cooper tme manual

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PL12EN-1300 08/05

N O R T H A M E R I C A

Cooper Power ToolsP.O. Box 1410

Lexington, South Carolina 29071-1410

E U R O P E

Cooper Power Tools GmbH & Co.Postfach 30

D-73461 Westhausen

Electric Tool Control

TME-100 Series

Version 2.4.1

Reference Document: PL12-1400 Parts Manual

For additional product information visit our website at http://www.coopertools.com

Programming Manual



Electric Tool Control TME-100 Series

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Disclaimer:

The information and data in this document has been prepared to the best of our ability.

Nonetheless, differences between the information and the actual product cannot be

excluded with absolute certainty. Cooper Power Tools does not assume any liability for

consequential errors and damages. We likewise do not assume liability for damages

resulting from defective circuitry inside the devices supplied. Cooper Power Tools

reserves the right, to ammend, supplement or improve this document or the productwithout serving prior notice.

Without the express approval of Cooper Power Tools this document must not be repro-

duced in its entirity or in part by any means; it must not be converted to any type of natu-

ral or machine readable language or be saved on data storage media of electronic,

mechanic, optical or other type.




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Contents Page

1 Getting Started 7

1.1 Safe Work Practices Symbol................................................................ 71.2 Checking Your Unit ............................................................................... 7

1.3 Software ............................................................................................... 71.4 Installing Unit ........................................................................................ 71.4.1 General................................................................................................. 71.4.2 Mounting............................................................................................... 81.4.3 Location Considerations....................................................................... 81.4.4 Source Power....................................................................................... 81.4.5 Intended Use........................................................................................ 81.4.6 EMC Measures..................................................................................... 91.5 Connecting Unit .................................................................................... 91.5.1 General................................................................................................. 9

1.6 Energizing Unit ................................................................................... 10

Attachment A.1 12

2 Controller Specifications 13

2.1 Understanding the Keypad................................................................. 132.2 Specifications ..................................................................................... 142.2.1 Enclosure ........................................................................................... 142.2.2 Display................................................................................................ 142.2.3 Keypad Overlay .................................................................................. 15

2.2.4 Indicators ............................................................................................ 152.2.5 CPU with PC 104................................................................................ 152.2.6 AC Input Power .................................................................................. 162.2.7 Inernal DC Power ............................................................................... 162.2.8 Input / Output Connectors .................................................................. 16

3 Programming 21

3.1 Navigator Menu .................................................................................. 213.1.1 Basic Navigation Instructions ............................................................. 213.1.2 Password Function............................................................................. 213.1.3 Print Screen........................................................................................ 223.1.4 Two Channel Features: General Description

(2-Channel V2.xx.xx C2 only)............................................................. 223.1.5 Navigator Menu .................................................................................. 233.2 Basic Application Builder.................................................................... 243.2.1 Basic Parameters for Torque Control / Angle Monitor ........................ 253.2.2 Basic Parameters for Angle Control / Torque Monitor ........................ 253.2.3 Basic Application Builder Parameters ................................................ 26




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3.2.4 Advanced Parameter Default Values .................................................. 263.2.5 Basic Application Builder / Copy ......................................................... 273.3 Standard Application Builder ............................................................... 283.3.1 Standard Application Builder / View Stages ........................................ 283.3.2 Standard Application Builder / View Stages / Copy............................. 293.3.3 Standard Application Builder / Select Sequence................................. 303.3.4 Standard Application Builder / Parameters ......................................... 323.3.5 Standard Application Builder / Advanced Parameters ........................ 383.4 Advanced ............................................................................................ 403.4.1 Advanced Application Builder / Application Matrix.............................. 403.4.2 Advanced Application Builder / Inputs................................................. 413.4.3 Advanced Application Builder / Outputs.............................................. 443.4.4 Advanced Application Builder / Fieldbus............................................. 473.4.5 Advanced / Linking.............................................................................. 513.4.6 Advanced / System Settings ............................................................... 523.5 RUN Screen........................................................................................ 54

3.5.1 Run Screen / Tool 2............................................................................. 563.5.2 Run Screen / Split Screen................................................................... 563.5.3 Run Screen / Configure....................................................................... 573.6 Oscilloscope........................................................................................ 583.7 Communication ................................................................................... 593.7.1 Communications / Data Transmission................................................. 593.7.2 Communication / Part ID..................................................................... 623.7.3 Communications / Printer.................................................................... 663.7.4 Communications / Work Cell ............................................................... 673.8 Tool Setup ........................................................................................... 683.9 Tool Library.......................................................................................... 69

3.9.1 Tool Library.......................................................................................... 693.10 Statistics.............................................................................................. 703.10.1 Statistics / Chronological History......................................................... 703.10.2 Statistics / Graphs ............................................................................... 713.10.3 Statistic / Parameter............................................................................ 743.11 Diagnostics.......................................................................................... 753.11.1 Inputs / Outputs................................................................................... 753.11.2 Diagnostic / Fieldbus........................................................................... 763.11.3 Tool / Calibration ................................................................................. 773.11.4 Tool / Angle Encoder ........................................................................... 783.11.5 Tool / Voltages..................................................................................... 793.11.6 Tool / TQ Measurement....................................................................... 803.11.7 Tool / Speed ........................................................................................ 813.11.8 Tool / Tool Memory .............................................................................. 823.11.9 Arcnet / Map........................................................................................ 823.11.10 Arcnet / Statistic .................................................................................. 833.11.11 Serial ................................................................................................... 853.11.12 Event Log............................................................................................ 863.12 Utilities................................................................................................. 87




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3.12.1 Utilities / Update Software .................................................................. 873.13 Administration..................................................................................... 883.13.1 Administration / Load/Save................................................................. 883.13.2 Administration / Print .......................................................................... 893.13.3 Administration / Password.................................................................. 903.13.4 Administration / Date & Time.............................................................. 913.13.5 Administration / Language.................................................................. 923.13.6 Administration / Counter..................................................................... 93

4 Statistics 95

4.1 Understanding Statistics ..................................................................... 954.1.1 The Nature of Variation....................................................................... 954.1.2 The Normal Curve .............................................................................. 954.1.3 The Procedure.................................................................................... 964.1.4 System Improvement........................................................................ 100

4.2 Statistic Symbols .............................................................................. 101

5 Glossary 103

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1 Getting Started

1.1 Safe Work Practices Symbol

!

The signal word "Warning" identifies all notes on safe work practices in this operating

instruction, alerting to hazards for life and health of people. Observe these notes and pro-ceed with special care in the cases described. Pass all safety instructions on to other

operators. In addition to the safety instructions in this operating instruction, the general

local safety and accident prevention rules must be observed.

CAUTION!The signal word "Caution!" identifies all portions of this operating instruction meriting

special attention to ensure that guidelines, rules, hints and the correct work procedures

are observed; and, to prevent damage to and destruction of the machine and/or parts.

1.2 Checking Your Unit

Take the time to ensure you have the required peripheral equipment and cables necessary to

setup and run your unit. If you do not have all the necessary items, contact your distributor.Refer to “Attachment A.1” on page 12 for illustration of your unit.

1.3 Software

Your unit has been pre-loaded with version 2.4.1 software and requires no additional software to

begin your fastening process. If you are interfacing your unit with an external computer, interfac-

ing software is required. Contact your distributor for the interfacing software.

1.4 Installing Unit

1.4.1 General

!It is mandatory that national, state and local safety and wiring standards be followed dur-

ing installation. These standards would take precedence over any information presented

in this section.

To avoid the hazard of electrical shock or burn, the following instructions must be

adhered to. Failure to follow these instructions may also cause damage to your unit and

void existing warranties.

• Do not energize the unit until all connections have been properly made.

• Equipment must be properly grounded before applying power. Units energized by

cord and plug must be connected to an approved and properly grounded receptacle.

• All units must be energized by an isolated line.

• The unit door must always be closed and secured prior to energizing the unit.

• Ensure the power switch is in the "off" position prior to connecting the power cord.

CAUTION!Though it is not mandatory, the following instructions are highly recommended for the

protected operation of your unit.

• Use an isolation transformer and surge arrestor on the incoming isolated line.

• Use oversized feeder lines to reduce electrical noise and voltage drop.




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1.4.2 Mounting

Each unit is used primarily as a single tool process/controller/monitor installed in a work station

or work area. It may be wall mounted, table mounted, beam mounted, suspended overhead,

pedestal mounted or used without mounting. Always choose a stable location to avoid the possi-

bility of unit damage and/or operator injury through hitting, falling, vibration or inconvenient

mounting. All cables attached to the unit should be located and secured in a manner to avoid

potential operator and passer-by injury. As with all electrical equipment, the unit will producesome heat and should be located so that ambient air can freely circulate around the box.

Refer to Illustration Q of the parts manual, PL12-1400 for mounting hole dimensions.

1.4.3 Location Considerations

Your unit should be located to allow access to the front panel and connectors. The unit should

be installed for unrestricted and comfortable viewing of the LCD & LED's by the operator. The

LCD menu screen, key pad and side door connectors must be readily accessible for the setup.

Dependent on the peripheral equipment purchased, the unit may be located in a remote position

but should still be accessible.

Attachment of accessories and tools should also be considered with the installation locations.

Items to be considered are:

• Location of printer (10 ft. cable maximum for the parallel interface).

• Attachment of a data collection unit, if desired.

• Attachment of redundant master transducers (less than 50 ft. is desirable).

• Attachment of remote annunciators, socket nest, or remote parameter select.

• Attachment of the unit in a network to a computer.

• Operation convenience/safety - keep cables off the floor or dangling in operator areas.

1.4.4 Source Power

Your unit, which is used as the process control and power supply for the Cleco DC electric tools,requires a power line with 10 amp capacity at 220-240 Volts AC (50/60 Hz) for the TME-111-30.

The TME-111-15 requires a power line with 15 amp capacity at 110-130 Volts AC (50/60 Hz).

1.4.5 Intended Use

The Electric Tool Control TME-100 Series must be operated only if the following condi-

tions are met:

• Industrial environment, EMC (electromagnetic compatibility) class A

• Use only the cable types approved by Cooper Power Tools.

• Use only accessory parts approved by Cooper Power Tools.

• Unauthorized remodelling, repairs, and modifications are forbidden for safety and product lia-

bility reasons.




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1.4.6 EMC Measures

• The filters required to meet the EMC regulations are integrated.

• The closed control cabinet and the shielded cables result in very low noise radiation and high

immunity to interference.

• The following relevant EMC regulations are met:

- EN 61000-6-4: 08-2002- EN 61000-6-2: 08-2002

- EN 61000-3-2: 2000

- EN 61000-3-3: 1995

• This is a class A device. In domestic areas, this device can cause radio interference. If

that is the case, the company operating it, can be obliged to introduce EMC measures

and cover the cost incurred.

• Operation without closed control cabinet is forbidden.

The properties of the shielding would be altered and the noise emission increase.

1.5 Connecting Unit

1.5.1 General

Connect all equipment to the correct input and output connectors. Refer to “Attachment A.1” on

page 12 for proper port locations.

!To avoid the hazard of electrical shock or burn the following instructions must be



• Ensure the power switch is in the "off" position and that the box cover is properly

secured prior to connecting power cord.

• Ensure equipment has been properly grounded before applying power.




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1.6 Energizing Unit

!To avoid the hazard of electrical shock or burn the following instructions must be



Upon application of power, the unit will initiate a self test. The initialization takes approximately

45 seconds.

The introduction screen shown below will be displayed for approximately 10 seconds and then

the Run Screen will be displayed.

c00276de.bmp

Fig. 1-1: Introduction Screen

c00407en.bmp

Fig. 1-2: Run Screen




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Press the Ship‘s wheel to display the Navigator Menu. After the Navigator Menu is displayed,

verify the Tool Memory by entering Tool Setup. If Tool Memory is not active then select a tool

using the Tool Library. Press the ship's wheel to return to the Navigator Menu.

Once Tool Setup is complete the application needs to be programmed. To do this, go to Basic

Application Builder. From this screen torque, angle, and speed parameters must be entered for

the selected application. Press the ship's wheel to return to the Navigator Menu.

The controller is now ready to begin fastening cycles. The torque and angle data can be viewedby pressing the Run Key. Tool and controller indicator lights will illuminate according to the

results.




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Attachment A.1

Mounting

Bracket

Sidedoor

Assembly

Connector

Box

(see detail

below)

Double-Bit

Enclosure

LCD

Display

Indicator

Lights

Keypad

Fig. 1-3: Controller

Tool Connector

Floppy Drive

Printer Power Out

Power In

Double-Bit Enclo-

sure key

Power Switch

I/O Outputs

I/O Inputs

Serial Ports (2)

Printer Port

Keyboard Port

.1 .1

Fig. 1-4: Connector Box Detail




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2 Controller Specifications

2.1 Understanding the Keypad

The following is a brief explanation of the keypad keys. You will need to become familiar with

these keys so you can smoothly program your unit.

Soft Keys (F1-F4) - used to select functions based on the screen displayed.

ESC Key - used at any time to return back one screen or exit the edit mode.

DEL Key - used to delete a numerical value on the LCD screen.

Arrow Keys - used to move the orange highlight around the screen.

ENTER Key - used to accept an answer/value on the LCD screen.

Ships Wheel - used at any time to return to the navigator menu.

Run - used at any time to return to Run Screen.

