FUSIONE-HS-3

Fusion
SYSTEM
OPERATION MANUAL

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 WARNING
All applicable national and local codes must be followed when installing and operating the equip-
ment detailed in this manual.

FAILURE TO ABIDE BY THESE CODES AND THE SPECIFICATIONS DESCRIBED IN THIS

MANUAL CAN RESULT IN SERIOUS INJURY TO PERSONNEL AND/OR DAMAGE TO THE
EQUIPMENT!

Any questions regarding the contents of this document or any related matter should be
directed to FEC INC. at (586) 580-2622, faxed to (586) 580-2620 or emailed to:
[email protected].

The information set forth in the following document is the property of FEC INC.

This document shall not be released to or copied for any person and/or organization
With out the expressed prior consent of FEC INC.

Unauthorized reproduction or distribution of this manual is strictly prohibited.

Please contact FEC INC. if you require additional copies.

 Revision History
Revision
Manual No. Content of Revision
date
2005/July First Edition Original Operation Manual

2007/August FUSIONE-HS-2 Revision 2 - Updated format & added relevant information

MINOR Revision – Chapter 2 – Page 2-4 (Chapter Rev. 2.1 now)
2008 / June FUSIONE-HS-2
Updated Power Consumption (Running & Idle)
MINOR Revision – Chapter 4 – Page 4-48 – 4-53 (Chapter Rev.2.1 now)
2008 / July FUSIONE-HS-2
Added DeviceNet Interface
2014 / Dec FUSIONE-HS-3 MAJOR Revision – Updated with all changes since 2008
Minor Rev. – Chap. 7 rev 3a -Updated Tubenut Op. Parameters (pg7-39
2015 / Oct FUSIONE-HS-3
– 7-40)

Manual Numbering Convention

FUSIONE -HS-3
DSP1500 = Servo Press Version Number
AFC1500 = Nutrunner (Major Revision Level)
FUSION = DC Hand Tool

HS = Controller unit Hardware

E = English Version
Operation Manual
S = Spanish Version
HM = Multi / Main Unit Hardware
*Japanese Version furnished by DDK uses Operation Manual
DDK numbering convention. HM-ENET = Ethernet Manual for
Multi / Main Unit
SW = Software Manual
 Introduction

Thank you for purchasing our Electric Servo Nutrunner – FUSION System.
This instruction manual describes the procedures for installation, wiring, and handling, and
actions to be taken in case of any failure.

◆ This instruction manual shall be delivered to the end user who operates the equipment.
◆ Read all instructions before use, and always keep this instruction manual with the equipment.
◆ Items not described in this instruction manual shall be considered “unavailable”.
◆ The product specification and appearance described in this instruction manual is subject to
change without notice.
◆ All rights reserved. Any disclosure, copying, distribution, or use of the information contained
herein for other than its intended purpose, is strictly prohibited.

For the safety of operator and equipment

◆ It is important for you to read all “Safety Precautions” before using the equipment, and under-
stand and observe all instructions and recommendations included in this manual.
◆ Read all instructions and recommendations included in this manual, understand the functions
and performance of this nutrunner, and correctly use this equipment.
◆ Wirings and parameter settings shall only be conducted by a qualified professional.
◆ Never conduct a withstand voltage test or insulation resistance test on this equipment.

◆ Indicate the following on all instruction manuals that use this equipment.
”This equipment is capable of high voltages hazardous to human life.”

Points to check when unpacking

Please confirm the followings when unpacking this equipment.

◆ Ensure that you received the correct model, as ordered.

◆ Ensure that there are no missing parts.
◆Check for any damage caused during transportation.
 Introduction

Warranty

Warranty Period
The standard warranty period is one year from the date of purchase or one year from delivery to
the designated End User (not to exceed 18 Months). Actual terms are order specific.

Provision of warranty
If your product proves to be defective, although it has been used properly in accordance with
this instruction manual, during the period of warranty, this product will be repaired free of
charge.
However, in the following cases, the customer will be required to pay for repair charges, even for
defects occurring within the warranty period.
1. Any defect due to improper conditions, improper circumstances, and improper handling.
2. Any defect due to modifications or repairs performed by the customer.
3. Any defect caused by other equipment.
4. Any defect caused by customer failing to meet the equipment’s specification.
5. Any defect due to natural disasters and accidents.
This warranty shall be limited to repairing or replacing this product. Any liability for indirect or
consequential loss or damage of any kind incurred or suffered by the customer due to a defect
of the product is excluded.
 Safety Precautions
Read all instructions before operating the equipment in order to use this equipment safely and cor-
rectly. Prior to use, read this instruction manual carefully and fully understand the equipments func-
tions, safety precautions and instructions. Safety precautions in this manual are marked with two
symbols [Warning] and [Caution].

To prevent danger to the user and other persons as well as property damage, instructions that must
be fully observed are marked with the symbols below.

◆ This instruction manual uses the following two symbols according to the degree of damage that
may be caused when the instruction is not observed.

This symbol indicates that failure to observe instruction marked

Warning with this symbol may result in severe personal injury or death.

This symbol indicates that failure to observe instruction marked

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

Caution
Even instructions that are marked with may result in severe damage if they are
not observed according to conditions.
Contents marked with the above symbols are very important instructions. For your safety, follow all
instructions and especially those marked with these symbols.

◆ This instruction manual uses the following additional symbols for instructions that shall be ob-
served.

Warning: Warning:
Electric shock Fire

Caution: Caution: Caution:

Fire Electric shock High Temperature

Prohibited Do not disassemble

Required Ground
 Safety Precautions

Warning

Do not remove the motors and gear cases of tools while power is applied..
The tool output spindle may rotate and cause injury.

Do not repair, disassemble, or modify the equipment individual components of the system..
Failure to observe this instruction may cause injury, electric shock, fire, and malfunction.

Never operate the equipment where it is exposed to water, near a corrosive atmosphere
or flammable gases. Failure to observe this instruction may cause fire.

Keep fingers away from the connectors while the equipment is turned ON and for a while af-
ter the equipment is turned OFF. Failure to observe this instruction may cause electric
shock.

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

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

Turn OFF the power when conducting wiring operation and maintenance.
Failure to observe this instruction may cause electric shock and injury.

Never damage the cables, apply excess stress to cables, or squeeze the cables.
Never use damaged cables.
Failure to observe this instruction may cause electric shock and fire.

Properly GROUND all Field Ground (FG) Connections and terminals including the ground
pin on the POWER CORD. NEVER operate this equipment without the ground pin on the
power cord grounded!
Failure to observe this instruction may cause electric shock.

In case of an abnormal odor, noise, or operation error occurrence, stop operation immediately
and turn OFF the power source. Failure to observe this instruction may cause injury and fire.

Install a Power shutdown device in order to ensure the safety of equipment.

Failure to observe this instruction may cause injury.

When equipment is automatically operated, install an emergency stop circuit on the outside of
equipment in order to stop operation promptly. Failure to observe this, may cause injury.

Keep away from the equipment during recovery from a temporary blackout, and ensure safety
measures are conducted after restarting the equipment. The equipment may suddenly restart.
Failure to observe this instruction may cause injury.
 Safety Precautions

Transportation / Storage Caution

Transport the equipment properly according to its weight.

Failure to observe this instruction may cause injury and malfunction.

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

◆Ambient temperature: -5°C～+55°C (Avoid freezing)
◆Ambient humidity: 50% RH or lower (Avoid moisture)
◆Package: Tight seal
◆Rust prevention measure: Apply light oil on steel portion of tools.
Failure to observe this instruction may cause earth leakage and malfunction.

Do not transport tools by grasping cables.

Failure to observe this instruction may cause injury and malfunction.

.The equipment shall be stored under the following conditions.

◆Ambient temperature: -5°C～+55°C (Avoid freezing)
◆Ambient humidity: 90% RH or lower (Avoid moisture)
◆Atmosphere: Indoors (Avoid direct sunlight)
No corrosive gases or flammable gases
No oil mist, dust, water, salt, iron powder
◆Avoid direct vibration or shocks
Failure to observe this instruction may cause a ground fault and malfunction.
 Safety Precautions

Installation / Wiring Caution

Install or provide torque reaction for all tools where they can bear the maximum torque during
operation. Failure to observe this instruction may cause injury and malfunction.

Make sure controller is firmly mounted and will not come lose or fall during operation.
Failure to observe this instruction may cause malfunction.

The power source shall be provided with safety measures such as breakers and
circuit protectors. Failure to observe this instruction may cause fire and malfunction.

Do not use tools or controller units that are damaged or missing parts.
Failure to observe this instruction may cause fire, injury, and malfunction.

Do not subject the equipment to excess shock and impact.

Failure to observe this instruction may cause malfunction.

Route all wiring(s) properly and firmly.

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

Operate the equipment within the specified power supply voltage.

