AFC3000 Ethernet-IP Fieldbus Expansion Unit

AFC3000E-FB-EN-3

MFC-EN

Ethernet-I/P

Fieldbus

expansion Unit

Ethernet-I/P Fieldbus Expansion Unit

PAGE 2

Revision History

Revision Date Manual No. Contents of Revision

08/20/2014 AFC3000E-FB-EN-1 First Release

02/18/2016 AFC3000E-FB-EN-2 Added Message Write Data info (pg. 35-38)

01/19/2018 AFC3000E-FB-EN-2 Minor revision - Message Output formats fixed (pg.13-24)

03/19/2019 AFC3000E-FB-EN-3 Updated PLC Message examples

Any questions regarding the contents of this document or any related matter should be

directed to FEC Automation Systems at (586) 580-2622, faxed to (586) 580-2620 or emailed to [email protected].

The information set forth in the following document is the property of

FEC Automation Systems.

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

Unauthorized reproduction or distribution of this manual is strictly prohibited.

Please contact FEC Automation Systems if you require additional copies.

Manual Numbering Convention

AFC3000E-FB-EN-1

DSP1500DSP1500DSP1500DSP1500 = Servo Press

AFC1500AFC1500AFC1500AFC1500 = Nutrunner

FUSIONFUSIONFUSIONFUSION = DC Hand Tool

HW = Hardware Operation Manual

SW = Software Manual

FB = Fieldbus Manual

DSP1500 = Servo Press

AFC3000 = Nutrunner

FUSION = DC Hand Tool

E = English Version

S = Spanish Version

*Japanese Version furnished by DDK

uses DDK numbering convention.

Version Number

(Major Revision Level)

CC = CC-Link

DN = DeviceNet

PB = Profibus

PN = ProfiNet

EN = Ethernet-I/P


PAGE 3

Forward

This manual is intended as a supplement to the AFC3000 Hardware Operation Manual and should be

used in conjunction with information provided in that manual. FEC recommends reading that manual

before the contents of this manual (which only applies to systems requiring the optional Ethernet I/P

interface).

Ethernet-I/P

The AFC3000 Ethernet-I/P System conforms to the open field network Ethernet-I/P. Control of tools and

transactions of message information are executed by Ethernet-I/P explicit message communication.

Due to conformance with the open field network Ethernet-I/P System, connections with Ethernet-I/P devices

(master/slave) of other manufacturers are enabled.

Also, remote I/O communication and message communication can be executed at the same time.

System Structure (Ethernet-I/P)

AFC3000 Ethernet-I/P System

MASTER

(1st Spdl.)

Remote I/O Communication

Message Communication

32nd

Spdl

Ethernet-I/P

Slave

Station Ethernet-I/P Slave Stations of

Other Manufacturers

2nd

Spdl

3rd

Spdl

SLAVE

PLC (Ethernet-I/P Master Station)


PAGE 4

Description of the Hardware (Ethernet-I/P)

Module

Status

LED

Network

Status

LED

Ethernet-I/P

Connector

Link/

Activity

LED


PAGE 5

● EDS File

An EDS file is an information file related to the communication specifications of Ethernet-I/P compatible

device and a separate, individual file exists for each device. The EDS file is necessary for using the

Ethernet-I/P configuration software to connect the MFC-EN and the PLC.

The EDS file is included in the installation CD for the AFC3000 User Console or may be downloaded from

the FEC website. Please refer to the instruction manual for the Ethernet-I/P configuration software

concerning the appropriate method for using the EDS file.

● Module Pin Configuration

No. Signal Description

1 TD+ Send data +

2 TD- Send data -

3 RD+ Receive data +

4 - Not used.

5 - Not used.

6 RD- Receive data -

7 - Not used.

8 - Not used.

* The cable is not included with the equipment. Please prepare a LAN cable of Category 5e or higher on

your own equipment. Please prepare these on your own. ････ Be sure to connect the cable with all power turned OFF.

1 8

Caution


PAGE 6

● List of LED Indications

The module LEDs indicate the states of the nodes of the AFC3000 Ethernet-I/P System and the network

state.

LED Color State Details

A

Network

Status

LED

Off Off Offline Offline, No power or no IP address

Green Lit up Online Online, One or more connections established

Flash Communication not established

online, connection is not establishe

Red Lit up Error

Fatal error has occurred. / Conflicting IP address.

Flash Connection timeout

One or more connection timeout has occurred

B

Module

Status

LED

Off Off Power OFF Power is not supplied.

Green Lit up Online Controlled by a scanner in RUN state -

Flash Communication not established

Incomplete / wrong configuration or scanner in idle state

Red Lit up Error Major Fault -A critical error has occurred.

Flash Error A recoverable error has occurred.

C

Link

Activity

LED

Off Off Link not established

ETHERNET link is not established and communication is not performed.

Green Lit up Link Established

ETHERNET link is established but not communicating

Flash Communicating ETHERNET link is established and communication is in progress.

A : Network

Status LED

B : Module

Status LED

C : Link

Activity LED


PAGE 7

I/O Signal Specifications (Ethernet-I/P)

I/O Input/Output Message Input/Output

MASTER Spindle ￫

PLC PLC ￫ MASTER

Spindle MASTER Spindle ￫

PLC PLC ￫ MASTER

Spindle Maximum

Setting 32bytes (256 points) 12bytes (96 points) 2048 word (4096 bytes) 16 word (32bytes)

Standard

Setting 32bytes (256 points) 8bytes (64 points) 2048 word (4096 bytes) 16 word (32bytes)

●●●● AFC3000 Ethernet-I/P System Signal Specifications (PLC ￫￫￫￫ MASTER Spindle) ･ Number of MASTER Spindle Input Points 4 words 8 bytes (256 points)

Input signals are factory set and cannot be changed.