Soft Keys

Ship´s Wheel




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2.2 Specifications

2.2.1 Enclosure

Model Weight* Width Height Depth

lb kg in mm in mm in mm

TME-111 80 36.4 16.5 419.1 17.5 444.5 12.3 312.4

* Mounting plate adds weight of 7 lbs / 3.2 kg and depth of 1.62 in / 41.1 mm

• Designed for NEMA 13/IP54 rating

• Lockable front door for customer specific key requirements

• Lockable 3-phase power switch

• Side door for connector/cable protection

• Removable Mounting Plate

• Removable, fully operational internal chassis

• Conductive front door gasket and lip to meet EMI regulations

• Orange textured powder coat

2.2.2 Display

• 7.7 in Passive Matrix Color LCD Module

• 640 x 480 resolution

• CCFT backlight

• Contrast and Brightness control




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2.2.3 Keypad Overlay

Key Definitions

Key Description

0-9 Numbers 0-9

. Decimal point

DEL Delete

ESC Escape

Navigator Menu

RUN Run Screen

Up Arrow

Down Arrow

Left Arrow

Right Arrow

ENTER Enter

Orange Border 4 Soft Keys

2.2.4 Indicators

5 Highly visible indicators

• 2 red groupings

• 1 green grouping

• 2 amber groupings

• Each grouping contains 12 high intensity LED´s @ 30 mcd each

2.2.5 CPU with PC 104

Minimum Requirements

• Pentium 166 Mhz

• 32 MB DRAM

• 32 MB DiskonChip

• 2 serial ports

• 1 parallel port

• Ethernet 100-Base T

• PC Keyboard input

• PC/104 Bus

• Floppy interface

• LCD/Flat Panel controller




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Arcnet PC/104 board

• Arcnet communication

• 4 +24 V inputs

• 12 +24 V outputs

• 24-position keypad decoder

• Battery-Backed SRAM, 1 MB

External I/O PC/104 board

• 8 optically isolated inputs

• 8 relay outputs

2.2.6 AC Input Power

• Selectable 115 VAC @15 A or 230 VAC @ 10 A, +/-5% on all voltages. External fuse should

be slow blow.

• Internal fuse

• Fault current circuit-breaker (10 mA)

• Isolation Transformer 4.5 kVA peak, meets VDA 0570 norm

Note: If necessary it's possible to connect two units to one 230 VAC power supply with a 16 A

slow blow fuse (C-Type).

2.2.7 Inernal DC Power

• Input: 85 VAC-264 VAC

• Output: +5 VDC @ 5 A, +12 VDC @ 1 A, +24 VDC @ 3 A, +/-5% on all voltages

• 110 W capability without a fan

• MTBF->20,000 hours

2.2.8 Input / Output Connectors

Tool Connector Matrix MS83723R/2028N

Serial (2) 9-pin Male D-Shell

Parallel 25-pin Female D-Shell

Keyboard Mini 6-DIN

Inputs (+24 V) Phoenix MSTBV 2,5/12-GF-5,08 Order No. 1777170

Outputs Phoenix ICV 2,5/12-GF-5,08 Order No. 1825792

Floppy 3.5in 1.44 MB

AC Power Input Standard male receptacle

AC Power Output Standard female receptacle



Tool

Pin # Description Value

1 +Excitation +12 V +/- .05 V

2 -Excitation 0 V

3 + Torque signal 0 to +5 V4 0 V Torque signal 0 V

5 Tool Memory TXD - -3 V to +3 V

6 Tool Memory TXD + -3 V to +3 V

7 Tool Memory RXD - -3 V to +3 V

8 Tool Memory RXD + -3 V to +3 V

9 Resolver Carrier R1 7 VAC

10 Resolver Carrier R2 0 VAC

11 Resolver Cosine S1 7 VAC

12 Red LED 0 to +24 V

13 Signal GND 0 V

14 Yellow LED 0 to +24 V

15 Motor PE 0 V

16 Start Switch 0 to +24 V

17 Reverse Switch 0 to +24 V

18 +24V +24 V

19 Motor Phase C 0 to 300 V

20 Transducer Calibration 0 to +5 V

21 Temperature Sensor + 0 to +5 V

22 Temperature Sensor - 0 to +5 V

23 Motor Phase B 0 to 300 V

24 Resolver Sine + S2 7 VAC

25 Resolver Cosine S3 0 VAC

26 Resolver Sine S4 0 VAC

27 Motor Phase A 0 to 300 V

28 Green LED 0 to +24 V

Housing PE 0 V


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Serial


1 DCD -25 V to +25 V

2 RxD -25 V to +25 V

3 TxD -25 V to +25 V

4 DTR -25 V to +25 V

5 GND 0 V

6 DSR -25 V to +25 V

7 RTS -25 V to +25 V




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8 CTS -25 V to +25 V

9 RI -25 V to +25 V

Parallel


1 Strobe 0 to +5 V

2 Data 0 0 to +5 V

3 Data 1 0 to +5 V

4 Data 2 0 to +5 V

5 Data 3 0 to +5 V

6 Data 4 0 to +5 V

7 Data 5 0 to +5 V

8 Data 6 0 to +5 V

9 Data 7 0 to +5 V10 Acknowledge 0 to +5 V

11 Busy 0 to +5 V

12 Paper Out 0 to +5 V

13 Select Out 0 to +5 V

14 Auto Feed 0 to +5 V

15 Error 0 to +5 V

16 Initialize 0 to +5 V

17 Select In 0 to +5 V

18 Gnd 0 V

19 Gnd 0 V20 Gnd 0 V

21 Gnd 0 V

22 Gnd 0 V

23 Gnd 0 V

24 Gnd 0 V

25 Gnd 0 V

Keyboard

Pin # Description Value1 Data 0 to +5 V

2 N/C N/A

3 Gnd 0 V

4 Power 0 to +5 V

5 Clock 0 to +5 V

Serial



Inputs


1 +24 V (Output) +24 VDC

2 Input 0 0 to +24 V

3 Input 1 0 to +24 V4 Input 2 0 to +24 V






10 Input Common (Input) 0 V

11 Signal Gnd (Output) 0 V

12 Spare N/A


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For signal description please see chapter 3.4.2Advanced Application Builder / Inputs41.

Outputs


1 +24 V (Output) +24 VDC

2 Output Common (Output) 0 to 30 V

3 Output 0 0 to 30 V




7 Output 4 0 to 30 V8 Output 5 0 to 30 V



11 Signal Gnd (Output) 0 V

12 Spare N/A

For signal description please see chapter 3.4.3Advanced Application Builder / Outputs44.




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3 Programming

3.1 Navigator Menu

c00277en.bmp

Fig. 3-1: Navigator Menu

3.1.1 Basic Navigation Instructions

nav.txtS

Each field in a screen is selectable with an orange highlight using the 4 arrow keys and Enter.

Upon entering a screen the top left most field is always highlighted. The Navigator key (ship's

wheel) will always return the user to the Navigator Menu. At the bottom of the screen 4 soft keys

are available. These functions will change from screen to screen. In some cases the screen

label will contain the (>>) character to indicate more functions are available when the key is

pressed.

To edit a textbox the user can use 0-9 or the DEL keys. To exit the edit mode the user can press

the arrow keys to move the highlight or press the ESC key. The ESC key will return the original

value.

In order to describe the soft key functions the left soft key is referred to as F1, center left soft key

F2, center right soft key F3 and right soft key F4. They are located in the orange display border.

F4 is always functions as Help for that screen.

Applications are selectable 1-255. When entering an application number of 1 or 2 digits (1-99), a

cursor blinks in the edit box. The number is accepted when the <ENTER> key is pressed, or

after 3 seconds. A 3 digit application number (100-255) is accepted as soon as the third charac-ter is typed.

Stages are selectable 1-6.

3.1.2 Work Cell

The user can connect to a remote unit by selecting Work Cell (F3) and choosing the IP Address

of the remote unit. To return, select Local TM Unit in the Work Cell List. To add units to the Work

Cell List, use the Work Cell screen in Communications.




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3.1.3 Password Function

Passwords can be configured to operate in one of two modes: Read Protected or not Read Pro-

tected. Refer to Administration / Password for configuration details

Read Protected: A password is required when selecting a section from the Navigator menu. It is

only required to enter the password once. If the user exits a section with programmable data

(Basic, Standard, Advanced, Communications, Tool Setup) that has been changed, then onlythe confirm entry in the password dialog is displayed.

Not Read Protected: No password is required when selecting a section from the Navigator

menu. If the user exits a section with programmable data (Basic, Standard, Advanced, Commu-

nications, Tool Setup) that has been changed, then the password entry dialog will be displayed.

If no password is activated, then only the confirm entry in the password dialog is displayed.

Once the password has been entered, it must be entered each time an appropriate screen is

exited.

3.1.4 Print Screen

A Print Screen function is available on all screens. In some cases a Print Screen soft key hasbeen added that will allow the bitmap to be saved to the floppy disk, disk, or print directly to a

printer (Laser, Inkjet). On screens that do not have this soft key, the user can reach this function

by pressing the "0" key. A dialog box allowing the user to assign a filename will be displayed.

Using the arrow keys, highlight the filename and enter up to 8 characters, then activate Accept

to save to the floppy.

3.1.5 Two Channel Features: General Description (2-Channel V2.xx.xx C2 only )

The user interface is identical to the single-channel configuration. On all screens, the data for

the currently selected tool is displayed. The current tool is selected by entering a 1 or 2 in the

“Tool” edit box. The Tool may be selected from the Run Screen, Basic Application Builder, Stan-

dard Application Builder, or Statistics screens. On screens where there is no Tool edit box, thecurrently selected tool is displayed in the blue title bar at the top of the screen. Both tools are

always operable regardless of which tool is currently selected by the user interface.

All editable parameters are set and saved individually for each tool, with the following excep-

tions:

• Language

• Date/Time

• Passwords

• Field Bus Parameters

• Torque Units

• Run Screen 2-Tool Display Configuration (Auto-select)

• Ethernet protocol, IP addresses and port number

• System Settings/General “Same for both tools” option (See “Advanced / System Settings”)

The 2-channel model has the following limitations:

• Field Bus (DeviceNet/Profibus): When active, all inputs and outputs are only applicable to the

operation of Tool 1.

• The auto-select feature does not apply to the Oscilloscope screen.




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3.1.6 Navigator Menu

Basic Application Builder

Basic Application Builder allows the user to graphically select and program a two-stage rundown

for Torque Control/Angle Monitor (Seq11+Seq30) or Angle Control/Torque Monitor

(Seq11+Seq50) for any of the 255 Applications. The user only enters Torque, Angle, and Speed

Setpoints in one screen. Other parameters such as timers, etc are automatically defaulted topre-determined values.

Standard Application Builder

Standard Application Builder allows the user to program up to a 6-stage rundown for any of the

255 Applications. Once the fastening sequences are selected for each stage, the associated

Torque, Angle, Speed, and Advanced parameters can be programmed.

Advanced Application Builder

Advanced Application Builder allows the user to View all Application setups at once, and per-

form I/O Mapping. The Application Matrix shows an overview of Application and Stage program-

ming by displaying the selected Fastening Sequence for each stage. I/O Mapping lets the user

select from a list of functions and assign that function to a given input or output.

RUN Screen

The Run Screen button takes the user directly to the display for Torque, Angle, and Status Indi-

cator Labels. The Oscilloscope function used for diagnosing torque traces is also located in the

Run Screen.

Communications

The Communications Setup allows the user to configure all communications for the Printer and

Serial Data Transmission. Appropriate communications settings for protocol, port, baud rate, etc

can be set in this screen.

Tool Setup

The Tool Setup displays the Tool Memory Data and allows the user to modify this information by

changing it directly or selecting from the Tool Library.

Statistics

Chronological History and associated statistics are viewable from this screen. Data can be

erased and printed as well.

Diagnostics

The System Diagnostics contains screens to determine if the system is functioning properly.

There are diagnostics for I/O, Arcnet, Tool and Tightening Module, Serial Communications, and

Transducer Calibration.

Utilities

Utilities contains functions for upgrading or changing the system software. From the Utilities

screen the user can update the TME-100 application software from the floppy, or install a new

firmware version in the Tightening Module from the floppy.




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Administration

From the Administration screen the user can load, save and configure system information.

Administration functions include loading and saving the system configuration to a diskette, set-

ting date and time, setting password protection, and printing the system configuration, and

selecting the application software language (English, German, Italian, Spanish, Czech, Portu-

guese, French, Polish, Dutch).

Work Cell

To connect to a remote unit configured in the work cell, press the <F3> "Work Cell" button from

the Navigator menu. From the "Work Cell List" dialog box, press the <ENTER> key do display

the droplist of configured units. Use the up or down arrow keys to select the desired unit, then

press the <ENTER> key again. Press the down arrow key to highlight the "OK" button and press

the <ENTER> key again. The user interface switches control to the selected unit. When a

remote unit is selected the IP address, station name, and station number of that unit are dis-

played in the title bar of all screens.

To return control to the local unit, return to the Navigator menu and use the above procedure,

this time selecting "Local TM Unit" in the Work Cell List dialog.

nav.txtE

3.2 Basic Application Builder

c00278en.bmp

Fig. 3-2: Torque Control / Angle Monitor



c00279en.bmp


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Fig. 3-3: Angle Control / Torque Monitor

basic.txtS

The Basic Application Builder allows the user to select a typical two-stage rundown where the

first stage is a high speed rundown and the second stage is a lower speed rundown that controls

on either torque or angle.