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

When operating the equipment in the following conditions, take sufficient measures
to shield the equipment.
◆Location where electrical noise is generated
◆Location where the equipment is subjected to a strong electric field or magnetic field
◆Location near a high power wire.
Failure to observe this instruction may cause injury, false operation, and malfunction.
 Safety Precautions

Operation / Adjustment Caution

Never operate the equipment with wet hands or while standing in a wet location.
Failure to observe this instruction may cause electric shock.

Properly GROUND all Field Ground (FG) Connections and terminals including the ground
pin on the POWER CORD. NEVER operate this equipment WITHOUT the ground pin on the
power cord grounded!
Failure to observe this instruction may cause electric shock.

Use the equipment under the following conditions.

◆Ambient temperature: 0°C～+45°C (Avoid freezing)
◆Ambient humidity: 90% RH or lower (Avoid moisture)
◆Atmosphere: Indoors (Avoid direct sunlight)
◆No corrosive gases or flammable gases
◆No oil mist, dust, water, salt, iron powder
◆Avoid direct vibration or shocks
Failure to observe this instruction may cause a ground fault and malfunction.

Confirm and adjust all parameters before operation in order to prevent unexpected
movement of the equipment.
Failure to observe this instruction may cause injury, false operation and malfunction.

The equipment may experience sudden torque reaction when operated by hand while
engaged to a part. Grasp tool firmly with firm footing when operating. Additionally, be sure
the work piece is securely clamped from any movement during torqueing operations.
Failure to observe this instruction may cause injury.

Do not turn ON and OFF the equipment repeatedly.

Failure to observe this instruction may cause malfunction.

Do not use the equipment at torque higher than the maximum torque.
Failure to observe this instruction may shorten equipment life or cause malfunction
due to the high temperature caused by overload.

In case any abnormality occurs, remove the cause and ensure safety before resetting
and restarting the equipment.
Failure to observe this instruction may cause injury.
 Table of contents

Table of Contents

Page
Chapter 1: Outline 1-1
1.1 About This operations manual 1-2
1.2 Features 1-3
1.3 Functions. 1-5
1.4 System requirements 1-6
Chapter 2: Specifications 2-1
2.1 Main Specifications 2-2
2.2 Duty Cycle Calculation 2-3
2.3 Controller Unit Specifications 2-4
2.4 Capability. 2-5
2.4.1 Nutrunner Tool Specification Table. 2-6
2.4.2 Nutrunner Decimal Point Display Table. 2-7
Chapter 3: System Description 3-1
3.1 Controller 3-2
3.1.1 Controller Part Number Breakdown 3-2
3.1.2 Controller Front Panel 3-3
3.1.3 Controller Back Panel 3-5
3.2 Fusion Tool 3-7
3.2.1 Fusion Tool Part Number Breakdown 3-7
3.2.2 Fusion Angle / Straight Tool Components 3-8
3.2.3 Fusion Pistol Tool Components 3-9
Chapter 4: System Setup and Wiring 4-1
4.1 Design and Build Procedure 4-2
4.2 Component Dimensions 4-3
4.2.1 Controller Unit Dimensions 4-3
4.3 Unit Arrangement 4-4
4.4 Nutrunner (Tool) Dimensions 4-5
4.4.1 Straight Tool 4-5
4.4.2 Right Angle Tool 4-6
4.4.3 Pistol Tool 4-7
4.5 Connection Diagrams 4-8
4.6 Power Requirements and Connections 4-9
4.6.1 Controller Unit 4-9
4.7 Wiring PLC I/O 4-10
4.7.1 Explanation of Controller Unit I/O 4-11
4.7.2 Work / Parameter Select Table 4-12
4.7.3 Bank Select Table 4-13
4.7.4 Bank Output Servo Error Table 4-15
4.7.5 PLC Wiring Sample 4-16
4.8 RS-232 Data Communication Ports. 4-18
4.8.1 Front Panel DB9 PC Connection for AFC User Console Software 4-18
4.8.2 Rear Panel DB9 PC Connection (RS232) 4-19
4.8.3 Rear Panel RS232 Communication Protocol 4.20
4.8.4 Rear Panel RS232 Alternate Communication Protocol 4-24
4.8.5 Rear Panel RS232 Alternate Communication Protocol 4-25

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Table of contents
4.9 Torque/Angle MON. DB9 (external monitoring connector). 4-26
4.10 Controller Unit DIP Switch setting. 4-27
4.10.1 Controller Unit DIP switch positions 1 ~ 3 4-27
4.10.2 Controller Unit DIP switch positions 4 ~ 8 4-28
4.11 Tool Connection (cabling) 4-29
4.11.1 Cable Installation Guidelines 4-30
4.11.2 Considerations for Cable Trolleys 4-31
4.11.3 Considerations for Flexible Cable Tracks 4-31
4.11.4 Considerations for Cable Trays and Ladders 4-31
4.11.5 Tool Cable - Preamplifier Connector. 4-32
4.11.6 Tool Cable - Motor Connector 4-32
4.11.7 Tool Cable - Resolver Connector 4-32
4.12 Firmware Flash Connector (CN8). 4-33
4.13 SYNC Connector 4-34
4.14 Options – Ethernet Card 4-35
4.14.1 Ethernet Set-up of PC to Communicate to Ethernet Module 4-36
4.14.2 Ethernet Module Connection 4-37
4.15 Options – Fieldbus Interfaces 4-38
4.15.1 Fieldbus Interfaces – Profibus-DP 4-39
4.15.2 Fieldbus Interfaces – Allen Bradley Remote I/O 4-47
4.15.3 Fieldbus Interfaces – DeviceNet 4-51
4.15.4 Fieldbus Interfaces – Ethernet I/P 4-57
4.15.5 Fieldbus Interfaces – CC-Link Ver. 2 4-66
4.15.6 Fieldbus Interfaces – Profinet 4-79
4.15.7 Fieldbus Interfaces – Message Output Format 4-90
Chapter 5: Power Up and Initial Checks 5-1
5.1 Before Powering On 5-2
5.2 Initial Data Setting 5-3
Chapter 6: Fastening Instructions 6-1
6.1 Fastening Control 6-2
6.1.1 Torque Control Method 6-2
6.1.2 Angle Control Method 6-6
6.2 Monitoring Functions 6-12
6.2.1 Peak Torque Monitoring 6-12
6.2.3 Final Torque Monitoring 6-14
6.2.3 Angle Monitoring 6-16
6.2.4 Point-to-Point Torque Rate Monitoring 6-18
6.2.5 Time 6-20
6.3 Speed Functions 6-21
6.4 Reverse Functions 6-23
6.5 Torque Recovery 6-24
6.6 Added Functions 6-25
6.6.1 Current Monitor / Control 6-25
6.6.2 Angle Correction 6-26
6.6.3 Reduced Fastening Reaction 6-26
6.6.4 VariSpeed 6-26
6.6.5 Work (Batch Counting) 6-26
6.6.6 Torque Inhibit 6-27

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 Table of contents

Chapter 7: System Operations 7-1

7.1 Fusion Display and Programming Unit Operation 7-2
7.1.1 Manual Fastening controls 7-2
7.1.2 Fastening Indicators 7-3
7.1.3 Fastening Preset / Result displays 7-3
7.1.4 Fastening Presetting / Result Display Controls 7-4
7.2 Run State Modes. 7-5
7.2.1 Display indication modes. 7-5
7.2.2 Real-time display indication mode. 7-6
7.2.3 Fastening results display mode. 7-7
7.2.4 Parameter display mode 7-8
7.2.5 Parameter Data List & Data Explanation 7-9
System “D-No.” Explanation 7-12
Batch / Sequence Function 7-27
7.2.6 Status Display 7-30
7.3 Download / Setup Mode Operation. 7-31
7.3.1 Download Mode selection 7-31
7.3.2 Setup Mode selection 7-32
7.3.3 Parameter Number Selection. 7-33
7.3.4 Data # selection 7-34
7.3.5 Data Edit Mode Operation 7-35
7.3.6 Parameter Copy 7-36
7.4 Calibration adjustment. 7-37
7.5 Optional Real Time Clock Module 7-38
7.6 Tubenut Head Setup 7-39
7.6.1 Recommended Parameter Setup for Tubenut Head 7-40
7.6.2 Tubenut Head Operation 7-41
Chapter 8: Maintenance and Inspection 8-1
8.1 Inspection Items 8-2
8.1.1 Nutrunner (Tool) 8-2
8.1.2 Tool Cable 8-2
8.1.3 Controller Unit 8-3
8.1.4 Auxiliary Tool Heads 8-3
8.2 Basic operational tests 8-4
8.2.1 Torque transducer. 8-4
8.2.2 Resolver. 8-4
8.2.3 Motor. 8-4
8.2.4 Transmission Disassembly and Inspection 8-6
8.3 Replacements 8-7
8.3.1 Controller Unit Replacement 8-7
8.3.2 Replace Nutrunner (tool) 8-8
8.3.3 Replace Homerun cables 8-8
Chapter 9: Troubleshooting 9-1
9.1 Abnormal Conditions. 9-2
9.2 Torque Transducer Abnormals. 9-3
Calibration Error 9-3
9.2.1 Code 1-0 Torque transducer / Zero Voltage error. 9-3
9.2.2 Code 1-1 Torque transducer / Cal Voltage error. 9-3