Word No. BIT Signal Word No. BIT Signal

No.01

0 STOP

No.03

0 SEQ SELECT No.17 1 RESET 1 SEQ SELECT No.18 2 REVERSE 2 SEQ SELECT No.19 3 START 3 SEQ SELECT No.20 4 SEQ SELECT BIT 0 4 SEQ SELECT No.21 5 SEQ SELECT BIT 1 5 SEQ SELECT No.22 6 SEQ SELECT BIT 2 6 SEQ SELECT No.23 7 SEQ SELECT BIT 3 7 SEQ SELECT No.24 8 SEQ SELECT BIT 4 8 SEQ SELECT No.25 9 CYCLE COUNT UP 9 SEQ SELECT No.26

10 CYCLE COUNT CLEAR 10 SEQ SELECT No.27

11 SEQ SELECT No. ENABLE 11 SEQ SELECT No.28

12 INPORT 1 12 SEQ SELECT No.29 13 INPORT 2 13 SEQ SELECT No.30 14 INPORT 3 14 SEQ SELECT No.31 15 INPORT 4 15 SEQ SELECT No.32

No.02

0 SEQ SELECT No.1

No.04

0 BYPASS SPDL No.1 1 SEQ SELECT No.2 1 BYPASS SPDL No.2 2 SEQ SELECT No.3 2 BYPASS SPDL No.3 3 SEQ SELECT No.4 3 BYPASS SPDL No.4 4 SEQ SELECT No.5 4 BYPASS SPDL No.5 5 SEQ SELECT No.6 5 BYPASS SPDL No.6 6 SEQ SELECT No.7 6 BYPASS SPDL No.7 7 SEQ SELECT No.8 7 BYPASS SPDL No.8 8 SEQ SELECT No.9 8 BYPASS SPDL No.9 9 SEQ SELECT No.10 9 BYPASS SPDL No.10

10 SEQ SELECT No.11 10 ID DATA CLEAR 11 SEQ SELECT No.12 11 ID SELECT ENABLE 12 SEQ SELECT No.13 12 13 SEQ SELECT No.14 13 14 SEQ SELECT No.15 14 15 SEQ SELECT No.16 15

(Please refer to AFC3000 Operations Manual Section 5-3-2 and 5-3-3 for description of respective

signals)


PAGE 8


No.05

0 BYPASS SPDL No.11

No.06

0 BYPASS SPDL No.27 1 BYPASS SPDL No.12 1 BYPASS SPDL No.28 2 BYPASS SPDL No.13 2 BYPASS SPDL No.29 3 BYPASS SPDL No.14 3 BYPASS SPDL No.30 4 BYPASS SPDL No.15 4 BYPASS SPDL No.31 5 BYPASS SPDL No.16 5 BYPASS SPDL No.32 6 BYPASS SPDL No.17 6 7 BYPASS SPDL No.18 7 8 BYPASS SPDL No.19 8 9 BYPASS SPDL No.20 9

10 BYPASS SPDL No.21 10

11 BYPASS SPDL No.22 11

12 BYPASS SPDL No.23 12 13 BYPASS SPDL No.24 13 14 BYPASS SPDL No.25 14 15 BYPASS SPDL No.26 15

* The word No. at the PLC side differs according to the setting of the node address, etc., so please be sure

to confirm before using. Please refer to the AFC3000 Operation Manual, Section 5-3-2 and 5-3-3 for

description of the respective signals.

The allocation of the input signals is fixed (cannot be changed).

The unused area of the inputs is also secured (and cannot be used by other

devices). Be careful of the following points when using the BYPASS No. # (1 to 32) signals. If a certain Unit is to be put in the BYPASS mode, set the corresponding signal

among the BYPASS No. # (1 to 32) signals to “ON” with the START signal of the Unit

being in the “OFF” state and the BUSY signal of the MASTER Spindle for PC

communication and I/O (PLC) control being in the “OFF” state. When fastening is executed with any of the spindle BYPASS No. # (1 to 32) signals

in the “ON” state, the fastening judgment of that Unit will be ignored as if it does not

exist. Also, when any of the BYPASS No. # (1 to 32) signals is set to “ON” with the BUSY

of the MASTER Spindle being in the “ON” state, the sequence judgment may result

in REJECT.

Caution

Caution


PAGE 9

●AFC3000 Ethernet-I/P System Signal Specifications (MASTER Spindle ￫￫￫￫ PLC) ･ Number of MASTER Spindle Output Points 32 bytes (256 bits)

The table below is an example of the Output mapping using Ethernet I/P. Output bits (256) are allowed to be user-programmed using the AFC3000 User Console Software. The allocation of the signals can be set on any bit/pin through the “PLC Output Layout” setting function of the AFC3000 Software. Please refer to “5-3-4 PLC Output Layout” of the <<AFC3000 Operation Manual>> for list of available output signals (Master and individual spindle signals) EXAMPLE ONLY: Actual signal placement may vary upon user configuration


Output word

No. 1

Output

Signal

Setting

Example 0 TOTAL REJECT

Output word

No. 3

Output

Signal

Setting

Example

0 SEQ No.17 SELECTED 1 TOTAL ACCEPT 1 SEQ No.18 SELECTED 2 TOTAL ABNORMAL 2 SEQ No.19 SELECTED 3 TOTAL READY 3 SEQ No.20 SELECTED 4 TOTAL BUSY 4 SEQ No.21 SELECTED 5 END 5 SEQ No.22 SELECTED 6 SEQ SELECT BIT 0 6 SEQ No.23 SELECTED 7 SEQ SELECT BIT 1 7 SEQ No.24 SELECTED 8 SEQ SELECT BIT 2 8 SEQ No.25 SELECTED 9 SEQ SELECT BIT 3 9 SEQ No.26 SELECTED