Fastening Strategies Torque Control/Angle Monitoring (Sequence 11/Sequence 30) or Angle

Control/Torque Monitoring (Sequence 11/Sequence 50) are selectable from the drop down list-

box in the upper right hand corner of the screen. Once a Strategy is selected, the appropriate

Parameters will be displayed for programming.

3.2.1 Basic Parameters for Torque Control / Angle Monitor

• Trigger Torque [Nm] - Torque to start collecting oscilloscope data.

• Turnoff Torque Stage 1 [Nm] - Torque to change from stage 1 to stage 2.

• Threshold Torque [Nm] - Torque to begin counting angle in stage 2.

• Torque Low Limit [Nm] - Minimum acceptable torque.

• Turnoff Torque Stage 2 [Nm] - Torque to turnoff the tool.

• Torque High Limit [Nm] - Maximum acceptable torque.

• Angle Low Limit [Deg] - Minimum acceptable angle.

• Angle High Limit [Deg] - Maximum acceptable angle.

3.2.2 Basic Parameters for Angle Control / Torque Monitor

• Turnoff Angle [Deg] - Angle to turnoff the tool.

• The rest of the Parameters are the same as Torque Control/Angle Monitor except Turnoff

Torque Stage 2 is eliminated.

Below are the acceptable ranges for each Parameter and its default value. For initial program-

ming, the Parameters automatically use the default values.




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3.2.3 Basic Application Builder Parameters

Parameter Name Range Typical

Fastening Strategy Torque Control/Angle Monitor

Angle Control/Torque Monitor

Torque Control/Angle Monitor

Trigger Torque [Nm] 0 to Tool Max 10% of Turnoff Torque

Turnoff Torque Stage 1 [Nm] 0 to Tool Max As appropriate

Threshold Torque [Nm] 0 to Tool Max 50% of Turnoff Torque

Torque Low Limit [Nm] -Tool Max* to Tool Max 90% of Turnoff Torque

Turnoff Torque Stage 2 [Nm] Low Limit to Tool Max As appropriate

Torque High Limit [Nm] Turnoff to 1.2 TQ-Cal. value 110% of Turnoff Torque

Angle Low Limit [Deg] 0 to 9999 90% of Turnoff Angle

Turnoff Angle [Deg] Low Limit to 9999 As appropriate

Angle High Limit Turnoff to 9999 110% of Turnoff Angle

Speed Stage 1 [RPM] 0 to Tool Max 80% of Tool Max

Speed Stage 2 [RPM] 0 to Tool Max 50

* Note: negative values may be entered by preceeding the value with two dots ".."

In the Basic Application Builder some parameters are not programmable and are also set to

default values. These values are located in the Standard Application Builder under Advanced

Parameters. However, if the parameters are changed using the Standard Application Builder,

then the Basic Application Builder does not reset them back to the default values.

3.2.4 Advanced Parameter Default Values

Parameter Name Stage 1 Stage 2

Start delay time [mS] 0 0

Start spike time [mS] 0 0

Max. Fastening time [mS] 10000 10000

End delay time [mS] 0 30

Torque Filter Factor 1 1

If an Application with more than two stages is required, or if a different Fastening Strategy has

previously been selected for the Application than described above, the Standard Application

Builder must be used.




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3.2.5 Basic Application Builder / Copy

c00362en.bmp

Fig. 3-4: Torque Control / Angle Monitor / Copy

From the Basic Application Builder, the user can copy the parameters of an application to one or

more other applications by pressing the Copy (F3) soft key. From this dialog box, the user can

specify the source and target tool and application. When using Copy function from the Basic

Application Builder, all stages of the selected application are copied. Multiple target applications

may be specified by separating the application numbers with a period as shown.

basic.txtE




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3.3 Standard Application Builder

3.3.1 Standard Application Builder / View Stages

c00280en.bmp

Fig. 3-5: View Stages

viewstag.txtS

From View Stages, Stages 1-6 and a Backoff Stage are programmable for a given tool and appli-

cation.

When the tool is started, each Stage having a programmed Fastening Sequence will be run in

succession based on the results from the previous stage. The Backoff Stage is used when the

tool is run in back-off direction or with the reverse button activated.

When the Counter Clockwise box is checked, each stage is run with the tool tightening in a

counter-clockwise direction. Sequence 41 (angle controlled backout) and the Backoff Stage are

run in the clockwise direction.

WARNING: When the Counter-Clockwise box is checked, the normal direction of rotation

is opposite from what is indicated by the label of the Reverse swich on the tool.

If a sequence has not been selected for a stage, then N/A is displayed for that stage. Otherwise

the Sequence number, description and icon are displayed. Sequences can be selected or

changed using the Select Seq (F1) soft key. This key is only valid when stages 1-6 are high-

lighted. The Fastening Sequence for the Backoff Stage is selected automatically.The parameters for any stage can be programmed using the Parameters (F3) soft key. This key

is only valid when a Sequence has been selected for a given Stage.




en03d141.fm, 07.10.2005 PL12EN-1300 08/05 29

3.3.2 Standard Application Builder / View Stages / Copy

c00366en.bmp

Fig. 3-6: View Stages / Copy

From the Standard Application Builder, the user can copy the parameters of an application or

stage to one or more other applications or stages by pressing the Copy (F2) soft key. From this

dialog box, the user can specify the source and target tool, application, and one or all stages. A

single stage can be copied to multiple applications and/or stages. Multiple target applications

and stages may be specified by separating the numbers with a period as shown.

viewstag.txtE




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3.3.3 Standard Application Builder / Select Sequence

c00281en.bmp

Fig. 3-7: Select Sequence

selectse.txtS

Fastening Sequences are selectable for a given Tool, Application and Stage by using the Control

and Monitor check boxes or selecting a Fastening Sequence directly from the drop down listbox.

The following Fastening Sequences or Fastening Strategies are available:

Sequence 11 High Speed Rundown

Sequence 30 Torque Control/Angle Monitor

Sequence 50 Angle Control/Torque Monitor

Sequence 41 Angle Controlled Backoff

When a Sequence is selected the Control and Monitor check boxes and Fastening Sequence

listbox will both display the appropriate settings for the selected Sequence. An icon portraying

the selected Sequence is also displayed in the bottom right-hand corner.

The following table shows a matrix of the Control and Monitor schemes for each Sequence:

Sequence 11 Sequence 30 Sequence 50 Sequence 41

Control

Torque Control X X

Angle Control X

Angle Control Reverse X

Monitor

Torque Monitor X X

Angle Monitor X X X

The Parameters (F3) soft key allows the user to program all associated control parameters for

the selected Sequence. It is only valid when a Sequence has been selected.




en03d141.fm, 07.10.2005 PL12EN-1300 08/05 31

The following is a detailed description of each Fastening Sequence:

Sequence 11

High Speed Rundown

This tightening method is generally used as a fast pre-tightening stage. The torque transducer

integrated into the nutrunner measures the torque during the tightening. The value is processed

by the control system. When the defined Turnoff Torque is reached the nutrunner is shut off.

Thereafter the peak torque is measured during a dwell time and is then processed as the tight-

ening torque of the bolt in the control system. This value is displayed on the Run Screen and can

be output to a printer or transmitted to other system components by data communication. When

the trigger torque is reached the torque curve is recorded and can be viewed and evaluated

using the oscilloscope function.

Sequence 30

Torque Control with Torque and Angle Monitoring

This tightening stage is normally preceded by a fast pre-tightening stage. The transducer inte-

grated into the nutrunner measures the torque and the resolver measures the angle during the

tightening. The values are processed by the control system. When the threshold torque is

reached the angle count starts. When the Turnoff Torque is reached the nutrunner is shut off.

Thereafter the peak torque is measured during a dwell time and is then processed as the tight-ening torque of the bolt together with the evaluation of the rundown in the control system. This

value is displayed on the Run Screen and can be output to a printer or transmitted to other sys-

tem components by data communication. When the trigger torque is reached the torque curve is

recorded and can be viewed and evaluated using the oscilloscope function.

Sequence 50

Angle Controlled Tightening with Angle and Torque Monitoring

This tightening sequence is generally preceded by a fast pre-tightening cycle. The transducer

integrated into the nutrunner measures the torque and the resolver measures the angle during

the rundown. The values are processed by the control system. When the Turnoff angle is

reached the nutrunner is shut off. Thereafter the final angle and the peak torque are measured

during a dwell time, and these tightening values for the bolt are then processed together with theevaluation of the rundown in the control system. These values are displayed on the Run Screen

and can be output to a printer or transmitted to other system components by data communica-

tion. When the trigger torque is reached the torque curve is recorded and can be viewed and

evaluated using the oscilloscope function.

Sequence 41

Angle Controlled Back-off with Angle Monitoring

This fastening sequence is generally used to loosen a bolt a specified number of degrees. The

resolver integrated into the nutrunner measures the angle during the untightening. The value is

processed by the control system. When the Turnoff angle is reached the nutrunner is shut off.

Thereafter the final angle is measured during a dwell time and is then processed as the back-off

angle of the bolt together with the evaluation of the untightening in the control system. This valueis displayed on the Run Screen and can be output to a printer or transmitted to other system

components by data communication. In this stage the oscilloscope function is not supported.

selectse.txtE




32 PL12EN-1300 08/05 en03d141.fm, 07.10.2005

3.3.4 Standard Application Builder / Parameters

c00282en.bmp

Fig. 3-8: Parameters

paramete.txtS

Parameters are programmable for a given Tool, Application and Stage based on the selected

Fastening Sequence and only the appropriate parameters are displayed for the selected Fasten-

ing Sequence.

The Next Stage (F2) key will increment to the next stage until it reaches the last stage having a

selected Sequence. It will then rollover to the first stage. In order to add a stage without a

selected Sequence the user must highlight the stage field and enter a number 1-6.

The following is a detailed description of each Fastening Sequence and associated Parameters:

Sequence 11 High Speed Rundown

This tightening method is generally used as a fast pre-tightening stage. The torque transducer

integrated into the nutrunner measures the torque during the tightening. The value is processed

by the control system. When the defined Turnoff Torque is reached the nutrunner is shut off.


ening torque of the bolt in the control system. This value is displayed on the Run Screen and can

be output to a printer or transmitted to other system components by data communication. When

the trigger torque is reached the torque curve is recorded and can be viewed and evaluated

using the oscilloscope function.




en03d141.fm, 07.10.2005 PL12EN-1300 08/05 33

The following parameters are programmable from the Standard Application Builder:

• Fastening Sequence = 11

• Trigger Torque (Nm) = trigger torque, beginning of measurement for the graphic display.

• Turnoff Torque (Nm) = turnoff torque for the pre-tightening stage.

• Speed = max speed of the nutrunner during the pre-tightening stage.


Fastening Strategy Sequence 11 High Speed Rundown


Turnoff Torque [Nm] Trigger to Tool Max As appropriate

Speed Stage 1 [RPM] 0 to Tool Max 80% of Tool Max

Sequence 30

Torque Control with Torque and Angle Monitoring

This tightening stage is normally preceded by a fast pre-tightening stage. The transducer inte-

grated into the nutrunner measures the torque and the resolver measures the angle during thetightening. The values are processed by the control system. When the threshold torque is

reached the angle count starts. When the Turnoff Torque is reached the nutrunner is shut off.


ening torque of the bolt together with the evaluation of the rundown in the control system. This

value is displayed on the Run Screen and can be output to a printer or transmitted to other sys-

tem components by data communication. When the trigger torque is reached the torque curve is

recorded and can be viewed and evaluated using the oscilloscope function.




34 PL12EN-1300 08/05 en03d141.fm, 07.10.2005

The following parameters are programmable in the Standard Application Builder:

• Sequence input value = 30

• Trigger Torque (Nm) = trigger torque, beginning of measurement for the graphic display.

• Threshold Torque (Nm) = threshold torque, beginning of angle counting

• Turnoff Torque (Nm) = shut-off torque for the stage.

• Torque High Limit (Nm) = max torque, high limit for torque reached.

• Torque Low Limit (Nm) = min torque, low limit for torque reached.

• Angle High Limit (deg) = maximum angle, high limit for angle reached. The nutrunner will

stop if this value is exceeded

• Angle Low Limit (deg) = minimum angle, low limit for angle reached.

• Speed = max speed of the nutrunner during the tightening stage.


Fastening Strategy Sequence 30 Torque Control/

Angle Monitor

Trigger Torque [Nm] 0 to Tool Max 10% of Turnoff TorqueThreshold Torque [Nm] 0 to Tool Max 50% of Turnoff Torque

Torque Low Limit [Nm] -Tool Max* to Tool Max 90% of Turnoff Torque

Turnoff Torque [Nm] Low Limit to Tool Max As appropriate

Torque High Limit [Nm] Turnoff to 9999 110% of Turnoff Torque

Angle Low Limit [Deg] 0 to 9999 70% of Final Angle

Angle High Limit Low Limit to 9999 130% of Final Angle

Speed [RPM] 0 to Tool Max 50





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Sequence 50

Angle Controlled Tightening with Angle and Torque Monitoring

This tightening sequence is generally preceded by a fast pre-tightening cycle. The transducer

integrated into the nutrunner measures the torque and the resolver measures the angle during

the rundown. The values are processed by the control system. When the Turnoff angle is

reached the nutrunner is shut off. Thereafter the final angle and the peak torque are measured

during a dwell time, and these tightening values for the bolt are then processed together with theevaluation of the rundown in the control system. These values are displayed on the Run Screen

and can be output to a printer or transmitted to other system components by data communica-

tion. When the trigger torque is reached the torque curve is recorded and can be viewed and

evaluated using the oscilloscope function.