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Table of contents
9.2.3 Code 1-2 Torque transducer / Zero check error. 9-4
9.2.4 Code 1-3 Torque transducer / Cal self-check error. 9-4
9.2.5 Code 1-4 Torque transducer / started on Zero condition error. 9-4
9.2.6 Code 1-5 Torque transducer / started on Cal condition error 9-4
9.2.7 Code 1-6 Torque transducer / Zero Level Self Check Error 9-5

9.3 Torque Over 9-6

9.3.1 Code 2-1 Torque Over Abnormal / Torque Inhibit High Limit 9-6
9.3.2 Code 2-2 Torque Over Abnormal / Angel Head Variation 9-6
9.4 Tool EEPROM Errors 9-7
9.4.1 Code 3-0 Preamplifier / Tool ID Checksum error 9-7
9.4.2 Code 3-1 Preamplifier / Tool type error 9-7
9.4.3 Code 3-2 Preamplifier / Started without tool connected 9-7
9.4.4 Code 3-3 Preamplifier / Tool is not connected 9-7
9.5 System Memory Errors 9-8
9.5.1 Code 4-0 system memory error / Flash ROM write error 9-8
9.5.2 Code 4-1 system memory error / Flash ROM read error 9-8
9.5.3 Code 4-2 system memory error / Servo Amp Flash ROM error 9-8
9.6 Servo Amplifier Response / Resolver 9-9
9.6.1 Code 5-0 Servo Amplifier reply error / No reply from Resolver 9-9
9.7 Servo Type Error 9-10
9.7.1 Code 6-0 Servo Type error / Servo Type mismatch 9-10
9.9 Servo Amplifier Error 9-11
9.9.1 Code 8-1 Servo Amplifier error / Servo is over heated 9-11
9.9.2 Code 8-4 Servo Amplifier error / Over current 9-11
9.9.3 Code 8-5 Servo Amplifier error /Internal power supply. 9-11
9.9.4 Code 8-6 Servo Amplifier error / Input Voltage abnormal 9-12
9.9.5 Code 8-9 Servo Amplifier error / Over speed. 9-12
9.9.6 Code 8-10 Servo Amplifier error / over load ( I square T) 9-12
9.9.7 Code 8-11 Servo Amplifier error / Resolver Signal Error . 9-12
9.9.8 Code 8-14 Servo Amplifier error / Motor Control Circuit Error . 9-13
9.9.9 Code 8-15 Servo Amplifier error / Power On Error . 9-13
9.10 Parameter Error 9-14
9.10.1 Code 9-0 Parameter Error / Missing speed preset. 9-14
9.10.2 Code 9-1 Parameter Error/ Missing Speed or Time 9-14
9.10.3 Code 9-2 Parameter Error/ Parameter Select Error 9-14
9.10.4 Code 9-3 Parameter Error/ Missing Reverse Speed 9-14
9.10.5 Code 9-4 Parameter Error/ Torque Speed not set 9-14
9.10.6 Code 9-5 Parameter Error/ Torque Setup Error 9-15
9.10.7 Code 9-6 Parameter Error/ Angle Setup Error 9-15
9.10.8 Code 9-7 Parameter Error/ Reverse Torque over. 9-15
9.11 AFC1500 SAN Unit Fastening Faults and Causes 9-16
9.11.1 Accept Conditions 9-16
9.11.2 Torque Reject Conditions 9-16

iv
FEC FUSION Operations Manual Chapter 1: Outline (Rev 3)

Chapter 1: Outline

Page 1-1
Chapter 1: Outline

1.1 About This operations manual

This manual details the configuration, components, specifications, and the operation of the FUSION Fastening
System.

The following table outlines the contents of each chapter:

Chapter Item Contents

Chapter 1 Outline Basic characteristics and requirements of the
FUSION System.
Chapter 2 Specifications General specifications of the FUSION System.
Chapter 3 System Description Description of standard and optional system
components.
Chapter 4 System Setup and Wiring Equipment installation procedure, dimensions,
Input and Output signal descriptions and
requirements for PLC programming.
Chapter 5 Power Up and Initial Checks Preliminary power on and operational tests.
Chapter 6 Fastening Instructions Basic fastening operations and presetting
procedures.
Chapter 7 System Operations Instructions for the input of preset data and
monitoring explanations.
Chapter 8 Maintenance and Inspection Guide for preventive maintenance.
Chapter 9 Troubleshooting Descriptions of fastening rejects, abnormal
operation faults, and corrective actions.

Page 1-2
FEC FUSION Operations Manual Chapter 1: Outline (Rev 3)

1.2 Features
The FUSION Fastening System is a culmination of over twenty years of electric fastening expertise
integrated with the latest electronic technology. The system is designed with modular construction in
mind. The basic elements of this system are:
1) A brushless DC permanent magnet high speed motor, with resolver feedback
2) A combination Fastening Controller / Servo Amplifier
3) 32-bit RISC (Reduced Instruction Set Computing) CPU for spindle control
4) Fully digital controlled drive amplifier
5) Configurable communications interfaces

 Compact Design
The controller can be set on a tabletop/shelf or back panel mounted using the mounting
holes on the controller back cover. The controller maintains a maximum width of
160mm in spite of the built-in power source, controller interface and servo amplifier.
Controllers operate on single-phase 100 ~ 230 VAC (Auto switching) for simplified
connection to standard plant floor receptacles.

 Front Keypad-Display.

A front keypad display is an integral component for programming single units and/or
monitoring the fastening results and status conditions in the system. Large
alphanumeric LED displays and status lights provide excellent visibility in plant
operations.

 Fastening Functions.
Fastening can be performed in either the Torque Control or the Angle Control method.
Angle (rotational) and torque rate monitoring provide additional error proofing functions.

 Parameter Selection
 Totally digitized system eliminates analog potentiometers.
 Up to 32 sets of parameters can be stored into Flash ROM.
 No battery-backup of memory is required.

 “No Cost” AFC User Console Programming Software

Nutrunner programming and data collection can be performed via the user-friendly AFC
software provided at no cost with every system. Functions such as Preset Parameter
programming, fastening data monitoring and fastening data analysis can be performed.
The software is primarily utilized on single spindle application in a detachable mode via
a laptop computer with RS232 communications.

 Communication and I/O Interface

(1) Programming and Display – Front Panel -Input/Output – Manual interface.
(1) RS232 – Front Panel - Input/output – Programming and Data collection
(2) RS232 – Rear Panel – Output – Printer or data collection device.
(1) T/A MON – Front Panel – Output – Analog Torque and Angle analysis.
(1) Discrete I/O Terminal – Rear panel - Control and PLC interface
(1) Optional Ethernet – Programming & Data collection (Removes Front RS232 if
installed)
(1) Optional Fieldbus I/O interfaces – Input/Output – Control and PLC interface

Page 1-3
Chapter 1: Outline

 Motor
A permanent magnet High Speed DC motor provides for improved fastening control.
The sealed design of the motor provides greater protection from contamination without
generating excess heat. The resolver is uniquely designed to withstand harsh
environments and provide high resolution control / angular feedback signals.

 Preamplifier
Quality control of the tool torque transducer is accomplished electronically (digitally)
through the EEPROM (Electrically Erasable Programmable Read Only Memory) in the
preamplifier. During factory setup of the torque transducer, the unit is Dead Weight and
Dynamically tested against Standards that are certified and traceable to the National
Institute of Standards and Technology. The resultant data is then programmed into the
preamplifier where it is stored on non-volatile EEPROM. The preamplifier also contains
the “Smart Tool ID” system which allows automatic tool recognition and protects against
misapplication of tools onto the wrong controller or set-up.

 Servo Amplifier (Servo Drive)

Reduced equipment size with improved drive circuit strength is the result of
incorporating Isolated Gate Bipolar Transistor (IGBT) technology into the drive System.

 Plug-In Firmware Update System

The CONTROLLER Firmware is stored in Flash ROM and can be rewritten with future
Firmware updates via a plug-in connector located on each unit. There is no need to
remove the unit or disassemble the unit for any Firmware upgrades.

 Motor, Resolver and Transducer Combined Cable

A single high flex cable incorporates durable metal connectors to provide for extended
life in harsh environments. Twist lock connectors provide easy separation of
connection points for maintenance, while maintaining superior contact under operating
conditions. Separate tool and extension cables (Straight and 90 Degree) are available
for improved cable management.