10 SEQ SELECT BIT 4 10 SEQ No.27 SELECTED 11 SPINDLE IN BYPASS 11 SEQ No.28 SELECTED 12 DATA AVAILABLE 12 SEQ No.29 SELECTED 13 CURRENT WARNING 13 SEQ No.30 SELECTED 14 CAL WARNING 14 SEQ No.31 SELECTED 15 ZERO LEVEL WARNING 15 SEQ No.32 SELECTED

Output word

No. 2

Output

Signal

Setting

Example

0 SEQ No.1 SELECTED

Output word

No. 4

Output

Signal

Setting

Example

0 REJECT No.1 1 SEQ No.2 SELECTED 1 ACCEPT No.1 2 SEQ No.3 SELECTED 2 ABNORMAL No.1 3 SEQ No.4 SELECTED 3 BYPASS No.1 4 SEQ No.5 SELECTED 4 REJECT No.2 5 SEQ No.6 SELECTED 5 ACCEPT No.2 6 SEQ No.7 SELECTED 6 ABNORMAL No.2 7 SEQ No.8 SELECTED 7 BYPASS No.2 8 SEQ No.9 SELECTED 8 REJECT No.3 9 SEQ No.10 SELECTED 9 ACCEPT No.3

10 SEQ No.11 SELECTED 10 ABNORMAL No.3 11 SEQ No.12 SELECTED 11 BYPASS No3 12 SEQ No.13 SELECTED 12 REJECT No.4 13 SEQ No.14 SELECTED 13 ACCEPT No.4 14 SEQ No.15 SELECTED 14 ABNORMAL No.4 15 SEQ No.16 SELECTED 15 BYPASS No.4


PAGE 10


Output word

No. 5

Output

Signal

Setting

Example 0 REJECT No.5

Output word

No. 7

Output

Signal

Setting

Example

0 RUN REV HI REJ No.5 1 ACCEPT No.5 1 RUN REV LO REJ No.5 2 ABNORMAL No.5 2 LO CUR LIMIT WARNING No.5

3 READY No.5 3 HI CUR LIMIT WARNING No.5

4 BUSY No.5 4 CURRENT WARNING No.5

5 BYPASS No.5 5 CAL VOLTAGE WARNING No.5

6 TORQUE HOLD No.5 6 ZERO VOLT WARNING No.5

7 PAR SEL (BIT0) No.5 7 JUDGE COMBO (BIT1) No.5





12 TORQUE HI REJ No.5 12 JUDGE COMBO (BIT6) No.5

13 TORQUE LO REJ No.5 13 JUDGE COMBO (BIT7) No.5

14 FTQ HI REJ No.5 14 JUDGE COMBO (BIT8) No.5

15 FTQ LO REJ No.5 15

Output word

No. 6

Output

Signal

Setting

Example

0 SNUG TQ HI REJ No.5

Output word

No. 8

Thru

No. 16

Output

Signal

Setting

Example

0 1 TQ INHIBIT HI REJ No.5 1 2 F ANGLE HI REJ No.5 2 3 F ANGLE LO REJ No.5 3 4 DIFF + ANG REJ No.5 4 5 DIFF – ANG REJ No.5 5 6 RATE 1 HI REJ No.5 6 7 RATE 1 LO REJ No.5 7 8 RATE 2 HI REJ No.5 8 9 RATE 2 LO REJ No.5 9

10 RATE 3 HI REJ No.5 10 11 RATE 3 LO REJ No.5 11 12 1ST TIME HI REJ No.5 12 13 1ST TIME LO REJ No.5 13 14 2ND TIME HI REJ No.5 14 15 2ND TIME LO REJ No.5 15

The example above (output word 5-7) shows an example of all available signals for each spindle.

While normally not all signals are used, any of the signals (for each spindle) can be preset

(programmed using the AFC3000 software) to any output bit.

* The word No. at the PLC input side differs according to the setting of the node address, etc., so please be

sure to confirm before using. Please refer to the AFC3000 Operation Manual, Section 5-3-2 and 5-3-3 for

description of the respective signals.

The unused area of Word 01 to 16 is also secured. Caution


PAGE 11

Fieldbus Setting (Ethernet-I/P)

The fieldbus settings are set in the “Fieldbus Setting” menu of the AFC3000 User Console. The following

setting window is displayed when “Multi” ￫ “Fieldbus Setting” is selected at the menu bar.

In the Bus Type Select/communication window, selection of the fieldbus type, uploading, downloading,

and verification of fieldbus settings with respect to the Unit, and browsing and saving of fieldbus settings

with respect to the PC can be performed.

- The standard set values are set as the factory settings in the

Unit. Do not change the settings unless there is a special reason.

- Be sure to perform backup before changing the fieldbus settings of the Unit.

● Bus Type Select: The type of bus is selected from the list. Also, when ”Upload” is executed, the bus

type is judged automatically and reflected in the selection part.

● Configuration File ･ Browse: A fieldbus configuration file (*.nrfcf) is read from the PC. ･ Save: A fieldbus configuration file (*.nrfcf) is saved in the PC.

● Upload: The fieldbus settings are read from the MASTER Spindle for PC communication

and I/O (PLC) control.

● Download: The fieldbus settings are written into the MASTER Spindle for PC communication

and I/O (PLC) control. (Re-activate the control power after writing.)

● Verify: The fieldbus settings of the MASTER Spindle for PC communication and I/O

(PLC) control and the fieldbus settings in the User Console are compared.

Caution


PAGE 12

In the Ethernet-I/P screen (of the AFC3000 Software), setting of the Ethernet-I/P interface is performed. The

network settings, the I/O size, and the Explicit message size can be changed.