• Trigger Torque (Nm) = trigger torque, beginning of measurement for the graphic display

• Threshold Torque (Nm) = threshold torque, beginning of angle counting

• Turnoff Angle (deg) = shut-off angle for the stage

• Angle High Limit (deg) = maximum angle, high limit for angle reached

• Angle Low Limit (deg) = minimum angle, low limit for angle reached• Torque High Limit (Nm) = max torque, high limit for torque reached and safety shut-off

• Torque Low Limit (Nm) = min torque, low limit for torque reached

• Speed = max speed of the nutrunner during the tightening stage


Fastening Strategy Sequence 50 Angle Control/

Torque Monitor


Threshold Torque [Nm] 0 to Tool Max As appropriate

Torque Low Limit [Nm] -Tool Max* to Tool Max 70% of Final Torque

Torque High Limit [Nm] Low Limit to Tool Max. 130% of Final Torque



Angle High Limit Turnoff angle to 9999 110% of Turnoff Angle

Speed Stage [RPM] 0 to Tool Max 50





36 PL12EN-1300 08/05 en03d141.fm, 07.10.2005

Sequence 41

Angle Controlled Back-off with Angle Monitoring

This fastening sequence is generally used to loosen a bolt a specified number of degrees. The

resolver integrated into the nutrunner measures the angle during the untightening. The value is

processed by the control system. When the Turnoff angle is reached the nutrunner is shut off.

Thereafter the final angle is measured during a dwell time and is then processed as the back-off

angle of the bolt together with the evaluation of the untightening in the control system. This valueis displayed on the Run Screen and can be output to a printer or transmitted to other system

components by data communication. In this stage the oscilloscope function is not supported.



• Turnoff Angle (deg) = shut-off angle, back-off angle

• Angle High Limit (deg) = maximum angle, high limit for angle reached.

• Angle Low Limit (deg) = minimum angle, low limit for angle reached.

• Speed = max speed of the nutrunner during the back-off stage.


Fastening Strategy Sequence 41 Angle Control in Reverse



Angle High Limit Turnoff angle to 9999 110% of Turnoff Torque

Speed [RPM] 0 to Tool Max 80% of Tool Max

Backoff Using Reverse Switch (Sequence 41 or Sequence 46)

The Backoff stage is automatically set to Sequence 46 for a tubenut tool and Sequence 41 for all

others. The automatic selection of a tube nut tool depends on a "T" in the tool model number.

That means, if a "T" appears in the model number a tube nut tool is expected. This fastening

sequence is selected when the tool is run in the reverse or untighten direction. It is also automat-

ically used to return a tubenut tool to the home position on every other trigger pull. The resolver

integrated into the nutrunner measures the angle during the untightening. The measured angle

value is processed by the control system. When the Turnoff angle is reached the nutrunner is

shut off. For a tubenut tool, the Turnoff angle is programmed so that the attachment will always

turn far enough to reach the home position and stop based on the torque reaction against the

pawl.


• Speed [rpm] = Max speed of the nutrunner during the backoff stage

Parameter Name Range Default

Speed [RPM] 0 to Tool Max 500 or 30% of Tool Max

(tubenut)




en03d141.fm, 07.10.2005 PL12EN-1300 08/05 37

The backoff parameters that are not displayed are set to values as in the table below.

Parameter Name Sequence 41 Sequence 46

Start delay time [mS] 0 0

Start spike time [mS] 0 0

Max. Fastening time [mS] 10000 10000

End delay time [mS] 30 30

Torque Filter Factor 1 1

Torque Target --- 3,5% of Tool max. Torque

Torque High Limit --- 10% of Tool max. Torque

Angle Low Limit 0 0

Angle Target 9999 370

Angle High Limit 9999 380

For at tube nut tool the maximum speed for backoff is 30% of Tool Max Speed. It is not possible

to enter a higher value.

Relax

This sequence is generally used at the end of a rundown to prevent mechanical locking of the

tool without loosening the joint.

The relax parameters are set to values as in the table below. These parameters cannot be pro-

grammed.

Parameter Name Value

Fastening strategy Sequence 46

Start delay time [ms] 0

Start spike time [ms] 0

Max. fastening time [ms] 3000

End delay time [ms] 0

Torque filter factor Used from preceding stage

Torque target 1/6 of Torque low limit from preceding stage

Torque high limit 1/3 of Torque low limit from preceding stage

Angle low limit 0

Angle target 3

Angle high limit 6

Speed stage [RPM] Used from preceding stage

The results are not displayed on the Run Screen unless the relax stage was NOK.

paramete.txtE




38 PL12EN-1300 08/05 en03d141.fm, 07.10.2005

3.3.5 Standard Application Builder / Advanced Parameters

c00283en.bmp

Fig. 3-9: Advanced Parameters

advparam.txtS

The user can enter the Advanced Parameters using the Advanced (F3) soft key from the Param-

eter screen. These parameters are identical regardless of the selected Fastening Sequence.

The Next Stage (F2) key will increment to the next stage until it reaches the last stage with a

selected Sequence. It will then rollover to the first stage. In order to add a stage without a

selected Sequence the user must highlight the stage field and enter a number 1-6.

Timers

Start delay time [mS] time delay before the stage will start

Start spike time [mS] time delay for the control system to start measuring torque after the stage

starts

Max. Fastening time [mS] max time for the tool to run during the stage.

End delay time [mS] time delay from tool turn off until shut-off of measured value recording.

Other

Torque Filter Factor used for torque averaging




en03d141.fm, 07.10.2005 PL12EN-1300 08/05 39

Speed Ramp-up, Beginning of Stage

Ramp-up time [ms]: Time to accelerate to tool max speed.

Speed Ramp-down, End of Stage

Deactivate Ramp-down: Allows the user to deactivate the ramp-down.

Begin Ramp-down [%]: Percentage of turn off torque (seq 11, 30) or high limit torque (seq 50),

where speed ramp-down begins.

Use Default for Target

Speed:

Default value for target speed is used. The default value depends on

parameter of the next stage. Refer to the programming manual for more

information.

Target Speed [RPM]: Target speed after ramp-down at turn off. From beginning of ramp down,

speed is reduced in 30 steps to target speed.

Flex-Stop, After Turn-off

Deactivate Flex-Stop: Allows the user to deactivate the flex-stop.

Flex-Stop [%]: Percentage of duration of flex-stop. The higher the percentage the longer it

takes to relieve torque after shut-off. The absolute time depends on the run-

down parameter and the joint.

Max Flex-Time [ms]: Max time for flex-stop to relieve torque after shut off

Advanced Parameters Default Range of Values

Start delay time [mS] 0 0 - 60000

Start spike time [mS] 0 0 - 999

Max. Fastening time [mS] 10000 1 - 60000

End delay time [mS] 30 0 - 999

Torque Filter Factor 1 1, 2, 4, 8, 16, 32

Ramp-up time [ms] 1000 100 - 2000

Begin Ramp-down [%] 90 1 - 100

Target Speed [RPM] (*) 1 - speed of stage

Flex-Stop [%] 50 10 - 100

Max Flex-Time [ms] 1000 1 - 2000

.

(*) The default value depends on parameter of the next stage. Refer to manual for more informa-

tion.

advparam.txtE




40 PL12EN-1300 08/05 en03d141.fm, 07.10.2005

3.4 Advanced

3.4.1 Advanced Application Builder / Application Matrix

c00284en.bmp

Fig. 3-10: Application Matrix

appmatri.txtS

The Application Matrix is a display matrix of 255 Applications vs. 6 Stages showing the selected

Sequence number for each stage. It gives the user an overview of controller programming in a

single screen. The arrow following the sequence number for a stage indicates the direction of

rotation ( > for clockwise; < for counter-clockwise).

appmatri.txtE




en03d141.fm, 07.10.2005 PL12EN-1300 08/05 41

3.4.2 Advanced Application Builder / Inputs

c00285en.bmp

Fig. 3-11: Inputs

Tool

Start

Tool Stop

in Final

Stage

Tool

Start

Inputs

I0. Application Select 0



I3. Tool Start

I4. Reject Release

I5. Tool Reverse

I6. Tool Enable

With Linking:

I7. Reset Linking /

Synchronization In

With Tool Synchronization:

I7. Reset Linking /Synchronization In

Start

Stage2

c00288en.bmp

Fig. 3-12: Input Timing Diagram

inputs.txtS




42 PL12EN-1300 08/05 en03d141.fm, 07.10.2005

Eight optically isolated, +24 V inputs are available at the Phoenix input connector under the right

side door and are defined as follows:

PIN 1 +24 VDC

PIN 2 Input 0

PIN 3 Input 1

PIN 4 Input 2

PIN 5 Input 3

PIN 6 Input 4

PIN 7 Input 5

Pin 8 Input 6

PIN 9 Input 7

PIN 10 Input Common

Pin 11 Signal Ground

Pin 12 Spare

Each of the physical inputs 0 - 7 can be programmed to have one of the following definitions:

Not Used Unused

Tool Enable When active, allows the tool to run in conjunction with Tool Start

Tool Start Starts the tool. Works in parallel with the start switch on the tool.

Tool Reverse When active, causes the tool to run in the counter-clockwise direc-tion using the Backoff strategy. Works in parallel with the reverse

actuator on the tool

Tool Ready Prepares the controller for a new rundown. When active, the previ-

ous outputs are cleared, and the yellow LEDs flash

Appl. Select 0 Application Selects 0-7 are used to select Applications 1-255

using a binary count of 0-254 where Appl. Select 0 is the

least significant bit. This feature overrides application

changes from the keypad. When Linking is activated, the

Tightening Group is selected with these inputs.

Appl. Select 1

Appl. Select 2

Appl. Select 3

Appl. Select 4

Appl. Select 5

Appl. Select 6

Appl. Select 7

Synchronization Input If enabled from Advanced / System Settings, the tool is prevented

from continuing to the next stage until this input is active




en03d141.fm, 07.10.2005 PL12EN-1300 08/05 43

All inputs are active high. They are referenced to an isolated Input Common (pin 10). When

using the internal +24 V (pin 1) to activate these inputs, you must connect Input Common

(pin 10) and GND (pin 11). For hardware pin location please see page 19.Note:

When active, the Fieldbus has the priority. Refer to help page for Advanced / Fieldbus.

inputs.txtE

Reset Linking When active, Linking (batch counting) is reset to position one

Reject Release Used when Reject Release is enabled from System Settings, and

the Release Method is "Release Input Toggle". When the tool is

disabled due to the reject limit being reached, it is re-enabled after

this input is toggled

Socket Tray Enable Socket Tray Enable is used along with Socket Tray Sel 0-2 to indi-

cate to the worker which socket to use.Socket Tray Sel 0

Socket Tray Sel 1

Socket Tray Sel 2




44 PL12EN-1300 08/05 en03d141.fm, 07.10.2005

3.4.3 Advanced Application Builder / Outputs

c00286en.bmp

Fig. 3-13: Outputs

ToolStart

Tool Stopin Final

Stage

ToolStart

Outputs

O0. Cycle OK

O1. Cycle NOK

O2. Torque High

O3. Torque Low

O4. Linking OK

O5. Linking NOK

O6. Cycle Complete

With Linking:

O7. Linking Complete /

Synchronization Out

With Tool Synchronization:

O7. Linking Complete /

Synchronization Out

As appropriate

As appropriate

As appropriate

As appropriate

As appropriate

As appropriate

As appropriate

EndStage1

StartStage2

c00287en.bmp

Fig. 3-14: Output Timing Diagram

outputs.txtS




en03d141.fm, 07.10.2005 PL12EN-1300 08/05 45

Eight relay outputs are available at the Phoenix output connector under the right side door and

are defined as follows:

PIN 1 +24 VDC

PIN 2 Output Common

PIN 3 Output 0

PIN 4 Output 1

PIN 5 Output 2

PIN 6 Output 3

PIN 7 Output 4

PIN 8 Output 5

PIN 9 Output 6

PIN 10 Output 7

PIN 11 Signal Ground

PIN 12 Spare

Each of the physical outputs 0-7 can be programmed to have one of the following definitions:

Not Used Unused

OK Active if Torque / Angle / Yield are within programmed limits

NOK Active if Torque / Angle / Yield are outside limits or some

other error has occurred

Torque Low Active if Peak Torque < Torque Low Limit

Torque High Active of Peak Torque > Torque High Limit

Angle Low Active if Angle < Angle Low Limit

Angle High Active of Angle > Angle High Limit

Torque OK Active if Peak Torque is within limits

Angle OK Active if Angle is within limits

Tool Running Active when the tool is running

Cycle Complete Active when a rundown has ended in the last stage

Linking Complete Active when rundowns of all positions of the selected batch

group are complete

Linking OK Active if all positions of Linking were OK

Linking NOK Active if one or more positions of Linking were NOK




46 PL12EN-1300 08/05 en03d141.fm, 07.10.2005

All relay outputs are active high. One side of all of the relay contacts is tied to a common point

called Output Common (pin 2). When using the internal +24 V (pin 1) as a source for these out-

puts, you must connect Output Common (pin 2) and +24 V (pin 1). The outputs will then be ref-

erenced to GND (pin 11). For hardware pin location please see page 19.