 ToolsNet / Network Connectivity

Optional Ethernet connectivity (10/100BaseT) available for export of fastening data or

connection to existing Atlas Copco ToolsNet network via the Open Protocol for
ToolsNet.

 Fastening Results Data Storage

Fastening Data results are stored in internal FLASH memory of each controller.
(Approx. 10,000 data cycles) and can be uploaded using the AFC Programming/Monitor
Software.
Past Torque Curves are stored in RAM memory and can be uploaded as long as power
has not been turned off to the controller. Once power is turned off, previous Torque
curves stored are erased. Torque curves are automatically stored after each cycle
when power remains “On”.

Page 1-4
FEC FUSION Operations Manual Chapter 1: Outline (Rev 3)

1.3 Functions.
 Fastening function.
The following fastening control methods can be selected for either clockwise (CW) or
counterclockwise (CCW) operation:
 Torque Control / Angle Monitoring
 Angle Control / Torque Monitoring

The Controller unit has capability for one, two & three step fastening.
Torque rate monitoring in up to 3 areas is available in any configuration.

 Multi-Speed Rundown
The Initial, Freerun, Slowdown, Torque and Reverse speed set-ups provide capability of
multi-speed fastenings for any application.

 Reject / Abnormal Condition Display

When a fastening Reject has occurred the system stops, outputs the appropriate signal
and displays the resultant data in the Keypad-Display. Upon a fastening reject, the unit
will not require resetting prior to the next cycle.

The System will output an abnormal signal when it detects there is a problem (Zero
Check out of limits, incorrect component connection, etc.) within the system itself. The
output will be displayed as a code on the Front Panel Display. Refer to Chapter 9
Troubleshooting for more details. Reset of the system is required on an abnormal
before normal operation can resume.

 Axis Bypass Function

When a PLC Bypass input signal is activated, the Bypass output signal is activated. In
this condition, the spindle will not START, REVERSE, CAL OR RESET.

 Auto Tool Recognition (Smart Tool ID)

The FUSION tools have an EEPROM in the preamplifier that contains tool data specific
for each tool. The Tool type check function reads the information of the tool EEPROM
and compares it to the information of the CONTROLLER unit; any mismatch is reported
as a Tool Type Error Abnormal.

The tool type check is performed during the following times:

1) When the equipment is powered on.
2) When preset data is downloaded from a user console to the Axis unit.

 Torque Recovery
The ability to “hold” torque after fastening allows the system to overcome problems
associated with joint relaxation or “slip stick” friction. After peak torque has been reach,
this function allows the tool to “hold” torque for a pre-programmed number of pulses.

 Batch Counting
The Batch Count function allows multiple fastening accepts to be counted for an overall
“Work Accept” of the work piece.

 Parameter Sequence
Up to an 8 Step Sequence can be programmed when additional sequencing or
parameters are required by applications or processes

Page 1-5
Chapter 1: Outline

1.4 System requirements

To ensure the most effective and extended use of all equipment, adhere to the following
specifications:

 Tool Installation
Tools can generate a large amount of torque during operation, and the reaction force is
applied to the Operator or mounting area of the tool. Therefore, tools must be installed
in the proper positions and with adequate reaction devices. Tools MUST be mounted
either using there supplied mounting plate or clamped only in designated areas of the
tool or tool damage may result.

Keep in mind that the fastening tool is a strain gage based instrument and, although it
has been designed to withstand sudden shock, repeated shock (over time) could
damage some components. Therefore, support devices must be used whenever
practical to ease in handling and operation of the Fastening Tool.

 Fastening Operation
Avoid fastening beyond the full scale torque. Do not use a duty cycle (the ratio of the
tool “On” time to Tool “Off” time) higher than 50%, even when the torque is below the
full scale value.

 Cable Wiring
 Use the specified cables for all System connections.
 Completely lock the tool cable twist lock connectors.
 PLC I/O cables must be run separate from any high voltage power sources or cabling, and
must not exceed 50 feet in length.
 GROUNDING of the controller is REQUIRED (Perform Class 3 grounding) – Make sure the
controllers power cable ground pin is connected to a proper ground.

 Control Equipment Installation Environment

 Controller units must be located a minimum of 600 mm from high transient voltage sources
such as transformers, motor starters, AC inverters and AC contactors. If it cannot be
avoided, the units must be properly shielded.
DO NOT use at the following locations.
 Areas under direct sunlight.
 Areas where the environmental temperature is out of the 32 °~122°F (0° ~ 45°C) range.
 Areas where the relative humidity is below the 20% range.
 Areas where the relative humidity is above the 90% range.
 Areas where the temperature changes quickly, which may cause moisture.
 Areas where conductive powder, oil mist, saline, or organic solvents exist.
 Areas that have corrosive or combustible gases.
 Areas that have strong electric or magnetic fields.
 Areas where a strong vibration or shock could be transmitted directly to a Controller unit or
tool.

 Static Electricity
FUSION System construction incorporates electronic Surface Mounted Devices (SMD).
It is advisable to strictly adhere to practices for safe electrostatic discharge in order to
prevent damage to the System when handling the units.

Page 1-6
FEC FUSION Operations Manual Chapter 1: Outline (Rev 3)

 Cleaning
Do not use any organic solvents, such as thinner, to clean a Controller unit or a tool.
The solvent could melt the surface paint, or penetrate inside and cause damage. A
cloth dampened with alcohol or warm water should be used to lightly wipe the
components.

 Handling and Shipping

It is critical that FUSION System components are properly handled and shipped in order
to maintain the System's integrity. Adhere to the following requirements for shipping
and handling:

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

static container or wrap to prevent damage from electrostatic discharge.
 Adhere to Chapter 2 Specifications for environmental requirements.

Page 1-7
Chapter 1: Outline

(Blank Page)

Page 1-8
FEC FUSION Operations Manual Chapter 2: Specifications (Rev. 3)

Chapter 2: Specifications

Page 2-1
Chapter 2: Specifications

2.1 Main Specifications

Power Supply Voltage
 Single Phase 100 ~ 240 VAC +/- 10% , 50/60 Hz Auto-Switching
(Supplied with 100-120VAC Cable 5meter)

Installation Requirement
 No Vibration should be applied directly to the Controller. Securely mount controllers to a fixed
point.

Range of Operation
 Duty cycle below 50% (reference Section 2.2 Duty Cycle Calculation)

Operating Conditions
 Temperature: 0° ~ 50°C (32° ~ 122°F)
 Humidity: 20% ~ 90%, no condensation shall be present
(In cases where equipment may be used outside of the prescribed conditions, forced cooling /
heating is required for operation)

Storage Conditions
 Temperature: -5° ~ 55°C (23° ~ 131°F) (no freezing)
 Humidity: Below 90%, no moisture

Shipping Conditions
 Temperature: -5° ~ 55°C (23° ~ 131°F) (no freezing)
 Humidity: Below 90%, no condensation shall be present
 Packing: Pack controllers in sealed (from open air) bags.
Apply light oil to any steel portion of the tool unit to prevent rust/corrosion

Page 2-2
FEC FUSION Operations Manual Chapter 2: Specifications (Rev. 3)

2.2 Duty Cycle Calculation

Duty Cycle is rated as a percentage of the time the motor is running to the time the motor is
idle. This is an important factor in determining overload protection for Servo Amplifiers and
motors as it directly relates to the amount of power or heat dissipation of the motor / servo
package. The rated duty cycle for the FUSION System is calculated as follows:

Tool Rotation Time

X 100 = Duty Cycle Percentage (%)
Total Cycle Time (Tool Rotation + Tool Idle)

Example: Tool Rotation Time = 3 Seconds x 100 = 25% Duty Cycle Percentage
Total Cycle Time = 12 Seconds

Duty cycle ratings vary between tools. As a general rule, however, it should not exceed 50%.
IF duty cycles remain above 60% for extended periods, a Servo Amplifier Error / Overload will
result (See abnormal CODE 8 -10). Protection for high duty cycle is a standard feature of the
Servo Amplifier to prevent servo or motor damage.

Page 2-3
Chapter 2: Specifications

2.3 Controller Unit Specifications

HFC-EC-16 (Silver Unit)

Controller Model HFC-EC-16C (Gold Unit)

Motor Model RM80, RM50

Controller Supply Voltage Single Phase 100~ 240 VAC 50/60/Hz

Approx. 100 watts/hour

Power Consumption (Running)
@ 99% Capacity / 50% Duty
Power Consumption (Idle) Approx. 37 watts/hour

Inrush Current @ Power on 11A

1.3A
Current During Fastening
(80% Torque, Hard Joint (<30deg rotation))

Caution

If the equipment is powered on and off repeatedly, internal circuit protection devices
may trip due to high in-rush current overload, and the Controller will not function until
it is cleared (powered off). (It may take up to five minutes of “off” time to clear the self-
protection circuit.)