● Default (the settings are set to the factory settings when this is selected) ･ Network Settings

IP address 192.168.11.50 Subnet Mask 255.255.255.0

Default Gateway 192.168.11.1 ･ I/O Setting Data Length (FEC INPUTS) [PLC to MFC Unit]: 12 bytes [96 bits] ･ I/O Setting Data Length (FEC OUTPUTS) [MFC Unit to PLC]: 32 bytes [256 bits] ･ Message Data Length [PLC to MFC Unit]: 32 bytes ･ Message Data Length [MFC Unit to PLC]: 4096 bytes * The number of message block bytes is fixed at 250 bytes.

● I/O Size setting ･ Data Length (FEC INPUTS) [PLC to MFC Unit] Setting range: 2 bytes [16 bits] to 12 bytes [96 bits] ･ Data Length (FEC OUTPUTS) [MFC Unit to PLC] Setting range: 2 bytes [16 bits] to 32 bytes [256 bits]

● Message Bytes Size Settings ･ Data Length [PLC to MFC Unit] Setting range: 0 byte to 32 bytes ･ Data Length [MFC Unit to PLC] Setting range: 0 byte to 4096 bytes

Note: Power must be cycled if any of this configuration is changed and downloaded to the Master controller


PAGE 13

Fieldbus Message Setting (MFC Unit ￫￫￫￫ PLC)

The message information output from the MASTER Spindle for PC communication and I/O (PLC) control

is set in the AFC3000 User Console software. The maximum size of the message output that can be

handled is 4096 bytes.

The output order of the message data is: “Multi Format Data” ￫ “Spindle format data of Spdl. No. 1” ￫

“Spindle format data of Spdl. No. 2” ￫･･･￫ “Spindle format data of Spdl. No. 32.”

The message output format is selectable (in the AFC3000 Software) to output either BCD format or

ASCII format, both examples are listed below.

Please contact the PLC manufacturer regarding the setting at the PLC side.

● Multi Format Output Items (BCD Format)

Output Items

Number of Bytes

Fastening Data

Multi Format

LSB (1word) PLC Input Data MSB (16word)

Date 4 2013／5／

28 20 13 5 28 - - -

~

-

Time 4 12:34:56 12 34 56 00 - - - -

ID *1 32 ABCDEF A B C D E F NUL NUL

SEQ No.

(1 to 32) 2 2 00 02 - - - - - -

SEQ

Judgment

*2

2

REJECT 00 01 - - - - - -

ACCEPT 00 02 - - - - - -

ABNORMAL 00 04 - - - - - -

STOP 00 08 - - - - - -

RESET STOP

00 10 - - - - - -

BYPASS 00 20 - - - - - -

START OFF 00 40 - - - - - -

IN CYCLE 00 80 - - - - - -

SEQ

Cycle Count

4 123456 00 12 34 56 - - - -

*1: The ID is fixed at 32 bytes (16 words) and is output in ASCII format. NULL letters are set as unset

values.

*2: Please refer to AFC3000 Operation Manual, “Sequence Judgment” regarding the details of SEQ

Judgment. ････ Do not use the following characters when inputting the ID data. ““““∖∖∖∖”: backslash (yen mark), “/”: slash, ““““:”: colon, “*”: asterisk, “?”: question mark, “””“””“””“””: double quotation, “<” “>”: inequality signs, “|”: pipe sign Caution


PAGE 14

●Multi Format Output Items (ASCII Format)

Output Items

Number of Bytes

Fastening Data

Multi Format

PLC Input Data “Letter String”

Date 10 2013／5／28 2 0 1 3 ／ 0 5 ／ 2 8

～

Time 8 12:34:56 1 2 ： 3 4 ： 5 6

ID*1 32 ABCDEF A B C D E F NUL NUL NUL NUL NUL

SEQ No.

(1 to 32) 2 2 ] 2

SEQ

Judgment

*2, *3

4

REJECT R E J ]

ACCEPT A C C ]

ABNORMAL A B N ]

STOP S T O P

RESET STOP R S T ]

BYPASS B Y P ]

START OFF S O F F

IN CYCLE I N C Y

SEQ

Cycle

Count

8 123456

] ]

1 2 3 4 5 6

*1: The number of output bytes of the ID is fixed at 32 bytes (16 words). NULL letters are set as unset

values.

*2: Please refer to AFC3000 Operation Manual, “Sequence Judgment” regarding the details of SEQ

Judgment.

*3: ␣ (20H) is the ASCII code for (space). ････ Do not use the following characters when inputting the ID data. ““““∖∖∖∖”: backslash (yen mark), “/”: slash,

“:”: colon, “*”: asterisk, “?”: question mark, “””“””“””“””: double quotation, “<” “>”: inequality signs, “|”: pipe sign Caution


PAGE 15

● Spindle Format Output Items (BCD Format)

Output Items Number of

Bytes Fastening

Data

Spindle format

LSB (1word) MSB (2 word)

Spindle No. (1 to 32) 2 1 00 01 - -

PAR No. (1 to 32) 2 2 00 02 - -

Spindle Judgment*1 4 ① ② ③ ④

Spindle Cycle Count (8 digits)

4 123456 00 12 34 56

TOOL Cycle Count (8 digits) 4 12345678 12 34 56 78

Peak Torque*2 4 12.34 00 12 34 02

Final Torque*2 4 12.34 00 12 34 02

Snug Torque*2 4 5.67 00 05 67 02

1st Peak Torque*2 4 12.34 00 12 34 02

2nd Peak Torque*2 4 12.34 00 12 34 02

Final Angle*2 4 123.4 00 12 34 01

Differential Angle*2 4 -12.3 00 01 23 11

Rate 1*2 4 1.234 00 12 34 03

Rate 1 Increment Torque*2 4 12.34 00 12 34 02

Rate 1 Increment Angle*2 4 123.4 00 12 34 01

Rate 2*2 4 -0.123 00 01 23 13



Rate 3*2 4 0.123 00 01 23 03



1st Time*2 4 123.456 12 34 56 03

2nd Time*2 4 123.456 12 34 56 03

Cycle Time*2 4 654.321 65 43 21 03

Peak Current*2 4 12.3 00 01 23 01

Angle at Peak Torque*2 4 123.4 00 12 34 01

Rundown Revolutions*2 4 12.34 00 12 34 02

ZERO Voltage*2 4 -0.123 00 12 34 13

CAL Voltage*2 4 3.512 00 35 12 03

Spindle Cycle Count (4 digits)*3

2 123456 01 23 - -

TOOL Cycle Count (4 digits)*3

2 12345678 23 45 - -

Load rate 2 20 00 20

*1: In regards to the Spindle Judgment, “Judgment Data 1” is output as ①, “Judgment Data 2” is output