Note: When active, the Fieldbus inputs have priority. Refer to help page for Advanced / Field-

bus.

outputs.txtE

Confirm App. Sel 0 Confirm application Selects 0-7 are used to indicate the

currently selected applications 1-255 using a binary count

of 0-254 where Appl. Select 0 is the least significant bitConfirm App. Sel 1

Confirm App. Sel 2

Confirm App. Sel 3

Confirm App. Sel 4

Confirm App. Sel 5

Confirm App. Sel 6

Confirm App. Sel 7

Sync Output If enabled from Advanced / System Settings it is active at

the end of each stage to allow for synchronization with

other controllers

Tool In Reverse Indicates that a tool reverse input or actuator is set

Socket Tray Enable Pass-through of Socket Tray Enable input signal

Socket Tray Sel 0 Pass-through of Socket Tray select 0-2 input signals

Socket Tray Sel 1

Socket Tray Sel 2

Fault (Active Low) Indicates the servo module has detected an error (trans-

ducer, resolver etc)




en03d141.fm, 07.10.2005 PL12EN-1300 08/05 47

3.4.4 Advanced Application Builder / Fieldbus

c00400en.bmp

Fig. 3-15: FieldBus

fieldbus.txtS

From the FieldBus Screen the user is allowed to choose from four options for fieldbus connec-

tions: None, DeviceNet, Profibus, or Ethernet/IP.

For selection of DeviceNet or Profibus additional hardware is required.

Field Bus Configuration

Node Address Defines the address of the TME controller. DeviceNet (1-63),

Profibus (2-125) , Ethernet/IP uses the controller IP address

configured in Communications / Data Transmission.

Baud Rate Defines the rate at which information is sent/received from

the TME controller. For DeviceNet three choices are avail-

able: 500KBits, 250 KBits, or 125 KBits. The rate should be

set to match the fieldbus system available. For Profibus and

Ethernet/IP, this option is not available. The Baud Rate is

automatically set to the master settings.

Part ID A checked box enables the Part ID function.

Disable on disconnect A checked box that disables further rundowns and displays a

"Check Cable" Message on Run Screen as long as the field-

bus doesn't work.Format Determines how the 32-bit Part ID is converted into readable

characters. When "Decimal" is selected, the resulting Part ID

is 10 characters in length. When "Hexadecimal" is selected,

the resulting Part ID is 8 characters in length.

Enable I/O Configuration

This section allows the user to control the information sent/received in the data stream. Inputs

and Outputs can be individually enabled.




48 PL12EN-1300 08/05 en03d141.fm, 07.10.2005

Inputs

Appl. Select (1-8) Allows the fieldbus to control the Application selected from 1

to 8

Reset Linking Allows the fieldbus to reset the linking to the first position

Remote Tool Start Allows the fieldbus to start the tool

Remote Tool Reverse Allows the fieldbus to control the rotation direction

Tool Ready Allows the fieldbus to blink the yellow LED on the tool

Tool Enable Allows the fieldbus to enable/disable the tool

Appl. Select (9-255) Allows the fieldbus to control the Application selected 1 to

255. This can only be enabled if Appl. Select (1-8) is set

Socket Tray Lamp

Select (1-8)

Allows the fieldbus to control the Socket Tray Lamp Select,

and enables the "Socket Tray Lamps Enable" input.

Outputs

Linking Outputs Output data will include linking OK, NOK, and Complete

Appl. Select (1-8) Output data will include current Application selection 1-8

Tool Enable from Socket

Tray

Output data will include the tool enable signal from socket

tray

Tool Running Output data will indicate when tool is in a rundown cycle

Tool Reverse Output data will indicate when tool is in reverse

Cycle Complete Output data will indicate when rundown cycle is completeTool Ready Input Pass-

Through

Output data will include the tool ready signal from the input

Green Tool Light

(Cycle OK)

Output data will indicate when cycle is within programmed

limits

Cycle NOK Output data will indicate when cycle is outside of programmed

limits

Yellow Tool Light Output data will indicate when cycle met the yellow light con-

ditions

Torque/Angle Results Output data will indicate results for the torque and angle spe-

cifically

Appl. Select (9-255) Output data will include current Application selection 1 to 255.

This can only be enabled if Application Select (1-8) is set

Socket Tray Appl.

Select (1-8)

Output data will indicate the socket tray appl. select

Fault Indicates the servo module has detected an error (transducer,

resolver etc)




en03d141.fm, 07.10.2005 PL12EN-1300 08/05 49

Signal Descriptions

Inputs

If DeviceNet configuration is selected, the input packet is 4 Words long (8 bytes) including Part

ID Number (4 bytes) if enabled, or 2 words long (4 bytes) if Part ID is not enabled.

If Profibus configuration is selected, the input packet is 4 words long (8 bytes).

WORD 0 BYTE 0 BIT 0-3: Spare

BIT 4-6: Application/Link. Select Code 1-8(Bit 4=LSB)

BIT 7: Reset Linking

BYTE 1: BIT 0: Remote Tool Start

BIT1: Remote Tool Reverse

BIT 2: Tool Ready (Flashing Yellow Light)

BIT 3: Tool Enable

BIT 4: Socket Tray Lamps Enable

BIT 5: Socket Tray Lamps Appl. Sel. 0



WORD 1 BYTE 0 BIT 0-4: Application/Link. Select Code 9-255 (Bit 0=LSB)

BIT 5-7: Spare

BYTE 1 ALL: Spare

WORD 2 BYTE 0 ALL: Part ID

BYTE 1 ALL: Part ID

WORD 3 BYTE 0 ALL: Part ID

BYTE 1 ALL: Part ID

Example of Part ID (BCD - HEX Format)

WORD 3 BYTE 1 00000000 - 00

BYTE 0 00000010 - 02

WORD 2 BYTE 1 11111111 - FF

BYTE 0 00000001 - 01

The HEX-Format (0002FF01) will be displayed on the Run Screen, Chrono History, and Printout.




50 PL12EN-1300 08/05 en03d141.fm, 07.10.2005

Outputs

The output packet will be 2 Words long (4 bytes). When Ethernet/IP is the selected field bus, and

the "Torque / Angle Values" box is checked, the output packet is 5 words (10 bytes). The status

of all fieldbus outputs is viewable from a diagnostics screen on the TME. All outputs are updated

continuously.

WORD 0 BYTE 0 BIT 0: Spare

BIT 1: Linking OK

BIT 2: Linking NOK

BIT 3: Linking Complete

BIT 4-6: Application/Link Select Code 1-8 (Mirror)

BIT 7: Tool-Enable from Socket Tray

BYTE 1 BIT 0: Tool In-Cycle

BIT 1: Tool Reverse Switch

BIT 2: Fault

BIT 3: Cycle Complete

BIT 4: Tool Ready pass-through from Input

BIT 5: Socket Tray Application Select



WORD 1 BYTE 0 BIT 0: Green Tool Light (Cycle OK)

BIT 1: Cycle NOK

BIT 2: Yellow Tool Light

BIT 3: Torque Low

BIT 4: Torque High

BIT 5: Angle Low

BIT 6: Angle High

BIT 7: Spare

BYTE 1 BIT 0-4: Application/Link Select Code 9-255 (Mirror)

BIT 5-7: Spare

WORD 2 BYTE 0 ALL: Torque

BYTE 1 ALL: Torque

WORD 3 BYTE 0 ALL: Torque

BYTE 1 ALL: Torque




en03d141.fm, 07.10.2005 PL12EN-1300 08/05 51

fieldbus.txtS

3.4.5 Advanced / Linking

c00315en.bmp

Fig. 3-16: Linking

linking.txtS

Linking allows the user to automatically change from application to application for a predefined

number of positions (up to 96). Each application is run when the start switch on the tool is acti-

vated in the order specified by its position. Upon completion of the cycle, the application will thenautomatically change to the next position. Up to eight different linking strategies called Tighten-

ing Groups can be programmed and are remotely selectable from the Application Inputs (0-2).

This feature can also be used for Batch Counting by entering the same application in the desired

number of positions.

To setup a linking strategy, a Tightening Group 1-8 should be selected and given a name. This

will designate which linking strategy is being used. The user can also program if the linking strat-

egy should reset to position 1 after an NOK or set the number of times a fastener can be retight-

ened after an NOK before advancing to the next position.

To configure linking, an Application 1-255 must be associated with a position in the linking strat-

egy. To do this, the user must enter App (1-255), and can also provide a Fastener ID and Posi-

tion Name. Pressing Add (F1) will place the selected application in the user-specified position of

the linking strategy. Pressing Delete (F2) will remove the user-specified position from the linkingstrategy. Once Linking is enabled, the controller will automatically run from position 1 to the last

programmed position. Note that the tool start switch or remote start input will have to be toggled

between positions. The Tightening Group and Position will also be displayed on the Run Screen.

The following inputs and outputs will also be active when Linking is enabled: Linking OK, Linking

NOK, Linking Complete, and Reset Linking. Please refer to the Inputs and Outputs section for

more information on these signals.

linking.txtE

WORD 4 BYTE 0 ALL: Angle

BYTE 1 ALL: Angle




52 PL12EN-1300 08/05 en03d141.fm, 07.10.2005

3.4.6 Advanced / System Settings

c00313en.bmp

Fig. 3-17: System Settings

sysset.txtS

From the System Settings Screen the user can configure parameters pertaining to the system.

General

Allows the user to assign an identifying name and number to the TME controller. This informa-

tion will be used when sending and printing data.

Station Name (10 characters - alphanumeric)

Station Number (10 characters - alphanumeric)

Same for both tools (2-Channel V2.xx.xx C2 only) When this box is checked, the

most recently entered Station Name and Station Number are

automatically synchronized and used for both tools. When

not checked, the Station Name and Station Number may be

programmed differently for each tool.

The use of this check box also affects the serial communica-

tion protocols Standard, Standard2, and 3964R. If "Same for

both tools" is not checked, then the 2-digit ASCII tool number

transmitted is taken from the Station Number field. If "Same

for both tools" is checked, then the 2-digit ASCII tool number

transmitted is hard-coded to be "01" or "02" depending onwhich tool the results data is from.




en03d141.fm, 07.10.2005 PL12EN-1300 08/05 53

Reject Release

Max Number of Rejects Allows the user to enter the maximum number of rejects that

will be permitted before a release signal is required. If 0 is

entered, the function is disabled.

Release Method Release on Backoff

allows the user to set running the tool in reverse as a release

signal.

Release Input Toggle

Allows the user to set a low-high-low pulse of the Reject

Release input as a release signal

Others

Torque Units Allows the user to select which units the TME controller uses

for presenting torque. Available choices: Nm, FtLbs, InLbs,

KgCm, and KgM. When the units are changed, all torque val-ues are immediately changed to the new units.

Tool Sync/Disable Linking Allows the user to enable Tool Synchronization and disable

the linking function.

NOK if Start Switch

Release

Causes NOK status after any rundown with Early Trigger

Release (ETR). ETR is any case in which the rundown did

not end progamatically, i.e. if the tool did not reach Turn Off

or High Limit torque or angle, or reach Max Fastening time.

In this case an NOK result is generated and the yellow LEDs

on the TME and tool will be illuminated.

Archive only if Torque >

Trigger

Allows the user to specify that only rundown cycles where

the torque is greater than the trigger torque of the last tight-ening stage will be saved in Chrono History.

External Application Select Allows the user to enable the requirement for an external sig-

nal into the inputs Appl. Select 0-7 (Appl. Select 0-2 with a

socket tray) for selecting the application. In the absence of a

signal, the TME controller defaults to application 1.

External Tool Enable Allows the user to enable the requirement for an external sig-

nal Input before the rundown cycle can begin.

Latched Remote Start Allows the user to enable the requirement for an external

pulse signal input to start the rundown cycle. If unchecked

the remote start signal must be maintained for the tool tocontinue running.

Blinking Lights in Reverse Allows the user to select the option of blinking lights on TME

controller and tool when the tool is in reverse. If the box is

unchecked, there is no visible indication that the tool is in

reverse.

sysset.txtE




54 PL12EN-1300 08/05 en03d141.fm, 07.10.2005

3.5 RUN Screen

c00289en.bmp

Fig. 3-18: Run Screen

runscrn.txtS

From the Run Screen the user sees rundown data as it occurs. The Torque and Angle readings

are displayed with a background color corresponding to the status of each.

The background is red if the value is too high, yellow if it is too low, and green if it is within limits.

The current tool model number, station name, and indicator labels are also displayed. The

desired Application (1-255), Tightening Group (1-8, if enabled), and Part ID (if enabled) are

selectable using the keypad.

When enabled, the Part ID and Part ID Status boxes are displayed below the Tool and Applica-

tion. When allowed, the Part ID edit box may be used to manually enter a Part ID using the key-

pad or an attached keyboard. NOTE: when manually entering a Part ID, the <ENTER> key mustbe pressed to validate the entry. During manual entry, the <ESC> key may be pressed to return

to the previous Part ID and state of validity.