 Controller Processor: 32-bit RISC (Reduced Instruction Set CPU)

 Parameter / Firmware Storage: Flash ROM

 Fastening Data Storage: More than 10,000 cycles (stored in flash)

 Fastening Method: Torque and Angle, 1 ~ 3 step fastening

 Torque Rate Calculation: 3 ranges

 Data communications:
(1) RS232 – Front Panel - Input/output – Programming and Data collection
(1) RS232 – Rear Panel – Output – Printer or data collection device.
(1) T/A MON – Front Panel – Output – analog Torque and Angle analysis.
(1) Discrete I/O – Rear panel - Control and PLC interface
(1) Real Time Clock Connection
(1) Optional Ethernet – Programming & Data collection (Eliminates RS232 Front
Panel Port)
(1) Optional Fieldbus – Input/Output – Control and PLC interface

Page 2-4
FEC FUSION Operations Manual Chapter 2: Specifications (Rev. 3)

2.4 Capability.
 Fastening Accuracy (Torque): From 1/4 to full scale torque: 3 sigma scatter less than 6%
From 1/2 to full scale torque: 3 sigma scatter less than 5%
Accuracy improvements available with application specific
setup

 Torque resolution: Full Scale Torque x 1/1000.

 Torque Display Resolution: 4-digit display with floating decimal point.

 Angle Resolution: 0.1 Degree (1024 pulses / motor rev.)

 Angle Display Resolution: 0.1 degree.

Forward Max. count 9999 degree
Reverse Max. count 1999 degree

 Torque transducer accuracy: (0 - Full Scale) ±1%

 Linearity of torque transducer: ± 0.5% of Full Scale value (Maximum).

Page 2-5
Chapter 2: Specifications

2.4.1 Nutrunner Tool Specification Table.

Mainly, two tool models have been used to date and is designated in the model number of
the tool itself. A “-01x” at the end of the tool model number indicates the original model
(these models are silver in color) A “-10x” at the end of the model designates the newest
models (these models are gold in color)
The two models require different tool CABLES (from the controller to the tool)
The original models use FEB-13xx-Mxx cable(s)
The newer models use C15-F7-Mxx cables

There is one controller for all size tools, however the newer model tools (gold in color) may
not be recognized by older (silver) controllers due to TOOL ID information not existing in the
controller firmware. In this case, request a controller firmware upgrade by contacting FEC.
SPEED Sq.
CALIBRATION TORQUE Weight Length
TOOL TYPE RPM Drive
NM KGM KGCM FTLB INLB MAX MIN (Kg) (inch) (mm)
HFT-015M50-A1 14.7 1.5 150 10.8 130.2 1215 1 1.3 3/8 371
HFT-025M80-A1 24.5 2.5 250 18.1 217.0 1070 1 1.7 3/8 391
HFT-040M80-A1 39.2 4.0 400 28.9 347.2 648 1 1.9 3/8 416
ANGLE

HFT-060M80-A 58.8 6.0 600 43.4 520.8 446 1 1.9 1/2 416
HFT-080M80-A 78.4 8.0 800 57.9 694.4 330 1 3.8 1/2 459
HFT-130M80-A 127.5 13.0 1300 94.0 1128.4 203 1 3.8 1/2 459
HFT-200M80-A 196.1 20.0 2000 144.5 1734.5 132 1 4.5 5/8 492

HFT-010M50-S1 9.8 1.0 100 7.2 86.8 1800 1 1.3 3/8 332
HFT-015M80-S1 14.7 1.5 150 10.8 130.2 1600 1 1.4 3/8 353
STRAIGHT

HFT-025M80-S1 24.5 2.5 250 18.1 217.0 1000 1 1.4 3/8 353
HFT-040M80-S 39.2 4.0 400 28.9 347.2 690 1 1.4 3/8 353
HFT-055M80-S 53.9 5.5 550 39.7 476.9 508 1 3.0 1/2 393
HFT-080M80-S 78.4 8.0 800 57.8 693.8 303 1 3.0 1/2 393
PISTOL

HFT-015M50-P1 14.7 1.5 150 10.8 130.2 1190 1 1.1 3/8 218
HFT-035M80-P1 34.3 3.5 350 25.3 303.5 778 1 1.4 3/8 242

CONVERSION GUIDE: 1 KGM = 100 KGCM = 9.8 NM = 7.2 FTLB = 86.8 INLB

FULL SCALE TORQUE VALUES (WORK 1~32 D-NO 10) IN CONTROLLER ARE BASED
UPON LIMIT SET BY Kgm VALUE.

The tool lists located throughout this manual identify the specifications for the stand-
ard tools used with the FUSION System. Additional tools are available. If additional
capacity, information or special needs are required, please contact FEC INC.

Page 2-6
FEC FUSION Operations Manual Chapter 2: Specifications (Rev. 3)

2.4.2Nutrunner Decimal Point Display Table.

POSITIONS FOR DECIMAL POINT DISPLAY
TORQUE TORQUE RATE
TOOL TYPE DECIMAL POINT DISPLAY DECIMAL POINT DISPLAY
NM KGM KGCM FTLB INLB NM KGM KGCM FTLB INLB
HFT-010M50-x 2 2 0 2 1 3 3 2 3 2
HFT-015M50-x 2 2 0 2 1 3 3 2 3 2
HFT-015M80-x 2 2 0 2 1 3 3 2 3 2
HFT-025M80-x 2 2 0 2 1 3 3 2 3 2
HFT-040M80-x 2 2 0 2 1 3 3 2 3 2
HFT-055M80-x 1 2 0 2 0 3 3 2 3 2
HFT-060M80-x 1 2 0 2 0 3 3 2 3 2
HFT-080M80-x 1 2 0 2 0 3 3 2 3 2
HFT-130M80-x 1 2 0 2 0 2 3 1 2 1
HFT-200M80-x 1 2 0 2 0 2 3 1 2 1

Example: HFT-025M80-A Torque Display = 25.00 NM (2 positions)

Torque Rate Display = 1.999 NM/degree (3 positions)

Page 2-7
Chapter 2: Specifications

[Blank Page}

Page 2-8
FEC FUSION Operations Manual Chapter 3: System Description (Rev 3)

Chapter 3: System Description

Page 3-1
Chapter 3: System Description

3.1 Controller
3.1.1 Controller Part Number Breakdown
Old (Silver) Controller

HFC-EC-16-[14]-[E]-[P]
A B C
(A) I/O INTERFACE Blank = 24VDC Discrete I/O - NPN
2 = 24VDC Discrete I/O - PNP
3 = Modbus Plus® Interface
4 = Profinet
6 = Allen Bradley Remote I/O Interface
9 = DeviceNet® Interface
10 = Ethernet I/P
13 = Profibus® Interface
14 = CC-Link® Interface

(B) OPTIONS Blank = Standard (with Real Time Clock)

E = Ethernet (Data Output / Toolsnet Connection)
B = Ethernet “Ready” – No Ethernet installed

(C) I/O OPTIONS Blank = Standard (NPN I/O)

P = Optional (PNP I/O)

New (Gold) Controller

HFC-EC-16[C]-[BU]-[EN]-[R]
A B C D

(A) MODEL C = Standard (Gold / Black Bezel)

D = STD. With Transformer (EC rated)
E = STD. W/No Front RS232 (For Ethernet models)

(B) FIELDBUS INTERFACE Blank = NPN 24VDC Discrete I/O

BU = Base board only (Anybus not installed)
CC = CC-LINK – (Ver2)
PIO= Profinet
DN = DeviceNet® Interface
EIP = Ethernet I/P
PB = Profibus® Interface
P = PNP 24VDC Discrete I/O

(C) ETHERNET OPTIONS EN = Ethernet Option (Baseboard + Processor)

EB = Ethernet Option (Baseboard only)

(D) CASE Blank = Standard (Hanging style)

R = Shelf top (hinges opposite – cover won’t fall off)

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

3.1.2 Controller Front Panel

2 3 4 5

9 10
1

13 11
6
14 12

7 8 16 15

18 19

17

Note: Numbers correspond to

item # in following table
g

Fig. 3.1.2 Front Panel description

Page 3-3
Chapter 3: System Description

FRONT PANEL DISPLAY FEATURES

ITEM ITEM AS MARKED ON UNIT DESCRIPTION
(Green) Lights to indicate that the spindle has completed an
1 ACCEPT acceptable fastening cycle. Flashes for an final accept during a
Batch Count.
(Green) Lights to indicate that the spindle has completed an
2 WORK ACCEPT
acceptable group of fastenings. (Reached Batch Count No.)
(Red). Indicates the spindle performed a rejected fastening, out
3 REJECT
of the operation limits. Flashes indicating a rate reject.
(Yellow). Indicates the “Data Display LED” is displaying Torque
4 TORQUE
fastening Data.
(Yellow). Indicates the “Data Display LED” is displaying Angle
5 ANGLE
fastening Data.
Four digit 7 segment LED display which function is dependent
6 LED Display upon the D-NO selected.
“ABn” is displayed here during an “Abnormal” condition.
Displays two-digit parameter number and, as required, will
7 WORK
override parameter output to display an Abnormal code.
Display number that indicates which data in the "DATA" display
field is being displayed and as required, will display an Abnormal
8 COUNT/D-NO.
Sub-code. Displays Fastening Count during Batch Count
function.