as ②, “Error Data” is output as ③, and “1st Reject Item” is output as ④. The values output as ①, ②,

and ③ are respectively set by bit allocation from “Fieldbus Message Setting” of the AFC3000 User

Console.

Note: shaded area described on next page


PAGE 16

*2: With each of the output items (besides “Spindle No.,” “Parameter No.,” “Spindle Judgment,”

“Spindle Cycle Count (8 digits • 4 digits),” “Tool Cycle Count (8 digits • 4 digits),” and “Load

rate”), the results are output in the order of: indication up to a maximum of 6 digits (without the

decimal point) in 2 words (4 bytes), sign, and number of digits to the right of the decimal point.

12 34 56 0 2 ①② ① Sign ② Number of Digits to the right of the Decimal Point

Indication Details Indication Details

0 + value 0 No digits right of decimal point

1 - value 1 1 digit right of the decimal point

2 2 digits right of the decimal point




*3: With each of “Spindle Cycle Count (4 digits)” and “Tool Cycle Count (4 digits),” numerical values of

the millions, hundred thousands, ten thousands, and thousands places are output as 4-digit BCD

data.

When the cycle count reaches 9,999,999 (99 99BCD), the next cycle will be 10,000,000, output as (00

00BCD).


PAGE 17

● Spindle Format Output Items (ASCII Format)

Output Items Number of Bytes

Fastening Data

Spindle format

1 word 2 word 3 word 4 word 5 word

Spindle No. (1 to 32)*1 2 1 ] 1 PAR No. (1 to 32) 2 2 ] 2

Spindle Judgment*2 4 ① ② ③ ④ Spindle Cycle Count (8 digits)

8 123456 ] ] 1 2 3 4 5 6

TOOL Cycle Count (8 digits)

8 1234567

8 1 2 3 4 5 6 7 8

Peak Torque*3 8 12.34 ] 1 2 . 3 4 Judgment Occurrence

Final Torque*3 8 12.34 ] 1 2 . 3 4 Judgment Occurrence

Snug Torque*3 8 5.67 ] ] 5 . 6 7 Judgment Occurrence

1st Peak Torque 6 12.34

] 1 2 . 3 4

2nd Peak Torque 6 12.34

] 1 2 . 3 4

Final Angle*3 8 123.4

] 1 2 3 ． 4 Judgment Occurrence

Differential Angle*3 8 -12.3 - ] 1 2 ． 3 Judgment Occurrence

Rate 1*3 10 1.234

] ] 1 . 2 3 4 Judgment Occurrence

]

Rate 1 Increment Torque 6 12.34 ] 1 2 . 3 4

Rate 1 Increment Angle 6 123.4 ] 1 2 3 ． 4

Rate 2*3 10 -0.123 -

] 0 . 1 2 3 Judgment Occurrence

]

Rate 2 Increment Torque 6 12.34

] 1 2 . 3 4

Rate 2 Increment Angle 6 123.4

] 1 2 3 ． 4

Rate 3*3 10 0.123

] ] 0 . 1 2 3 Judgment Occurrence

]

Rate 3 Increment Torque 6 12.34

] 1 2 . 3 4

Rate 3 Increment Angle 6 123.4

] 1 2 3 ． 4

1st Time*3 10 123.456 1 2 3 . 4 5 6 Judgment Occurrence ]

2nd Time*3 10 123.456 1 2 3 . 4 5 6 Judgment Occurrence ]

Cycle Time*3 8 654.321 6 5 4 . 3 2 1

]

Peak Current*3 10 12.3

] ] ] ] 1 2 ． 3 Warning

]

Angle at Peak Torque 6 123.4

] 1 2 3 ． 4

Rundown Revolutions*3 8 12.34 1 2 ． 3 4 Judgment Occurrence

]

ZERO Voltage 6 -0.123 - 0 ． 1 2 3

CAL Voltage 6 3.512

] 3 ． 5 1 2 Spindle Cycle Count (4 digits)*4

4 123456 ] 1 2 3

TOOL Cycle Count (4 digits)*4

4 1234567

8 2 3 4 5

Load rate 4 20

] ] 2 0

*1: (20H) is the space code (space).

*2: In regards to the Spindle Judgment, “Judgment Data 1” is output as ①, “Judgment Data 2” is output

as ②, “Error Data” is output as ③, and “1st Reject Item” is output as ④. The values output as ①, ②,

and ③ are respectively set by bit allocation from “Fieldbus Message Setting” of the AFC3000 User

Console.


PAGE 18

*3: With each of the output items for which there are set values of high and low limits, the results are

output in the order of: sign, result indication (including the decimal point), judgment code, and 1st

Reject (failure) item. Also with items besides the differential angle and rates 1 to 3, ① is not output,

and for the peak current, ③ is not output.

‘‘‘‘---- 123.5123.5123.5123.5LLLL XXXX’’’’ ① ②③ ①Sign ②Judgment Code

Indication Details Indication Details

Space (20H) + value Space (20H) Within high and low limit, no warning (peak

current)

- (2DH) - value H (48H) Outside high limit, high limit warning (peak

current)

L (4CH) Outside low limit, low limit warning (peak

current) ③1st Reject Item

Indication Details

X (58H) 1st Reject item

Space (20H) Reject item besides the 1st Reject

*4: With each of “Spindle Cycle Count (4 digits)” and “Tool Cycle Count (4 digits),” numerical values of the millions, hundred thousands, ten thousands, and thousands places are output as 4-digit BCD data.

