆ Compact Design

The controller operates on single-phase 100V ~ 240V, making installation work related to the

primary power source easy.

☆ Fastening Functions

Fastening can be performed by the torque method or the angle method. An angle monitor and a

torque rate monitoring function are provided as functions for error proofing. A fastening counting

function can be used as an additional error proofing method.

☆ 64 Programmable Parameter Sets

64 selectable parameter sets are available for ‘on-the-fly’ model/torque setting changes

Work (parameter) selection can be performed by external signals.

Controller memory is non-volitile - a backup battery is not required, thus no need to worry about

problems such as dead batteries, battery maintenance, etc.

☆ Data Communication

An RS-232C interface is incorporated to enable data communication with external devices.

A dedicated Ethernet connector that enables communication with a PC (for dedicated software) is

provided. Connectors enabling sending of result data to a PLC or other external device are also

provided.

Optional fieldbus interfaces that allow fastening data to be sent of over the same fieldbus connection

to the PLC, can be installed. (ie. Ethernet I/P, Devicenet, Profinet, CCLINK, etc.)

☆ Motor

A permanent magnet High Speed DC motor provides for improved fastening control. The sealed

design of the motor provides greater protection from contamination without generating excess heat.

The resolver is uniquely designed to withstand harsh environments and provide high-resolution

control / angular feedback signals.

☆ Preamplifier

Quality control of the tool torque transducer is accomplished electronically (digitally) through the

EEPROM (Electrically Erasable Programmable Read Only Memory) in the preamplifier. During

factory setup of the torque transducer, the unit is Dead Weight and Dynamically tested against

Standards that are certified and traceable to the National Institute of Standards and Technology.

The resultant data is then programmed into the preamplifier where it is stored on non-volatile

EEPROM. The preamplifier also contains the “Smart Tool ID” system that allows automatic tool

recognition and protects against misapplication of tools onto the wrong controller or set-up.

☆ Self-Check Function

Each time a fastening operation starts, a calibration check of the torque transducer is performed to

check functionality including those of the controller and the cables to prevent abnormal fastening.

☆ Abnormal Condition Display

When an abnormality occurs, the corresponding abnormal state No. is displayed on the front panel.

Chapter 1 Outline

PAGE 1-4

☆ Fastening Result Record

Fastening resultant data is saved in a nonvolatile controller memory (approx. 12,000 cycles of data).

100 sets of torque curve data is stored in volatile memory (RAM).

100 sets of Reject curve data is stored in nonvolatile memory.

The fastening resultant data and the Reject curve data are therefore preserved even if the power is

turned off. However, the normal torque curve data is lost when the power is turned off. The above

data can be read with the User Console software.

●Fastening Result Storage Feature List of HFC3000 System

Function Name

Automatic Save *1

Stored Data

HFC3000

User Console

Fastening

Data

Curve Data

Fastening Data

Setting Tab

Preferences

Auto Upload

Stored Data

Storage Content

Stored Data

Curve Data

Stored Data

Abnormals

Storage Location

PC

Each controller

Storable Records

-

12000

results

500 results

Setting Item

Yes

No

JUDGMENT

ACCEPT

○

REJECT

○

ABNORMAL

○

BYPASS

○

STOP

○

RESET

STOP

○

START OFF

○

*1：’Automatic Save’ must be enabled during data collection in the Fastening Data screen of

the AFC3000 User Console

Function Name

Stored Curve Data

CF Card *2

HFC3000

User Console

Stored Curve Data

-

Storage Content

Stored Curve

Data *3

Stored Reject

Curve Data

Stored

Data

Curve Data

Storage Location

Each controller

CF Card

Storable Records

100 results

-

Storage Format

Torque-Angle (540deg)

-

Torque-Angle (180deg)

JUDGMENT

ACCEPT

○

REJECT

○

ABNORMAL

○

BYPASS

○

STOP

○

RESET

STOP

○

START OFF

○

*2：CF CARD Option and CF CARD are required separately.

*3：The stored (curve data) will be cleared when the control power of the controller is turned OFF.

Chapter 1 Outline

PAGE 1-5

1-3 Usage Precautions

To insure use in the best conditions, please conform to the following instructions.

☆ Handling of tool

Tools can generate a large amount of torque during operation, and the reaction force is applied to the

Operator or mounting area of the tool. Therefore, tools must be installed in the proper positions and

with adequate reaction devices. Tools MUST be mounted either using their supplied mounting plate

or clamped only in designated areas of the tool or tool damage may result.

Keep in mind that the fastening tool is a strain gage based instrument and, although it has been

designed to withstand sudden shock, repeated shock (over time) could damage some components.

Therefore, support devices must be used whenever practical to ease in handling and operation of the

Fastening Tool.

☆ Fastening

Avoid fastening beyond the full scale torque. Do not use a duty cycle (the ratio of the tool “On” time

to Tool “Off” time) higher than 50%, even when the torque is below the full scale value.

☆ Cable Connection

 Use the specified/supplied cables for all system connections.

 Completely lock the tool cable twist lock connectors.

 PLC I/O cables must be run separate from any high voltage power sources or cabling, and must

not exceed 50 feet in length.

 GROUNDING of the controller is REQUIRED (Perform Class 3 grounding) – Make sure the

controllers power cable ground pin is connected to a proper ground or DANGER OF ELECTRICAL

SHOCK EXISTS. Supply primary power with a cable no SMALLER than 1.25mm2 (17AWG).

☆ Installation Environment

 Controller units must be located a minimum of 600 mm from high transient voltage sources such as

transformers, motor starters, AC inverters and AC contactors. If it cannot be avoided, the units must be

properly shielded.

DO NOT use at the following locations.

 Areas under direct sunlight.

 Areas where the environmental temperature is out of the 32 °~122°F (0° ~ 45°C) range.

 Areas where the relative humidity is below the 20% range.

 Areas where the relative humidity is above the 90% range.

 Areas where the temperature changes quickly, which may cause condensation.

 Areas where conductive powder, oil mist, saline, or organic solvents exist.

 Areas that have corrosive or combustible gases.

 Areas that have strong electric or magnetic fields.

 Areas where a strong vibration or shock could be transmitted directly to a Controller unit or tool.

☆ Static Electricity

Since the controller is composed of many electronic components, please be aware of static

electricity. Excessive static electricity may occur at dry locations, therefore we recommend the

operator to touch grounded metal before operating the front panel operation switches to discharge

the static electricity charged inside the human body.

Chapter 1 Outline

PAGE 1-6

☆ Cleaning

Do not use any organic solvents, such as thinner, to clean a Controller or a tool. 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.

☆ Noise

The controller is made up of electronic components – therefore, make sure there is no equipment

that will generate strong electrical noise in the surroundings.

Make sure that the cables that connect the controller and the tool are not placed inside a duct, etc.,

together with a power source line or other wiring.

☆ Handling and Shipping

It is critical that FUSION System components are properly handled and shipped in order to maintain the

System's integrity. Adhere to the following requirements for shipping and handling:

 Loose FUSION System components must be individually packaged in an approved anti-static

container or wrap to prevent damage from electrostatic discharge.

 Adhere to Chapter 2 Specifications for environmental requirements.

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FEC Handheld Nutrunner HFC3000 User manual

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