FRONT PANEL CONTROL FEATURES

9 CAL Manual calibration (CAL) check pushbutton
10 RESET Manual zero check and system reset pushbutton.
11 UP - Arrow Data change increase pushbutton.
12 DOWN - Arrow Data change decrease pushbutton.
13 MODE Display mode selection pushbutton.
14 SET Data change confirmation set pushbutton.
15 WORK RIGHT - Arrow Parameter selection increase pushbutton.
16 WORK LEFT - Arrow Parameter selection decrease pushbutton.
17 POWER 0 / 1 0-Off / 1-On controller power switch

FRONT PANEL CONNECTOR FEATURES

Optional DB9 connector for Torque / Angle monitor.
18 T/A MON.*
Analog outputs for use with external analysis equipment.
RS232 communications port for interfacing with the AFC user
19 PC*
console software. (Removed if Ethernet option installed)

*Controllers with Ethernet option OR “HFC-EC-16B” versions do NOT include these two ports

Page 3-4
FEC FUSION Operations Manual Chapter 3: System Description (Rev 3)

3.1.3 Controller Back Panel

2 6

1 10
8

3 4

11

Note: Numbers correspond to

item # in following table

Fig. 3.1.3 Back Panel Description

Page 3-5
Chapter 3: System Description

BACK PANEL CONNECTOR FEATURES

ITEM ITEM AS MARKED ON UNIT DESCRIPTION
Twist Lock single connector for tool cable connection. Twist
lock type connector can be connected and disconnected by
1 CN1 twisting the outside ring 90 degrees Clockwise and Counter
Clockwise respectively

DB9 connector for fastening result data Output only. Utilized for
2 RS232C connection to a PLC, printer, personal computer, etc.

Primary power-supply input connection.

Input for 100 ~ 240 VAC single-phase 50/60Hz.
A
AUTO SWITCHING
3 AC100 ~ 240 VAC
*DO NOT RUN WITHOUT GROUND CONNECTED!

Connection point for discrete inputs and outputs (I/O). When

wired in, the entire connector can be removed by loosening the
4 TB1 upper and lower retaining screws. Refer to chapter 4 for
detailed descriptions of I/O signal.
.
Ground terminal for connection to the Back Panel Cover’s
5 Ground Lug
ground wire
6 RTC Connection 8 pin plastic connector – Real Time Clock Connection
7 SYNC Connection 4 pin plastic connector – Sync. Connector
8 Interface option Mtg. Interface adapter port – Optional Fieldbus or Ethernet board
Electrical Leakage Breaker / Ground Fault detector.
9 Breaker
I=on, 0=off
Optional Slot for Fieldbus Interface [Devicenet, Profibus,
10 Fieldbus Interface slot
CCLink, Ethernet I/P, Profinet, etc]
Optional Slot for Ethernet interface. Used for Ethernet
11 Ethernet Connection connection with the AFC programming/monitoring software PC
and/or Ethernet Data Server

WARNING!: DO NOT RUN THIS SYSTEM WITHOUT A PROPER GROUND CONNECTED

TO THE CONTROLLER. THE CONTROLLER IS SUPPLIED WITH A 3-PRONG AC
CABLE INCLUDING A GROUND CONDUCTOR. DO NOT BYPASS THE GROUND
CONNECTION OR SEVERE INJURY OR SHOCK MAY RESULT!

Page 3-6
FEC FUSION Operations Manual Chapter 3: System Description (Rev 3)

3.2 FUSION Tool

3.2.1 FUSION Tool Part Number Breakdown

HFT-[051][M80]-[A][1][ ]-[01][A]
A B C DE F G

(A) MAXIMUM TORQUE 010 = 1.0Kgfm (9.8Nm / 7.2ft lb)

015 = 1.5Kgfm (14.7Nm / 10.8ft lb)
025 = 2.0Kgfm (24.5Nm / 18.0ft lb)
040 = 4.0Kgfm (39.2Nm / 28.9ft lb)
055 = 5.5Kgfm (53.9Nm / 39.7ft lb)
060 = 6.0Kgfm (58.8Nm / 43.3ft lb)
080 = 8.0Kgfm (78.4Nm / 57.8ft lb)
130 = 13.0Kgfm (127.5Nm / 94.0ft lb)
200 = 20.0Kgfm (196.1Nm / 144ft lb)
(B) MOTOR M50 = Only used on 015 Angle & Pistol Tools
M80 = Used on all other tools
(C) TOOL TYPE A = Angle
S = Straight
P = Pistol
T = “T” Type Pistol
(D) MODEL REVISION BLANK = Original Release
1 = 1st Generation
(E) SPECIAL BLANK = Normal Function

(F) MINOR REVISION Two Digit Minor Rev. Level (Factory Use Only)
01 = Silver Tool Type (Uses FEB-1309-Mxx cable)
10 = Gold Tool Type (Uses C15-F7-Mxx cable)
(G) OPTION BLANK = Through hole in Square Drive
P = Plunger Detent in Square Drive

Page 3-7
Chapter 3: System Description

3.2.2 FUSION Angle / Straight Tool Components

5 1 4 2 3

6 7 8

TOOL MAJOR COMPONENT IDENTIFICATION

ITEM ITEM AS MARKED ON UNIT DESCRIPTION
Provides feedback for speed regulation to the Servo Amplifier.
1 MOTOR / RESOLVER Provides angular rotation monitoring for fastening operation.
Totally enclosed DC permanent magnet motor.
Durable planetary gear transmission.
2 TRANSMISSION Refer to Chapter 2 for standard tools and gear ratios.
Durable right angle head.
3 ANGLE HEAD Refer to Chapter 2 for standard tools and gear ratios.
Highly accurate strain gage transducer.
Highly durable, compact design minimizes space requirements.
4 TRANSDUCER / PREAMP Intelligent transducer design uses an “ID Chip” to verify
integrity of fastening operations.
Twist lock single connector for tool cable connection. Twist
lock type connector can be connected and disconnected by
5 CABLE CONNECTOR twisting the outside ring 90 degrees clockwise and counter
clockwise respectively.
Variable speed start switch. Depressing the Start switch
partially initiates a manually controlled slow speed start.
Depressing the Start switch fully initiate a fastening cycle as
programmed into the controller. Releasing the Start switch at
6 START SWITCH any time terminates the fastening operation.

Used to initiate a reverse tool operation when in

Reverse/Backout mode.
Momentary Reverse selector switch or Twist Ring (“-10”
models). Depressing the Reverse selector switch places the
tool in the Reverse/Backout mode. The Accept/Reject LED
7 REVERSE SWITCH display on the tool flashes to indicate Reverse operation
selection. Depressing the Reverse selector switch again,
places the tool back in the fastening mode.
360 degree LED display ring.
Green indicates an accept condition.
Red indicates a Reject condition.
8 LED DISPLAY RING Flashing Red and Green indicate Reverse/Backout mode.
Solid Red and Green during power on for verification.
Alternating Red/Green indicates RESET signal being input

Page 3-8
FEC FUSION Operations Manual Chapter 3: System Description (Rev 3)

3.2.3 FUSION Pistol Tool Components

2 3 1
1

TOOL MAJOR COMPONENT IDENTIFICATION

ITEM ITEM AS MARKED ON UNIT DESCRIPTION
Provides feedback for speed regulation to the Servo Amplifier.
1 MOTOR / RESOLVER Provides angular rotation monitoring for fastening operation.
Totally enclosed DC permanent magnet motor.
Durable planetary gear transmission.
2 TRANSMISSION Refer to Chapter 2 for standard tools and gear ratios.
Highly durable, compact design minimizes space requirements.
3 TRANSDUCER / PREAMP Intelligent transducer design uses an “ID Chip” to verify
integrity of fastening operations.
Twist lock single connector for tool cable connection. Twist
lock type connector can be connected and disconnected by
4 CABLE CONNECTOR twisting the outside ring 90 degrees clockwise and counter
clockwise respectively.
Variable speed start switch. Depressing the Start switch
partially initiates a manually controlled slow speed start.
Depressing the Start switch fully initiate a fastening cycle as
programmed into the controller. Releasing the Start switch at
5 START SWITCH any time terminates the fastening operation.