When the cycle count reaches 9,999,999 (99 99BCD), the next cycle will be 10,000,000, output as

(00 00BCD).


PAGE 19

● Judgment Data 1 and 2 Items (in common with BCD and ASCII)

The Judgment data and Abnormal data of the fastening results are set by bit allocation. The actual bit

configuration is setup in the AFC3000 Software. Please refer to “Fieldbus Message Setting” in the

<<AFC3000 User Console Instruction Manual>>.

Classification Item Details

Logic - Message information to be output by a combination of OR and AND is set.

Spindle Judgment

REJECT This is output when a fastening result falls outside a judgment range.

ACCEPT This is output when fastening ends with the fastening results being within the judgment ranges.

ABNORMAL This is output when an error occurs in the system or during the fastening operation.

BYPASS This is output when the BYPASS signal is set to “ON” at the start of fastening

or during the fastening process.

STOP This is output when the STOP signal is set to “OFF” at the start of fastening or

during the fastening process.

RESET STOP This is output when the RESET signal is set to “ON” at the start of fastening or during the fastening process.

START OFF This is output when the START signal is set to “OFF” during the fastening operation with “Deadman” being set as the start method in the sequence setup.

Fastening

Reject Items

Torque Reject

Peak torque low limit Reject/peak torque high limit Reject

Final torque low limit Reject/final torque high limit Reject

Snug torque high limit Reject

Start torque inhibit high limit Reject

Angle Reject Final angle low limit Reject/final angle high limit Reject

Differential - angle Reject/Differential + angle Reject

Rate Reject

Rate 1 low limit Reject/Rate 1 high limit Reject



Time Reject 1st time low limit Reject/1st time high limit Reject

2nd time low limit Reject/2nd time high limit Reject

Rundown

Revolutions Rundown revolution high limit Reject/rundown revolution low limit Reject

Current Value

Warnings Low current value limit warning/high current value limit warning

Auxiliary Information Signal

Judgment Combination Bits 1 to 8

Allows the configuration of multiple REJECT items to be combined onto single outputs (8 combination outputs available). The configuration of these signals is set using the AFC3000 Software (Fieldbus Message Setup Screen). ● Abnormal Data Items (in common with BCD and ASCII)

Abnormal State No. Details

Abnormal State 1 Torque transducer error

Abnormal State 3 Preamplifier error

Abnormal State 4 System memory error

Abnormal State 5 Servo apply error

Abnormal State 6 Servo type error

Abnormal State 8 Servo amplifier error

Abnormal State 9 Setting data error

Abnormal State 10 Multi signal error


PAGE 20

● 1st Reject (Failure) Item (in common with BCD and ASCII)

Identifies the reason or cause for a fastening that is stopped / interrupted BEFORE reaching the target

torque (or angle) due to a Reject (outside of the programmed limits). (Some programmed limits can cause

the fastening process to stop due to a Reject prior to fastening completion)

Example: A cycle run with a missing fastener will cause a ‘1ST Time High Limit Reject’. A fastener that

reached the Final Angle High Limit setting before reaching Standard Torque will cause a ‘Final Angle High

Limit reject’.

Note: If the fastening reaches the end of the fastening cycle and rejects, no data will be reported in

this data item.

The BCD output format data is shown below for each type of reject item.

Item Output Format (BCD Format)

No REJECT 00

Peak torque high limit REJECT 01

Final torque high limit REJECT 03

Final angle high limit REJECT 05

Rate 1 high limit REJECT 09

Rate 1 low limit REJECT 10





1st time high limit REJECT 15

2nd time high limit REJECT 17

Rundown revolution high limit REJECT

19

Snug torque high limit REJECT 21

Start torque inhibit high limit REJECT

22


PAGE 21

● Fastening Judgment Data Output Items: Example of Spindle Judgment Output Data 1 & 2 (common with

BCD and ASCII format)

The spindle fastening judgment (from a performed fastening cycle) is set by bit allocation of these 2

data bytes. These judgment status bits are set at the end of a completed fastening cycle.

Note: Actual Bit configuration is set using the AFC3000 software in the ‘Fieldbus Message Setup’

screen – Actual bit placement may differ than what is shown.

⋅ Judgment data setting (example from AFC3000 software)

Item Judgment Data 2 (BIT) Judgment Data 1 (BIT)

7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0

Logic OR OR OR OR OR OR OR OR OR OR OR OR OR OR OR OR

ACCEPT ○

REJECT ○

ABNORMAL ○

BYPASS ○

STOP ○

RESET STOP

○

Peak Torque High Limit REJECT

○

Peak Torque Low Limit REJECT

○

Final Torque High Limit REJECT

○

Final Torque Low Limit REJECT

○

Final Angle High Limit REJECT

○

Final Angle Low Limit REJECT

○

~ ･ Error (Abnormal) Data Setting

The error data (Abnormal reason) of Spindle judgment is set by bit allocation of 1 byte. The data

corresponds to the abnormal state No. when an abnormal condition occurs.