The Part ID Status box contains three indicators:

1. Valid: Indicates whether or not the part ID is valid, and when not valid, whether or not the

tool is enabled:

- “Part ID Valid” (green LED): Part ID is valid. The tool is always enabled.

- “Part ID Invalid; Tool Disabled” (red LED): When configured in INTERLOCK mode, an

invalid Part ID causes the tool to be disabled. A new, valid Part ID must be entered to

enable the tool.

- “Part ID Invalid; Tool Enabled” (yellow LED): When configured without INTERLOCK

mode, the tool may be run without entering a valid Part ID.




en03d141.fm, 07.10.2005 PL12EN-1300 08/05 55

2. Function: Indicates the status of Part ID Data Function:

- “Data function: not configured” (clear LED): Part ID “Data Function” is configured to

"None".

- “Function: None” (yellow LED): Part ID “Configure Data” is enabled, but the Part ID is

invalid or does not match any Configure Data entries.

- “Function: XYZ” (green LED): Part ID “Configure Data” is enabled, and the current Part ID

has engaged function XYZ (see Communications - Part ID help screen for function defini-tions).

3. Input status: Indicates whether or not a new Part ID can be entered.

- “Accepting Part ID input” (green LED): A new Part ID may be entered.

- “Not Accepting Part ID input” (red LED): A new Part ID may not be entered.

- A new Part ID may not be entered when the tool trigger is active.

- “NEW INPUT IGNORED!” (red LED): This status is displayed if a new Part ID is entered

while “Not Accepting Part ID input” is true.

Below the Torque and Angle display is the “Status” window. This window displays various mes-

sages related to the tool, rundown status, or errors.The <F1> “Print” soft key causes any rundown data that has not previously been printed to be

sent to the parallel port printer interface. If the Part ID is configured to “Print Interlock”, the Part

ID is invalidated, and the tool is disabled.

The <F2> “Oscilloscope” soft key displays the Oscilloscope function for evaluating Torque and

Angle curves. It is automatically updated after each cycle.

The Run Screen may be optionally configured to display Rundown Details or Counter informa-

tion as shown. These options are available by pressing the Configure (F3) soft key. See "Run

Screen / Configure". Counter information is available for individual applications and tightening

groups (linking). See "Administration / Counter". The rundown details include the application

number, the stage number of the Torque/Angle results currently displayed, the total number of

stages in the application, and the rundown status summary (Good, A High, T Low, etc).

(2-Channel only) Tool display options are Manual Select, Auto Select, and Split Screen. See

"Run Screen / Configure". In the single tool display, when tool 2 is selected, the run screen dis-

play has the labels for the result LEDs on the right side. When navigating to other screens, the

"active" tool for other functions is the tool selected in the "Tool" edit box.

When Split Screen is selected, the side of the display containing the focus (red highlight) deter-

mines the "active" tool. Split Screen limitations:

• With Linking enabled, the total number of tightening positions is not displayed.

• With Linking enabled, the display of the tightening group name is limited to 5 characters. If

the group name is longer than 5 characters, only "Group" is displayed.

• With Part ID enabled, the Part ID status box is not displayed.

• A long Part ID may not be completely displayed.




56 PL12EN-1300 08/05 en03d141.fm, 07.10.2005

3.5.1 Run Screen / Tool 2

c00363en.bmp

Fig. 3-19: Run Screen / Tool 2

(2-Channel V2.xx.xx C2 only) When tool 2 is selected, the run screen display has the labels for

the result LEDs on the right side.

runscrn.txtE

3.5.2 Run Screen / Split Screen

c00386en.bmp

Fig. 3-20: Run Screen / Split Screen

(2-Channel V2.xx.xx C2 only) When "Split screen" is selected, the run screen simultaneously

displays the results and status from both tools.

runscrn.txtE




en03d141.fm, 07.10.2005 PL12EN-1300 08/05 57

3.5.3 Run Screen / Configure

c00364en.bmp

Fig. 3-21: Run Screen / Configure

runcfg.txtS

Run Screen / Configure allows customization of the Run Screen display. The user may select

the display of counter information and/or rundown details. The counters are activated and reset

using the "Administration / Counter" screen. When the "Station Name" box is checked, and Link-

ing is disabled, the Station Name programmed in "Advanced / System Settings" is displayed

next to the application number.

(2-Channel V2.xx.xx C2 only) The user has the option of having the Run Screen display auto-

matically switch to the tool which has most recently reported results, or simultaneously display-

ing the results from both tools. This is done by checking the Auto Select box, or Split Screenrespectively.

runcfg.txtE




en03d141.fm, 07.10.2005 PL12EN-1300 08/05 59

Parameters

At the bottom of the display is a summary of the parameter settings for the rundown.

The Save softkey (F2) lets you print a hardcopy.

oscope.txtE

3.7 Communication

3.7.1 Communications / Data Transmission

c00404en.bmp

Fig. 3-23: Data Transmission

commdata.txtS

From the Data Transmission Screen the Serial and Ethernet connections can be configured.

Serial

Protocol None, Standard, Standard2, PFCS, CT01 3964R,

Appolo 3.1, FEP

Port COM 1, COM 2

Baud Rate 2400, 4800, 9600, 14400, 19200, 38400, 57600, 115200

Data Bits 4, 5, 6, 7, 8

Parity None, Odd, Even, Mark, Space

Stop Bits 1, 1.5, 2

Flow Control None, Hardware, Xon/Xoff

Protocol allows the user to select between different data transmissions. If Appolo 3.1 is selected,

then after linking is OK, a special protocol for a label printer is sent to the programmed COM

port. With each other selection, the serial data transmission is sent after each cycle. The basic

settings are Port, Baud rate, Data bits, Stop bits, Parity, and Protocol.




60 PL12EN-1300 08/05 en03d141.fm, 07.10.2005

(2-Channel V2.xx.xx C2 only) The Standard, Standard2, and CT01 3964R serial communica-

tions protocols can be configured as a unique serial port (COM1 or COM2) for each tool, or such

that a single serial port is shared between the tools. The transmitted "Tool Number" is a two-digit

ASCII field as programmed in Advanced / System Settings "Station Number". When the option

Advanced / System Settings: "Same for both tools" is checked, the Tool Number field is hard-

coded as "01" or "02" as appropriate.

The following table details the transmission data for Standard:

Start End Length or Value Description

1 1 42 hex B

2 3 2 Digit ASCII Tool Number

4 5 2 Digit ASCII Parameter Set

6 17 12 Char ASCII Date and Time (YYMMDDHHMMSS)

18 24 7 Digit ASCII Peak Torque

25 31 7 Digit ASCII Low Torque Limit

32 38 7 Digit ASCII High Torque Limit

39 39 1 Char ASCII Status Torque Status Flag

L = low

A = accept

H = high

40 46 7 Digit ASCII Final Angle

47 53 7 Digit ASCII Low Angle Limit

54 60 7 Digit ASCII High Angle Limit

61 61 1 Char ASCII Status Angle Status FlagL = low

A = accept

H = high

62 62 1 Char ASCII Status Overall Status Flag

A = accept

R = reject

63 64 2 Digit ASCII Link/Position

(Only for Linking)

65 66 2 Digit ASCII Number of linked positions

(Only for Linking)

67 67 0D hex CR (carriage return)

68 68 0A hex LF (line feed)




en03d141.fm, 07.10.2005 PL12EN-1300 08/05 61

The following table details the transmission data for Standard2:

Start End Length or Value Description

1 1 42 hex B

2 3 2 Digit ASCII Tool Number

4 6 3 Digit ASCII Parameter Set

7 18 12 Char ASCII Date and Time (YYMMDDHHMMSS)

19 25 7 Digit ASCII Peak Torque

26 32 7 Digit ASCII Low Torque Limit

33 39 7 Digit ASCII High Torque Limit

40 40 1 Char ASCII Status Torque Status Flag

L = low

A = accept

H = high

41 47 7 Digit ASCII Final Angle

48 54 7 Digit ASCII Low Angle Limit

55 61 7 Digit ASCII High Angle Limit

62 62 1 Char ASCII Status Angle Status Flag

L = low

A = accept

H = high

63 63 1 Char ASCII Status Overall Status Flag

A = accept

R = reject

64 65 2 Digit ASCII Link/Position

(Only for Linking)

66 67 2 Digit ASCII Number of linked positions

(Only for Linking)

68 68 0D hex CR (carriage return)

69 69 0A hex LF (line feed)

If Part ID is ENABLED, then a 25 character ASCII part ID is transmitted prior to CR/LF.




62 PL12EN-1300 08/05 en03d141.fm, 07.10.2005

Ethernet

Protocol None, Standard, PFCS, FEP

The ethernet settings include:

• Server IP Address

• Gateway

• Host

• Subnet Mask

• Port Address

The MAC address of the ethernet interface is displayed for informational purposes only and is

not configurable. See your network administrator for proper settings. To enable communications

with TMCom, the IP address of for TM Unit, Gateway, and Subnet must be entered. For further

protocol descriptions contact a Technical Service Representative in Customer Satisfaction.

(2-Channel V2.xx.xx C2 only). When the ethernet "Standard" protocol is selected, there is one

connection made per controller. For all messages containing a "Station Number", the station

number for tool 1 is used. For the Rundown packet (#4), the "Spindle Number" field is 1 or 2depending on the associated tool. Refer to Engineering Specification 543027 "Network Software

Specification" for more information.

commdata.txtE

3.7.2 Communication / Part ID

c00405en.bmp

Fig. 3-24: Part ID

comprtid.txtS

The Part ID configuration screens allow the user to specify the interface and functionality of the

Part ID used on the Run Screen and archived with the rundown data. Changes to the Part ID

and Configuration Data edit screens are saved when the “Communications” screen is exited

(Run Screen or Navigator button pressed). At this time the request to save the configuration is

confirmed with a password dialog box.




en03d141.fm, 07.10.2005 PL12EN-1300 08/05 63

The Part ID may be entered manually from the run screen, input using a barcode reader

attached to a serial port, or transmitted through a FieldBus. A Part ID may consist of any

sequence of Alphanumeric characters, including spaces.

(2-Channel V2.xx.xx C2 only) The Part ID configuration settings are unique for each tool. The

Barcode Serial Interface can be configured as a unique serial port (COM1 or COM2) for each

tool, or such that a single serial port, and therefore each Part ID, is shared between the tools.

When the tools share a common Part ID source and serial port, the "Number of Characters"must be identical for both tools.

Settings

Enable Defines the level of functionality of the Part ID

Disable The Part ID interface is completely disabled. No Part

ID information is present on the Run Screen, and a

part ID string of “(Disabled)” is archived with each run-

down. The part ID is not transmitted with the standard

serial protocol output data.

Enable The Part ID interface is enabled, and is present on theRun Screen. A valid part ID is NOT REQUIRED to run

the tool. Following a rundown, the Part ID or the string

“(Not Valid)” is archived with the rundown data. The

Part ID is transmitted with the standard serial protocol

output data.

Enable Inter-

locked

The Part ID interface is enabled, and is present on the

run screen. A valid Part ID is REQUIRED to run the

tool. Following a rundown, the Part ID is archived with

the rundown data. The Part ID is transmitted with the

standard serial protocol output data. Following either a

good rundown (linking disabled) or good linking

sequence (linking enabled) the Part ID is invalidatedand the tool is disabled.

Print Inter-

locked

The Part ID interface is enabled, and is present on the

Run Screen. A valid Part ID is REQUIRED to run the

tool. Following a rundown, the Part ID is archived with

the rundown data. The Part ID is transmitted with the

standard serial protocol output data. The Part ID is

valid and the tool is enabled until the operator presses

the <F1> “Print” key on the Run Screen.

At this time, the Part ID is invalidated, the tool is dis-

abled, and any rundowns which have not previously

been printed are sent to the parallel port printer inter-

face.

Part ID Source Defines a source of the Part ID (i.e. Barcode reader through the serial port

or fieldbus). Fieldbus is only available if the Part ID option is enabled in

the Advanced\Fieldbus screen.

Number of

Characters

Defines the length of the Part ID, not including any termination characters

which may be sent by the barcode reader.

• Valid values are 1 to 25




64 PL12EN-1300 08/05 en03d141.fm, 07.10.2005

Barcode Serial Interface

Defines the serial port used to interface to the barcode reader.

Note:The default port for the serial barcode interface is COM2.

Port COM1, COM2

Baud Rate 2400, 4800, 9600, 14400, 19200, 38400, 57600, 115200

Data Bits 4, 5, 6, 7, 8

Parity None, Odd, Even, Mark, Space

Stop Bits 1, 1.5, 2

Flow Control None, Hardware, Xon/Xoff

Termination Defines what (if any) characters the barcode reader appends

to the barcode when transmitting to the serial interface

(None, CR/LF, LF, CR)

Configure Data

The Part ID: Configure Data screen is entered by pressing <F3> “Configure Data” from the Part

ID edit screen. Up to 12 position/value pairs may be entered, along with corresponding func-

tions. When a new Part ID is received by the controller, the table of entries is scanned. An entry

which matches a Part ID character “Value” in the corresponding “Position” causes the associ-

ated "Function" to be engaged.

The entries are displayed in a table at the top of the screen. The “Position”, “Value”, “Function”

and “App/Group” edit boxes are at the bottom of the screen. Pressing the <F1> “Add” key

Keypad Entry Defines whether or not a Part ID can be entered manually

Allowed A Part ID can be entered manually by highlighting the

Part ID box on the Run Screen and typing from the

keypad or an attached keyboard.