Used to initiate a reverse tool operation when in

Reverse/Backout mode.
Momentary Reverse selector switch or Twist Ring (“-10”
models). Depressing the Reverse selector switch places the
tool in the Reverse/Backout mode. The Accept/Reject LED
6 REVERSE SWITCH display on the tool flashes to indicate Reverse operation
selection. Depressing the Reverse selector switch again,
places the tool back in the fastening mode.
LED display ring.
Green indicates an accept condition.
7 LED DISPLAY RING Red indicates a Reject condition.
Flashing Red and Green indicate Reverse/Backout mode.
Solid Red and Green during power on for verification.

Page 3-9
Chapter 3: System Description

(Blank Page)

Page 3-10
FEC FUSION Operations Manual Chapter 4: System Setup and Wiring (Rev. 3)

Chapter 4: System Setup and Wiring

Page 4-1
Chapter 4: System Setup and Wiring

4.1 Design and Build Procedure

Review Chapters 1 and 2 prior to designing a System. If the requirements and specifica-
tions in these two (2) Chapters are not addressed, there is a chance of degraded System per-
formance.

WARNING:
Follow Lockout/Tagout and other safety precautions when connecting and/or
disconnecting cabling, wiring, and equipment.

No. Items Comments Reference

Section
Keep torque range between 30% and 75 % of tool
capability for best performance and to capacity for 2.4.1
1 Select correct tool size. future fastening specification revisions. 4.4.1
Verify fastener location and tool clearance 4.4.2
concerns.
Determination of suspension and reaction
2 Determine tool suspension requirements is dependent upon end user 4.4
/reaction requirements. standard ergonomic design guidelines and 4.4.3
preferred supplier lists.
3 Different controller options are available. Ensure
Select correct Control Unit 3
the correct one is selected.

4 Select the circuit Circuit protection for Controller Units should be 4.5
protectors. separate from other units. 4.6

5 Select a PLC which will facilitate direct connection 4.7

Select an adequate PLC.
to the FUSION System I/O (24 VDC true low).

6 Design (or review) PLC A PLC logic program can be written using signal 4.7
logic. descriptions and timing charts provided.
Keep clearances among units according to the
7 Determine Controller recommended installation layout. End user 4.2
mounting requirements. specific input should be used to determine 4.3
mounting requirements.
8 Set Controller Unit dip 4.10
Check the setting before connecting the Unit.
switches.
9 4.2
Mount the Controller Units. Refer to recommended installation layout. 4.3

10 Connect the power cables. VERIFY VOLTAGE 4.6

Wire power connections.
PRIOR TO APPLYING POWER.

11 Connect all I/O wiring. VERIFY VOLTAGE 4.7

Wire I/O connections.
SOURCE PRIOR TO CONNECTION.
Connect Tool / extension
12 VERIFY POWER IS OFF, then connect cables for
cables. Appendix A
every motor, encoder and preamplifier.

13 VERIFY WIRING AND THE VOLTAGE OF ALL 5.1

Turn on the equipment.
POWER SUPPLIES PRIOR TO POWERING UP.

14 Set the preset data for torque, angle, speed, time, Chapter 6
Input preset data. Chapter 7
etc.
15 5.2
Verify normal function. Confirm normal operation.

Page 4-2
FEC FUSION Operations Manual Chapter 4: System Setup and Wiring (Rev. 3)

4.2 Component Dimensions

The specifications for all of the FUSION standard system equipment are outlined in this
Chapter to aid in determining space, mounting & wiring requirements.

4.2.1 CONTROLLER Unit Dimensions

FIG. 4-2-1 Controller Unit Dimensions

Controller weight is 8.6 Kg (18.9lbs.)

Mounting: (4) points rear panel (Use M6 Screw or equivalent >9mm in length)

The Unit(s) must be mounted with a minimum clearance of 25mm on the left side and 126mm
on the right side to allow for proper heat dissipation. If mounting multiple controllers side by
side you must leave a minimum clearance of 260mm between the units for clearance when
opening the back cover. Programming Cable connections on the front of the Unit require
100mm of clearance. Cable connections on the rear of the Units require 150mm of clearance
below the unit for exiting the Rear cover other than straight down. Controller Units must be
located at a minimum 300mm from any high transient voltage power source. High transient
sources such as relays, AC contactors, AC motor drives, etc. may cause malfunction of the
FUSION Controller unit. All motor cables and I/O cables must be run separate from all high
transient voltage sources. When locating inside an enclosure, avoid mounting at or near the
top where internal enclosure heat is most extreme.
Do not install in a location subject to continuous vibration

Page 4-3
Chapter 4: System Setup and Wiring

4.3 Unit Arrangement

** See preceding page for actual unit width

FIG. 4-3 Unit Arrangement

Figure 4-3 provides a reference for the layout of the FUSION System components. The
Units may be mounted in any desired configuration as long as the minimum spacing require-
ments are not neglected. Clearance for opening the controller (260mm) and accessing the
back connectors should be maintained as shown.

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

4.4 Nutrunner (Tool) Specifications

Tool dimensions and mounting specifications are critical in determining the design of the sus-
pension / reaction equipment required for the tool assemblies. Provide adequate clearance to
ensure that the tool assemblies do not come in contact with any object. Failure to provide
adequate clearance may result in torque inaccuracies in the monitoring capability of the sys-
tem, possible damage to the tool assembly, or operator injury.

Customer specific ergonomic guidelines and preferred supplier lists should be used in deter-
mining suspension / reaction equipment requirements

WARNING: Torque tools generate large amounts of torque that can cause injury
when held in the hand of an operator. Be sure all precautions are taken to ensure
torque reaction devices are installed to absorb or suppress reaction torque from oper-
ators! It is recommended that some type of torque reaction device is employed for
torque over 10Nm to prevent repetitive operator injury.

4.4.1 Straight Tool

Clamp area only

FIG. 4-4-1 Straight Tool

TORQUE Total Weight Square

MODEL TYPE (NM / ft lb) SPEED Length (Kg / Lb) Drive
(mm)

HFT-010M50-S1-10 9.8 / 7.2 1800 rpm 332.5 1.3 /2.8 3/8

HFT-015M80-S1-10 14.7 / 10.8 1600 rpm 352.5 1.4 / 3.2 3/8
HFT-025M80-S1-10 24.5 / 18.1 1000 rpm 352.5 1.4 / 3.2 3/8
HFT-040M80-S-10 39.2 / 28.9 690 rpm 415.5 1.4 / 3.2 3/8
HFT-055M80-S-10 53.9 / 39.7 508 rpm 393 3.0 / 6.6 1/2
HFT-080M80-S-10 78.4 / 57.8 315 rpm 393 3.0 / 6.6 1/2

Mounting: Tool may be mounted by using a clamp collar located on the area shown in
the drawing above. Tolerance for diameter of inside of clamp must be +0.1
to + +0.2mm of diameter of the “clamping area” so damage to the (tool) nut does
not occur.

Note: Dimensions shown are subject to change without warning due to design improvements.
Page 4-5
Chapter 4: System Setup and Wiring

4.4.2 Right Angle Tool

Clamp area only

FIG. 4-4-2 Right Angle Tool

TORQUE Total Weight Square

MODEL TYPE (NM / ft lb) SPEED Length (Kg / Lb) Drive
(mm)

HFT-015M50-A1-10 14.7 / 10.8 1215 rpm 365 1.6 / 3.5 3/8

HFT-025M80-A1-10 24.5 / 18.1 1070 rpm 385 1.7 / 3.8 3/8
HFT-040M80-A1-10 39.2 / 28.9 648 rpm 410 1.9 / 4.2 3/8
HFT-060M80-A-10 58.8 / 43.4 446 rpm 410 1.9 / 4.2 1/2
HFT-080M80-A-10 78.4 / 57.8 325 rpm 459 3.6 / 7.9 1/2
HFT-130M80-A-10 127.5 / 94.0 195 rpm 459 3.6 / 7.9 1/2
HFT-200M80-A-10 196.1 / 144.5 132 rpm 492 4.5 / 9.9 5/8

Mounting: Tool may be mounted by using a clamp collar located in the area shown in the
drawing above.

Warning: Tolerance for diameter of inside of clamp must be +0.1 to +0.2mm of diameter
of the “clamping area” so damage to the (tool) nut does not occur.

Note: Dimensions shown are subject to change without warning due to design improvements.

Page 4-6
 FEC FUSION Operations Manual Chapter 4: System Setup and Wiring (Rev. 3)

4.4.3 Pistol Tools

The FEC Pistol tool is available in two sizes (15Nm & 35Nm).

Note: It is recommended when using pistol type tools, that the “Ergo-Smoothing” function or
other torque reaction devices are used on applications with target torques over 10Nm to re-
duce operator fatigue or repetitive use injury.

The FEC Pistol tool incorporates the latest “active Ergonomic smoothing” technology to re-
duce operator torque reaction to very low levels. This works by using an electric “pulsing”
function to apply torque to the fastener. This is extremely effective in applications where the
tool is supported from some type of cable of other balancer. (See Parameter data list (7.2.5)
for set-up of Ergo-Smoothing function – Data No. 80 - 89)

Tools may be used in horizontal or vertical applications using supplied hanging bracket.