Item Error (Abnormal) Data BIT

7 6 5 4 3 2 1 0

Abnormal state 1 (Torque Transducer) ○ Abnormal state 3 (Preamplifier) ○ Abnormal state 4 (System Memory) ○ Abnormal state 5 (Servo Amp Reply) ○ Abnormal state 6 (Servo Type) ○ Abnormal state 8 (Servo Amp) ○ Abnormal state 9 (Parameter) ○ Abnormal state 10 (Multi Signal) ○


PAGE 22

● Example 1: Spindle judgment is “ACCEPT” (Using setup of Judgment data from previous page)

Output Item

1word 2word ①①①① Judgment

Data 1

②②②② Judgment

Data 2 ③③③③ Error Data

④④④④ Occurring

Fastening Reject

Spindle Judgment

01 00 00 00

● Example 2: Spindle judgment is “REJECT”: “Final Torque Low Limit Reject”

Output Item


Data 1




Fastening Reject

Spindle Judgment

02 08 00 04

● Example 3: Spindle judgment is “ABN3-3”

Output Item


Data 1




Fastening Reject

Spindle Judgment

04 00 02 00

● Example 4: Spindle judgment is “REJECT” : “Peak Torque Low Limit Reject”

Output Item


Data 1


Data 2

③③③③ Abnormal

Data ④④④④ 1st Reject Item

Spindle Judgment

02 02 00 02

Also, if the fieldbus message is unset, the following contents are output.

Data Format Output Item Number of

Bytes

BCD Format Spindle cycle count (4 digits) 2bytes

Tool cycle count (4 digits) 2bytes

For each of the cycle counts, numerical values of the millions, hundred thousands, ten thousands, and

thousands places are output as 4-digit BCD data. When the cycle count reaches 9,999,999 (99 99BCD),

the next cycle will be 10,000,000, output as (00 00BCD). In the case of a 32-Spindle system, the total

length of the message data is 64 words (128 bytes).

● Fieldbus Message Output Example (when not set) (Note:PLC output ref. for Allen Bradley)

Format

Spindle No.

Output Item Result Output PLC Output

1 Spindle cycle count 1234 C00 00 01

Tool cycle count 12345 C01 00 12



~

~

~

~

~




PAGE 23

● Message Information Output Example (Multi Format) (Note:PLC output ref. for Allen Bradley)

Multi Format

Output Item Result Output PLC Input (BCD Format) PLC Input (ASCII Format)

Sequence Cycle Count

216 C00 00 00 C00 to

C07 ‘_____216’

C01 02 16

Date 2013-06-21 C02 20 13 C08 to

C17 ‘2013-06-21’

C03 06 21

Time 10:23:36 C04 10 23 C18 to

C25 ‘10:23:36’

C05 36 00

Sequence Judgment REJECT C06 00 01 C26 to

C29 ‘REJ_’

Sequence No. 1 C07 00 01 C30 to

C31 ‘_1’

~

~

~

~

~

Final Message Information

Area

(when 250 bytes are set)

C124 C124

* (20H) is the space code (space).


PAGE 24

● Message Information Output Example (Spindle Format) (Note:PLC output ref. for Allen Bradley)

Spindle Format

Spdl.

No. Output Item

Result

Output PLC Input (BCD Format) PLC Input (ASCII Format)

1

Peak Torque [N･m] 12.34 C00 00 12 C00 to

C07 ‘_12.34__’

C01 34 02

Final Torque [N･m] 12.34 C02 00 12 C08 to

C15 ‘_12.34__’

C03 34 02

Final Angle [deg] 123.4 C04 00 12 C16 to

C23 ‘_123.4HX’

C05 34 01

Rate 1 [N･m/deg] 1.234 C06 00 12 C24 to

C33 ‘__1.234___’

C07 34 03

Rate 2 [N･m/deg] 5.678 C08 00 56 C34 to

C43 ‘__5.678___’

C09 78 03

Rate 3 [N･m/deg] 9.012 C10 00 90 C44 to

C53 ‘__9.012___’

C11 12 03

1st Time [sec] 12.345 C12 01 23 C54 to

C63 ‘_12.345___’

C13 45 03

2nd Time [sec] 6.789 C14 00 67 C64 to

C73 ‘__6.789___’

C15 89 03

2 Peak Torque [N･m] 23.45 C16 00 23

C17 45 02

~

~

~

~

~

3 Peak Torque [N･m] 34.56 C32 00 34

C33 56 02

~

~

~

~

~

4 Peak Torque [N･m] 45.67 C48 00 45

C49 67 02

~

~

~

~

~

Free area C74 C74

~

~

~

~

~

~

Final Message Information

Area

(when max 4096 bytes setup)

C4095 C4095

* (20H) is the space code (space).

Note: Each spindle’s data will reside in the same location regardless of whether the spindle is used in a

particular fastening cycle.

(Example: If a system has 3 connected spindles and spindle #1 is not used in a sequence (for a particular

model for example), then the data for spindle #2 & #3 will only be sent and will reside in their spindles data

location skipping the spindle #1 location)


PAGE 25

PLC Setting Example

This procedure is written for using Rockwell Automation RXLogix5000 V15.02.00 and Allen Bradley

CompactLogix L32E. If the system is not the same as listed above, setup may be different. Please

contact to PLC manufacturer for detail as each PLC may be different

1. Register MASTER Spindle Fieldbus unit to network

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

Select “ABCC” “Anybus-CC Ethernet/IP from “Select module Type” list and click the “Create” button.


PAGE 26

Edit Name of the module and IP address then click “Change…” button for editing I/O Size.

Edit Input and Output size. NOTE: These values must match with the controller’s setup set at page 4 of this document.

I/O Size Setup for AFC3000 Controller.

Click OK button then click Apply button.


PAGE 27

Enter I/O Description into Tag Table Input signal of AFC3000 system fixed as shown in the below table.