Disallowed The Part ID can not be entered manually from the run

screen.

Data Function Allows the tool functionality to be automatically controlled based on the

Part ID. See “Configure Data” below.

None The Part ID characters have no control over the tool

functionality. The <F3> “Configure Data” soft key on

the Part ID configuration screen is disabled. NOTE:

setting this option to “None” does NOT cause Config-

ure Data table entries to be lost.

Configure Data The Position/Value pairs on the Configure Data screen

may be used to control the tool functionality. When

selected, the <F3> “Configure Data” key is enabled.From the Configure Data screen, the user may enter

Position/Character pairs with associated functions to

control the tool based on the part ID.




en03d141.fm, 07.10.2005 PL12EN-1300 08/05 65

causes the current values in the edit boxes to be added to the table. All values are validated

prior to insertion in the table. New entries are always inserted at the END of the table. Pressing

the <F2> “Delete” key brings up a dialog box in which the user types the table entry number to

be deleted. The delete function may be aborted by selecting “Cancel”. Pressing the <F3> “Part

ID” key returns the user to the Part ID configuration screen.

Note:

When the table is scanned for a Part ID Position/Value pair match, the scanning is termi-

nated after the first match in the table has been found. The Part ID character positions are

numbered from left to right.

Position 1-<Number of Characters>

Value Any Alphanumeric character

Function Use Application X, Use Tightening Group X, Tool Enable,

Tool Disable

App/Group 1-255 when function "Use Application X" is selected

1-8 when function "Use Tightening Group X" is selected

Ignored when function "Tool Enable" or "Tool Disable" is

selected

comprtid.txtE




en03d141.fm, 07.10.2005 PL12EN-1300 08/05 67

3.7.4 Communications / Work Cell

c00389en.bmp

Fig. 3-26: Work Cell

workcell.txtS

From this screen, the user can add IP addresses to the list of remote units. To add a remote unit,

enter the IP address and select Add (F1). To delete a remote unit, select Delete (F2) and enter

the position number of the IP address. To get the status of the remote unit select Verify (F3).

Workcell.txtE

3.8 Tool Setup

c00293en.bmp

Fig. 3-27: Tool Memory

toollist.txtS




68 PL12EN-1300 08/05 en03d141.fm, 07.10.2005

The Tool memory data is displayed for the selected tool and redundancy. Only the Field Torque

Calibration (+/- 20% of nominal) and the static current factor are editable, in order to correct the

torque calibration of the selected tool. If no Tool memory is available, then all data is program-

mable.

In case a tool with memory is changed to another tool with memory of the same type the tool will

continue to work without any necessary changes. In case the tool is changed to a tool without

memory or to a different type, then after power on or when pressing the start switch a messageis displayed which prompts the user to verify the Tool Setup.

If tool memory is not available, F1 and F2 will change to Standard Tools and Fixtured Tools,

respectively.

Pressing the Standard Tools (F1) key will allow the user to select from a library of predefined

hand tools. This library can be used to program the tool parameters when tool memory is not

available or to change the existing tool memory values.

Pressing the Fixtured Tools (F2) key will allow the user to select from a library of predefined fix-

tured tools. This library can be used to program the tool parameters when tool memory is not

available or to change the existing tool memory values.

The Safety Shutoff mechanism uses current monitoring to turn off the tool in the event of a trans-

ducer failure during a rundown, thereby preventing unexpected high torque. If an application

experiences undesired shutoffs due to current spikes, this feature can be disabled at the discre-tion of the user. When disabled, the tool will still be shut off if the measured current exceeds

what is allowable for that tool.

Calibration with an external (master) transducer and torque monitor traceable to a third

party standard is only required for the following circumstances:

Before putting a new tool in service, after the tool has been repaired; continuous reading

errors; periodic basis of 6 months or 100,000 cycles (whichever occurs first), or as man-

dated by Quality Assurance.

Each transducer's calibration values should be documented for future reference.

Note:

toollist.txtE




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3.9 Tool Library

3.9.1 Tool Library

c00294en.bmp

Fig. 3-28: Tool Library

toollib.txtS

Using the arrow keys, move the orange highlight to the desired tool. Press ENTER to select that

model or ESC to exit. If a model is selected these new parameters will be used as the tool

parameters. Note that it is extremely important that the correct model is chosen to avoid damage

to the tool or injury to the worker.

Use Page Up (F2) and Page Down (F3) when appropriate to view more tool models.

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3.10 Statistics

3.10.1 Statistics / Chronological History

c00297en.bmp

Fig. 3-29: Chronological History

chrono.txtS

The user can view the Chronological History of rundowns for any or all applications, filtered

using the criteria from Statistics / Parameters. This history includes time, date, application, sta-

tus, torque, angle, and Part ID.

Use Prev Page (F1) and Next Page (F2) in order to go through the Chronological History. At the

top right the Entries: XXXX / YYYY display indicates the number of Chrono entries matching the

filter criteria / the total number of chrono entries stored in the database. The Page XXXX / YYYYindicates the current page being displayed / the total number of pages of entries matching the fil-

ter criteria. The Clear Chrono (F3) soft key allows the user to delete all rundowns.

To view additional details on a particular rundown, use the up or down arrow keys to highlight the

desired rundown, then press the <ENTER> key.

chrono.txtE




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3.10.2 Statistics / Graphs

c00357en.bmp

Fig. 3-30: Statistical Histogram

c00361en.bmp

Fig. 3-31: Range



c00358en.bmp


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Fig. 3-32: X-Bar

graphs.txtS

The Statistics / Graphs screens are used to view the statistics from the selected rundowns in

summary and in graphical form. Refer to Chapter 4 Statistics for a description of the meaning of

the statistics values. The rundowns are selected by the "Application" on the Graphs screen, and

are further filtered using the criteria in the Statistics / Parameters screen. The user may also

select the Subgroup Size (2-25) or switch between calculations for Torque and Angle. The (F3)

soft key is used to toggle the view between the Histogram, Range, and Xbar charts. The (F1)

soft key is used to toggle between Manual and Automatic update. In Automatic mode, the statis-

tics are recalculated, and the graph redrawn, whenever a new rundown is entered into the Chro-

nological History. In Manual mode, the recalculation is done only when the user presses the (F2)

"Refresh" key. With large data sets, it may be desirable to set Manual update mode for perfor-

mance reasons.

The left side of the screen contains a textual summary of the statistical calculations. The table at

the bottom of the screen displays the relevant programmed parameters for the currently

selected application.




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3.10.3 Statistic / Parameter

c00401en.bmp

Fig. 3-34: Statistical Parameter

statpara.txtS

From the Parameter Screen the user is able to apply a filter to the chrono data.

Filter

1. Select from the pull down menu: "All, OK, or NOK" rundowns.

2. Enter a number for the "Count (Last n)" field. A value of 0 disables this filter criteria.

3. Enter the Start date/time and the End date/time.

The parameters are verified and updated whenever the selected field is changed, or when

the Parameter screen is exited. The parameters selected from this screen apply to both the

Chrono History and Graphs displays.

Export Chrono

This softkey allows the user to send the filtered data to the Floppy Drive or the Printer. A file-

name may be entered.

statpara.txtE




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3.11 Diagnostics

3.11.1 Inputs / Outputs

c00298en.bmp

Fig. 3-35: Inputs / Outputs

opaldiag.txtS

Inputs and Outputs are divided into Internal and External I/O. The Internal I/O displayed on the

left side is used for tool start, direction, and Led outputs. The External I/O displayed on the right

side can be reached at the Phoenix connectors located under the side door. This screen will give

a live update of all system I/O. If a green box is shown next to the I/O description, then it is

active.

Otherwise the space next to the I/O description will be blank indicating it is inactive.

(2-Channel V2.xx.xx C2 only) The Diagnostics Inputs / Outputs screen displays the status of the

+24V digital inputs and outputs for both tools simultaneously.

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3.11.2 Diagnostic / Fieldbus

c00403en.bmp

Fig. 3-36: Fieldbus

diafield.txtS

A light box for each available input and output is displayed to show the current status. In case an

input or output is active, the light will be green.

You will find a detailed description of these signals under Advanced / Fieldbus.

A light box near the bottom of the screen indicates the status of the field bus Connection: active

(green) or inactive (red). The Part ID currently being received over the field bus is displayed in

both hexadecimal and decimal format.

diafield.txtE




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3.11.3 Tool / Calibration

c00299en.bmp

Fig. 3-37: Tool / Calibration

testcali.txtS

This test function cyclically recalibrates the system with the values used immediately before the

start of a rundown. The spindle must be released for this function! The values "Offset Voltage"

and "Full Scale Voltage" of the torque transducer are displayed. If redundancy is activated, the

values of the second transducer are displayed. If a value is out of tolerance, it is shown in red.

Rated values and tolerances:

Value Rated value Tolerance

Calibration offset: 0 V +/-200 mV

Calibration voltage: 5 V +/-150 mV

Note:Entering a password and viewing of a warning is required prior to running any "active"

tool diagnostics.

testcali.txtE




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3.11.4 Tool / Angle Encoder

c00301en.bmp

Fig. 3-38: Tool / Angle Encoder

testangl.txtS

The tool start switch starts the spindle with a speed of 30% of the maximum. After one revolution

of the output shaft (set angle 360 deg), measured with the tool resolver, it is stopped. During a

permanently adjusted dwell time of 200 ms any further angle pulses occurring are traced. The

total result is shown as "Actual Angle". The "Shut-off Torque" displayed is the torque prevailing

at shut-off or the maximum value reached during the dwell time if that value is higher than the

torque at shut-off.

If the test run is not terminated by a monitoring criterion, the total result equals or is higher than

360 degrees and is evaluated as okay ("OK"). Monitoring criteria are the torque of transducer 1

and a monitoring time. If the torque of transducer 1 exceeds 15% of its calibration value (evenduring the dwell time), or if the monitoring time of 5 seconds is elapsed, the test run is termi-

nated with "NOK".

The user must check himself, if the output shaft has actually turned by the value indicated (e. g.

put mark on the spindle). If the angle reached by the output shaft does not agree with the value

displayed, either the angle factor is or the resolver is defective.

testangl.txtE




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3.11.5 Tool / Voltages

c00300en.bmp

Fig. 3-39: Tool / Voltages

testvolt.txtS

The table displays the measured voltages of a channel.

These are the most important supply voltages on the measuring board, required for proper

torque and angle measurement. Therefore, these must be monitored continuously. If a voltage is

out of tolerance, it is shown in red.

Designation voltage Rated value Tolerance

Logic voltage: +5 V +250 mV/-400 mV

Pos. analog Positive analog

voltage

+12 V ±600 mV

Neg. analog Negative analog

voltage

-12 V ±900 mV

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3.11.6 Tool / TQ Measurement

c00302en.bmp

Fig. 3-40: Tool / TQ Measurement

testmeas.txtS

This test function recalibrates the system with the values used immediately before the start of a

rundown. The spindle must therefore be released still when this function is called up! Then the

tool is started at zero speed and the torque is continuously measured and displayed. The field

"Current torque" displays the current torque, "Peak torque" displays the highest value measured

since the start of the function. If "Redundancy" is activated, the values of the second transducer

are also displayed.

testmeas.txtE




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3.11.8 Tool / Tool Memory

c00316en.bmp

Fig. 3-42: Tool / Tool Memory

testiden.txtS

Provides a constant update of the tool memory data in the attached tool.

testiden.txtE

3.11.9 Arcnet / Map

c00303en.bmp

Fig. 3-43: Arcnet / Map

arcmap.txtS

The ARCNET map displays information on the current number of participants in the network,

their ARCNET-ID, status, serial and software number and identification. The display is continu-

ously updated, e. g. if the connection with a participant is interrupted, it is removed from the

table, or if a new participant is added, it is added to the ARCNET table.

arcmap.txtE




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3.11.10 Arcnet / Statistic

c00304en.bmp

Fig. 3-44: Arcnet / Statistic

arcstat.txtS

The ARCNET statistics allow to check the stability of the field bus system. There are two differ-

ent statistics:

arcstat.txtE

• For all external hardware components (bridges, TMs)

• For the station controller

The following is a description of the parameters required for stable operation.

TM Bridge

Description

Reconfigurations Change upon each reset of a participant

Own reconfigurations Change upon each reset or severe failure

Excessive NAK Should be stable

New next ID Change upon switch-off/on of downstream participant

CRC error Should be stable

Lost Token Should be stable

Send repetitions Should be stable

Send termination Should be stable

Receive terminations Should be stable

Command errors Should be stable

Unassignable ACKs Should be stable

ACKs with Bit 14/15-Packets without CPT protocol Should be stable

Input queue overflow Should be stable




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Packet not assigned by node Should be stable

Discarded input packets Should be stable

Host Driver Statistics

Reconfiguration Change upon each reset of a participant

Host reconfiguration Change upon each reset or severe failure


Outbound packets - Inbound packets - Next ID Change upon switch-off/on of downstream participant

Excessive NAK Should be stable

Lost Token Should be stable

Statistics of ARCNET Manager

Broadcasts received -

Synchronous starts -

Stopped synchronous starts -


Timeout A Should be stable

Timeout B Should be stable

Wrong ARCNET ID received Should be stable

Packets not for host Should be stable

ACKs in READY status

ACKs in ERROR status Should be stable

Unassignable ACK Should be stable

ACKs with Bit 14/15

Packets without CPT protocol Should be stable

Input queue overflow Should be stable

Packet not assigned by node Should be stable

Discarded input packets Should be stable

TM Bridge




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3.11.11 Serial

c00305en.bmp

Fig. 3-45: Serial Port Diagnostics

serial.txtS

The serial diagnostics allows the user to test the selected COM port by displaying sent (black

text) and received data (red text).