Name Description Name Description Name Description

O.Data[0].0 Emergency Stop O.Data[4].0 SEQ NO.17 Select O.Data[8].0 Spindle 11 BYPASS

O.Data[0].1 Reset O.Data[4].1 SEQ NO.18 Select O.Data[8].1 Spindle 12 BYPASS

O.Data[0].2 Reverse O.Data[4].2 SEQ NO.19 Select O.Data[8].2 Spindle 13 BYPASS

O.Data[0].3 Start O.Data[4].3 SEQ NO.20 Select O.Data[8].3 Spindle 14 BYPASS

O.Data[0].4 Sequence Select Bit 0 O.Data[4].4 SEQ NO.21 Select O.Data[8].4 Spindle 15 BYPASS





O.Data[1].1 Cycle Count UP O.Data[5].1 SEQ NO.26 Select O.Data[9].1 Spindle 20 BYPASS

O.Data[1].2 Cycle Count Clear O.Data[5].2 SEQ NO.27 Select O.Data[9].2 Spindle 21 BYPASS

O.Data[1].3 Sequence Select

Method O.Data[5].3 SEQ NO.28 Select O.Data[9].3 Spindle 22 BYPASS

O.Data[1].4 Input Wait Port 1 O.Data[5].4 SEQ NO.29 Select O.Data[9].4 Spindle 23 BYPASS




O.Data[2].0 SEQ NO.1 Select O.Data[6].0 Spindle 1 BYPASS O.Data[10].0 Spindle 27 BYPASS






O.Data[2].6 SEQ NO.7 Select O.Data[6].6 Spindle 7 BYPASS O.Data[10].6




O.Data[3].2 SEQ NO.11 Select O.Data[7].2 ID Data Clear O.Data[11].2 Message Command Request

O.Data[3].3 SEQ NO.12 Select O.Data[7].3 ID Select enable O.Data[11].3 Message Spindle Offset Bit 0

O.Data[3].4 SEQ NO.13 Select O.Data[7].4 O.Data[11].4 Message Spindle Offset Bit 1





PAGE 28

AFC3000 Output signals are programmable as it was mentioned in page 4 of this document. Open “PLC Output Layout Setup” (AFC3000 software)


PAGE 29

In the AFC3000 software, edit the PLC output signal as desired.

Enter the Tag Table Description as it was mapped in AFC3000 Userconsole Software.


PAGE 30

Data Exchange between PLC and MFC Controller

The AFC3000 system supports explicit message function to exchange data between the PLC and controller such as importing part ID data to the controller and exporting fastening result data to the PLC.

Transfer part ID Data to AFC3000 controller using MSG function AFC3000 Userconsole Software Configuration The AFC3000 controller can receive part ID data from its RS232C port or fieldbus message. The Data source needs be selected as “fieldbus” to use this function. In the AFC3000 Software, select RS232C Input Format / Data Input Setup from Multi menu.


PAGE 31

Select “From Fieldbus” at Data Input Select.

Download RS232C Input / Output Format to AFC3000 Controller.


PAGE 32

Adding Message program to PLC One “Message” tag and one SINT[32] tag needs to be added to use this function. In this example, “AFC_PART_ID” AND “PART_ID_DATA” are used.

The size of PART_ID_DATA should match with the Message Size Setup set up in the AFC3000 controller. Refer to page 4 of this document. Add MSG command into PLC Logic program.

MSG command needs be activated “BEFORE” the AFC3000 system receives a START signal.


PAGE 33

The configuration of AFC_PART_ID should be as shown below.

Service Type Set Attribute Single Service Code 10 (Hex) Class A2 (Hex) Instance 1 Attribute 5 Path Specify the AFC3000 controller.


PAGE 34

Part ID Data

Part ID data should be in ASCII formatted data (20 Hex ~ 7E Hex) in order for the AFC3000 system to handle it correctly. However, this ID data is also used as a part of the torque curve file name when it is (set to) save automatically so it is recommended to avoid file name prohibited letters such as /, ¥, ?, %, *, :, |, “, < and > letters.


PAGE 35

Transferring the Fastening Result data to PLC using the MSG function For setting up the MESSAGE function, first the AFC3000 system needs to be configured for the data type that needs to be sent to the PLC. Configuration is done in the AFC3000 Software. Select “Field Bus Message Setup” from “Multi” pull down menu.

Select the DATA TYPE format (BCD or ASCII). Data from the Multi and Axis (Spindle) must be configured in each tab of the table below. The Multi format contains the “Header” data (such as Date, Time, Sequence #, Cycle Count, etc. – aka data that is for all connected spindles). The Axis format contains the actual spindle fastening data (such as Torque, Angle, Time, Rate, etc.) Right click on the table and select the item from the pop-up window that you wish to be transferred to the PLC.

(Example of Multi format selection shown above) Note: Selecting “Null” deletes the item from the list.


PAGE 36

(Example of Axis format selection shown below – 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 total fastening status 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 32 spindles


PAGE 37

After the fastening result data has been selected, download the configuration to the AFC3000 controller. The setup for this configuration is part of “FIELDBUS MESSAGE SETUP” file (.nrmes).


PAGE 38

Adding program to PLC One “Message” tag and one SINT[250] tag needs be added to use this function. In this example, “FASTENING_RESULT” AND “FASTENING_RESULT_DATA” are used.

The size of FASTENING_RESULT_DATA should match with Message Size Setup set for AFC3000 controller. Refer to page 4 of this document. Add MSG command into PLC logic program.

MSG command needs be activated “AFTER” AFC3000 system complete fastening cycle.


PAGE 39

The configuration of FASTENING_RESULT should be as shown below.

Service Type Get Attribute Single Service Code e (Hex) Class A2 (Hex) Instance 1 ~ 17 Attribute 5 Path Specify the AFC3000 controller.


PAGE 40

Fastening result and tag memory.


PAGE 41

Retrieving more than 250 bytes of data The AFC3000 system can send up to 4096 bytes of fastening result data but the explicit message function can only transfer 250 bytes at time (by protocol limitation). To retrieve the fastening data after 250th byte, change the instance ID in the MSG function to switch the memory area to be retrieved.

Add another set of message and data tag logic and call the MSG function for second 250 bytes.

Documents

AFC3000 Ethernet-IP Fieldbus Expansion Unit