The <F 1> “Start Hardware Test” transmits 10 characters. It reads back a byte based on the CTS

signal. For this test an external Adapter with shorted pins is necessary. Note that serial data dis-

play is only available with serial data transmission configured as “Standard” or “CT01 3964R”.

The Clear Screen (F2) soft key will clear the displayed bytes

The (F3) soft key toggles the transmission record display between ASCII and hexadecimal.

serial.txtE




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3.11.12 Event Log

c00387en.bmp

Fig. 3-46: Event Log

eventlog.txtS

The Event Log allows viewing of errors and events that aid in diagnosing controller or opera-

tional problems. The log displays system startup action, abnormalities detected by the STMH

servo, and field bus communications problems. The <F1> Prev Page and <F2> Next Page func-

tion keys are used to navigate through the list. Up to 999 events are stored. The <F3> "Clear

Event Log" key is used to delete the archive of events

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3.12.2 Utilities / System Settings

c00391en.bmp

Fig. 3-48: System Settings

utilsysset.txtS

System Settings displays the total memory and the available memory of the controller.

utilsysset.txtE

3.13 Administration

3.13.1 Administration / Load/Save

c00307en.bmp

Fig. 3-49: Load / Save

loadsave.txtS

Using the check boxes, the user can select the parameters to load or save to the floppy diskette.




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The Load from Floppy (F2) soft key will search the floppy for the selected parameters and

update them accordingly.

The Save to Floppy (F3) soft key will save the selected parameters to the floppy diskette.

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3.13.2 Administration / Print

c00308en.bmp

Fig. 3-50: Print

setuppri.txtS

Using the check boxes, the user can select the parameters to print. These will be sent to the

printer defined in the Communications setup or to a file on the floppy diskette if selected.

The Print (F3) soft key will start printing. Upon printing a message will be displayed to show the

number of pages being printed.

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3.13.5 Administration / Language

c00360en.bmp

Fig. 3-53: Language

language.txtS

The Administration / Language screen is used to select the language for the user interface. Use

the up and down arrow keys to highlight the desired language, then press <ENTER> to confirm

language.txtE




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3.13.6 Administration / Counter

c00365en.bmp

Fig. 3-54: Counter

counters.txtS

From the Administration / Counter screen, the user may view, enable, disable, or reset any of

the available counters. Counters are provided for each application (1-255) and for each linking

group (1-8). The view is toggled between Application and Linking view by selecting either Appli-

cation or Linking in the pull-down menu.

Each counter may be enabled or reset by highlighting the desired type of operation in the "Sta-

tus" pulldown menu, then pressing the Enter key. When "- Backoff" is selected, the counter is

enabled, and the current count is decremented each time the tool is started in the backoff direc-

tion. The "- Backoff" mode is not available for Linking counters.

The "Auto Reset Mode" allows the counter to operate like a batch counter. In this mode, the

counter is automatically reset to zero after the total number of rundowns (OK + NOK = Size) or

number of OK rundowns (OK = Size) equals the value programmed in the "Size" edit box.

Each counter may be reset manually by highlighting the "Reset" checkbox and pressing

<ENTER>.

Note:The counters are not enabled, disabled, or reset until the Accept (F3) soft key is pressed,

and the correct password (if enabled) and confirmation are provided.

counters.txtE




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3. Designate the Sample Frequency

Selection of the sample frequency should be based on economic considerations for the cost of

measurements and the potential loss that may occur if samples are not taken often enough.

Early in the production run, samples should be taken more frequently and then extended after

satisfactory control is verified. The frequency may be expressed as a time interval or as a por-

tion of quantities produced.

4. Assure Measurement Accuracy

Measurement accuracy is mandatory for successful statistical control. Measuring and test equip-

ment must be of a type suitable for the characteristic being evaluated, and must be calibrated

and properly used. Decisions resulting from the analysis of a control chart will be no better than

the measurement data.

5. Complete the Data Sheet Headings

It is important that all heading entries on the data sheet be completed. They include the part

number and description, the operation performed, the name of the operator, the machine or

equipment used, and the specification limits. The data sheet and control chart can provide evi-

dence of quality for use by the Quality Assurance organization if the information is properly

recorded and traceable to the products manufactured.

6. Start Production

Take samples of five units (preferably consecutive units produced) at the designated frequency,

and record each measurement (X) on the data sheet. For each sample of five calculate the aver-

age ( ) and range (R), and plot the results on the chart (see graph 4-3).

0

4

8

12

16

20

R

X

- Add the five measurements and divide the sum

by five. For a sample of five, it is often easier to mul-

tiply the sum by two and move the decimal one place

to the left.

R - Substract the smallest measurement from the

largest. (Note that the range can never be negative.)

a n g e

v e r a g e

Fig. 4-3: Entries for Range and Average




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calculating the average or range for a sample, and plotting a point on the control chart incor-

rectly.

Special cause variation may be indicated by one of the following situations:

• A point outside a control limit.

• A shift, with several consecutive points inside a control limit but on the same side of the cen-

ter line.

• A trend of consecutive points that moves steadily toward a control limit.

Outside of Limit Shift Trend

Fig. 4-6: Indications of Special Cause Variation

Since we are controlling by evaluating only small sample sizes from the process, the criteria for

continuing production must be the control limits. For this reason, we do not place the specifica-

tion limits (which are recorded on the data sheet) on the control chart.

4.1.4 System Improvement

There are always two risks associated with statistical control. The first is the risk of accepting

bad product, and the second is the risk of rejecting good product. Both are undesirable, but our

primary concern is usually the first since it has a direct impact on customer satisfaction.

The six sigma spread of the process described in this procedure is in general use throughout

American industry. When properly applied, it assures us that at least 99.7% of all units produced

will meet specification. This relates to a risk of delivering three substandard units for each thou-

sand produced. While this provides much better quality than can be obtained with an uncon-

trolled process and 100% inspection, it may not be good enough in the future as competition

becomes stronger in the world market.

So it's important that we continue to improve the manufacturing system - to reduce the influence

of conditions that affect variations in the performance of people, machines, and materials (see

graph 4-7). There will be practical and economic limitations to this effort, but to the extent that

we can further reduce process variation we will increase the probability that all delivered product

meets the specification.

Variation Variation

Spec. Toler. Spec. Toler.

Fig. 4-7: Improving The System By Reducing Variation




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5 Glossary

accepted data data that fall within the acceptable limits in a fastening

strategy

accepted rundown a run cycle within limits

angle capability indexes a measure of acceptable variation of final angle values in

a fastening process

angle control a fastening strategy by which you are controlling a tool by

predetermined angle limits

angle encoder a device that measures the angle of rotation

angle high active if final angle > angle high limit

angle high limit (AHL) the maximum acceptable angle for a run cycle

angle limits the range between the maximum and minimum accept-

able angle for one cycleangle low active if final angle < angle low limit

angle low limit (ALL) the minimum acceptable angle for a run cycle

angle monitor a fastening strategy by which you are monitoring a tool by

predetermined angle limits

angle reject a cycle rejected when the acceptable angle is not

achieved

application a programmed setting of the unit for a given application;

TME 100 has eight application settings. Often referred to

as product groupapplication select 0-2 application selects 0-2 are used to select applications 1-8

using a binary count of 0-7 where app. sel. 0 is the least

significant bit

baud rate the frequency at which the unit communicates

capability of process (Cp) The ratio of the process tolerance to 6 standard devia-

tions. Ranges from 0.0 to infinity with larger values indi-

cating a more capable process. (Often referred to as

Process Potential Index or Inherent Capability Index.)

capability index (Cpk) An index combining the process potential and the mea-

sure of the difference between process and the specifica-tion mean. CPK will equal Cp if the process mean is

centered on the target (nominal) specification value; if

CPK is negative, the process mean (X-Bar) is outside the

specification limits; if CPK is between 0 and 1, then some

of the 6 sigma spread will fall outside of the specifications;

if CPK is larger than 1 then the 6 sigma spread is com-

pletely within the specification tolerance.




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control parameters the parameters that define the fastening strategy

sequence for a given tool

cycle complete active whenever tool is not running

cycle NOK active if torque/angle/yield are outside limits or some

other error has occurred

cycle OK active if torque/angle/yield are within programmed limits

cycle start switch the switch on a tool that initiates a run cycle

default parameters parameters automatically selected by the unit

desired final torque the final torque desired in a fastening process (referred to

as torque setpoint)

end delay time [ms] time delay from the tool turnoff until the torque measure-

ment ends

engineering units units of torque measurement

external transducer a transducer physically located on the outside of a tool

fastener rotation direction in which a fastener rotates

fastening strategy a strategy used to control or monitor a fastening process

final angle the final angle desired in a fastening process

histogram a printout generated from statistical data output

if NOK go to stage gives the control system direction if the stage is NOK

internal transducer a transducer physically located inside the tool

LCD screen the screen on the unit that provides directions to program-ming the unit

LED flashing in reverse if yes, the tool LED's will blink when the tool is in reverse

LED screen the screen on the unit that provides the readout data from

a run cycle

linking Allows the user to automatically change from application

to application for a predefined number of positions (up to

32). Up to eight different linking strategies called Tighten-

ing Groups can be programmed and are remotely select-

able from the Application Inputs (0-2). This feature can

also be used for Batch Counting by entering the same

application in the desired number of positions.

load refers to the amount of torque applied to a device or tool

main menu the first menu that appears on LCD screen

marking output output from paint marker solenoid after each cycle

master transducer a transducer used as a benchmark to calibrate another

transducer




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max. fastening time [mS] max time for the tool to run during the stage

mean (Xbar) the average of all readings taken in a sample

number of Repeats NOK

(linking)

Selects the number of time a fastener can be retightened

after an NOK before going to the linking position.

NOK after reverse if yes, the controller will report an NOK if the tool is run inreverse

peak torque the maximum torque achieved in a run cycle

port the socket used for connecting a cable or peripheral

equipment

position (linking) A number 1 to 32 that determines the order in which appli-

cations will be run during linking.

power supply a unit used to supply power to an electrical device

pulses per degree number of encoder pulses generated by the tool when

rotating the head exactly 1 degree or 1/360 of a revolution

range (R) a statistical measurement of the difference between the

lowest and highest reading taken in a sample

redundant transducer secondary transducer used to read torque

redundant transducer calibra-

tion

the calibration process of the secondary transducer

reject interlock the stopping of further operation of the system after a pre-

determined number of rejected cycles has occurred

rejected data the data generated by unacceptable rundowns

rejected rundown a rundown that has not met the criteria of a fastening

strategy

remote parameter select a remote device that bypasses the parameter select but-

ton on your unit

reset after NOK (linking) Determines whether the controller will reset to linking

position 1 after an NOK.

rundown printout gives the control system direction for when to print

run number number of accepted and rejected rundowns

second transducer frequently referred to as the redundant transducer

sequence 11 high speed rundown

sequence 30 torque control/angle monitor

sequence 50 angle control/torque monitor

sequence 41 angle controlled backoff

speed max speed of the nutrunner during the tightening stage




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standard deviation (σ) the measurement of the scatter of the population around

a mean

start delay time [ms] time delay before the stage will start

start spike time [ms] time delay for the control system to start measuring

torque after the stage starts

statistical data data used to measure the performance and accuracy of

the unit and tool

status light lights located either on the unit or tool that represent

accepted and rejected cycles

sub group size (Sub Sz) the sub group size of data used for statistical analysis; the

smallest sub group size = 5

synchronization input when active allows the tool to start from stage to stage in

conjunction with tool start

synchronization output active at the end of each stage to signal a stage is com-

plete

threshold torque [Nm] torque to begin counting angle

tightening group (linking) Contains a specific linking strategy of up to 32 positions.

It is remotely selectable from the Application Inputs (0-2).

tool enable when active allows the tool to start in conjunction with tool

start

tool rpm capability maximum allowable speed of the tool

tool reverse when active prior to tool start, the tool will run counter-

clockwise using the backoff strategy

tool start (LCD and outputs

also clear)

starts the tool

tool stop stops the tool

torque capability indexes a measure of acceptable variation of final torque values in

a fastening process

torque control a fastening strategy by which you are controlling a tool by

predetermined torque limits

torque filter factor used for torque averaging

torque high active of peak torque > torque high limit

torque high limit (THL) the maximum acceptable torque value for one cycle

torque low active if peak torque < torque low limit

torque low limit (TLL) the minimum acceptable torque value for one cycle

torque monitoring a fastening strategy by which a tool is monitored based on

predetermined torque limits




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torque reject a cycle rejected when the acceptable torque is not

achieved

torque threshold (TTH) the point at which the angle counting starts

transducer a device used to read torque

transducer span(torque cal.)

full load reading of transducer

trigger torque [Nm] torque to start collecting oscilloscope data

turn off angle the angle at which a tool is shutoff

turn off torque the torque at which a tool is shutoff

cooper tme manual

Documents