“P” Type Pistol Tool Cable Balancer Mounting

Bracket Mounts Here

Clamp area only

Fig. 4.4.3 “P” Type Pistol Tool

TORQUE Total Weight Square

MODEL TYPE (NM / ft lb) SPEED Length (Kg / Lb) Drive
(mm)

HFT-015M50-P1 14.7 / 10.8 1190 rpm 218 1.1 / 2.2 3/8

HFT-035M80-P1 34.3 / 25.3 778 rpm 242 1.4 / 3.1 3/8

NOTE: If clamp will be used to support the tool, clamp in ONLY the area shown above or
damage may occur to tool

*Cable Balancer Mounting Bracket is included (bolts area shown above)

*Optional top cable entry available (contact FEC)

Page 4-7
Chapter 4: System Setup and Wiring

4.5 Connection Diagram

A basic layout of System component interconnection is shown in Figure 4-5. Detailed refer-
ence drawings can be found throughout this Chapter, and also in Appendix A.

WARNING: Follow Lockout/Tagout and other safety precautions when connecting and/or
disconnecting cabling, wiring, and equipment.

FIG. 4-5 Connection Diagram

The Fusion controller can be connected to various external devices for control and monitoring
the fastening process. The system will operate with no connection to any external devices.
If control I/O is required, discrete Inputs / Outputs or optional fieldbus connection is available
for external controllers (PLC or PC Control). Serial RS232 or optional Ethernet is available
for resultant fastening data output. Additionally, the front panel provides easy access for
RS232 connection with a computer running the AFC User Console software.

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 FEC FUSION Operations Manual Chapter 4: System Setup and Wiring (Rev. 3)

4.6 Power Requirements and Connections

4.6.1 Controller Unit

The Controller uses a standard “computer” power cord which connects to the AC power con-
nector located at the back of the unit and to a standard wall outlet. The unit operates on
single phase power (100-240VAC 50/60Hz). Power consumption is 80watts while idle &
1200watts @ max. Torque. Inrush current (at power on) is 11amps.

WARNING: Do not disconnect power cable while system is in cycle.

PIN NUMBER DESCRIPTION

1 FRAME GROUND
2 100 – 240 VAC 50/60Hz
3 100 – 240 VAC 50/60Hz

Fig. 4-6-1 Controller Unit Power Connector

NOTE:
After a Controller unit is powered down, the power must not be applied again for at
least five (5) seconds. Repeated power up and power down may temporarily disable a
Controller unit as a self protection feature. If a Controller unit does become disabled,
turn the power off for five (5) minutes before making another attempt to power up.

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Chapter 4: System Setup and Wiring

4.7 Wiring PLC I/O

All interface devices must accommodate active true low logic for correct operation with the
STANDARD FUSION CONTROLLER Unit DC inputs and outputs (I/O). (Optional PNP active
true high is available) Four output relay contacts are provided for isolated connection to an
external controller. Optional Fieldbus interfaces are available. Outputs are rated at 12~24
VDC, 200mA. When activated, open collector sinking outputs (normally high) pull the input
device signal low (0 VDC). Inputs are (normally high) and activated when pulled low (0
VDC). (The opposite is true with the optional PNP version controller)

TB1 I/O is enabled even if a Fieldbus interface is installed. (Both I/O will be active)

Once wired, the TB1 terminal block can be quick disconnected from the Controller by loosen-
ing the captive screws located at the top and bottom of the terminal strip, for quick change-
over to a new controller without disconnecting the terminal wires.

CAUTION:
The PLC I/O wiring must be routed a minimum of 300 mm away from any transient high volt-
age sources. Cable length must not exceed 50 feet.

***NPN VERSION SHOWN***

NOTE: IF Optional PNP version, A9 & B9 polarity is REVERSED. A9 is (0v) common

and B10 is (+) common (see 4.7.5 for wiring example)

FIG. 4-7-1 Controller Unit PLC Connector

* Output signals shown on terminals A11 – B14 are for BANK 1 signals only. If BANK
SELECT inputs are used, these outputs WILL CHANGE DEFINITION according to the Bank
Select output table and the selection of BANK SELECT INPUTS.

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FEC FUSION Operations Manual Chapter 4: System Setup and Wiring (Rev. 3)

4.7.1 Explanation of CONTROLLER Unit I/O

INPUT SIGNALS
Pin # SIGNAL NAME DESCRIPTION

Reset Input (Normally Open)

When active (on), this signal will clear all fastening data, discrete
outputs, and communication buffers. A Zero Check of the torque
transducer will be completed. During the Zero Check, the Tool
ACCEPT and REJECT lamp will light to indicate the performance of
the Zero Check. During a RESET signal, the tool Red/Green LED’s
A1 RESET
will alternately light. If the system has been disabled by an Abnormal
output, the system will not return to normal operation until the
Abnormal condition has been corrected, and this signal has been input
for 200~500 milliseconds. Do not input this signal between cycles,
due to the potential for data loss. During RESET, the connected tools
RED/GREEN LED will alternate
Emergency Stop Input (Normally Open)
This signal must be inactive (off) for controller operation. When this
signal is active (on), controller operation will stop, and input/outputs
B1 STOP
will be disabled. Note: This signal can inversed (Signal must be
ON) configured using the AFC Software (Sequence Tab in
Graphic Parameter Setup Screen)
Start Cycle Input (Normally Open)
The Start input automatically resets the previous cycle, clears all data
A2 START
to zero, and initiates the next fastening cycle. The Start input must be
maintained "on" for the entire cycle.
Reverse Spindle Rotation Input (Normally Open)
B2 REVERSE The spindle will rotate in an opposite direction for as long as this signal
is activated (on) and maintained. (input disabled during RESET)
SELF CHECK Input signal used to disable the performance of the automatic Self
A3
DISABLE Check function at the beginning of the fastening cycle.
Spindle Bypass Input (Normal Open)
B3 BYPASS When active, all functions of this spindle are bypassed, and the
Bypass output is active. Programming of the Controller is enabled
Bank Select Input Signals (Normally Open)
These two (2) inputs form a binary code that is used to define the
A4 BANK SELECT 0
B4 BANK SELECT 1 function/definition of outputs for Bank Data 0~7 (A11-B14). This
allows up to 32 different output definitions with only 8 discrete outputs
(4 Banks, 8 available outputs per Bank). See 4.7.3 Bank Select Table.
A5 WORK SELECT 1 Work / Parameter Select Input (Normally Open)
B5 WORK SELECT 0 These 5 inputs form a binary code which is capable of selecting up to
A6 WORK SELECT 3 32 different sets of Fastening Parameters. Refer to Section 4.7.2
B6 WORK SELECT 2 Work Sequence Select Table.
A7 WORK SELECT 4* Note: Work 4 was added Firmware version 5.00 & higher
Reset Batch count to the initial condition/Count. D-NO display will be
B7 WORK OK RESET cleared. (If controller is setup for the work select from TB1, this input
MUST be used to reset the batch count)
A8 NOT USED
A9 INPUT COMMON Input signal common. Connection to +12 ~ 24 VDC required.
B9 OUTPUT COMMON Output signal common. Connection to 0 VDC required
A10 DC POWER (+24v) Internal auxiliary 24VDC power – 0.5amp max.
B10 DC POWER (0v) Zero volt common for Internal auxiliary power

Page 4-11
Chapter 4: System Setup and Wiring

OUTPUT SIGNALS

A14 BANK DATA 7

B14 BANK DATA 6
A13 BANK DATA 5 Bank Data Output Signals (Normally Open)
B13 BANK DATA 4 These output signals designate various fastening conditions and re-
A12 BANK DATA 3 sults as determined by Bank Select 0 & 1 (Pins A4 & B4) inputs. Re-
B12 BANK DATA 2 fer to 4.7.3 Bank Select Table for output data descriptions.
A11 BANK DATA 1
B11 BANK DATA 0

B15 Future Programmable Dry Contact Relay output

Relay Contact “A”
B16 Rating : 0.3A @125VAC or 1A @ 30VDC
Cycle End Dry Contact Relay output
A15 Relay Contact
Output when Reverse Mode is active and Operator activates start trig-
A16 “CYCLE END”
ger (used as operator “Auxiliary Output”)
Batch Accept Dry Contact Relay output
B17 Relay Contact Output after the number of accepts programmed in the Work Count
B18 “WORK OK” parameter is met. (D-No 74) (Rating as above) Output can be pro-
grammed as either “Pulse” or “State” type using the AFC software.
A17 Relay Contact Accept Pulse (300 – 500 msec) Dry Contact Relay output – used to
A18 “OK PULSE” replace a QL click style torque wrench. (Rating as above)

4.7.2 Work / Parameter Select Table

PARAMETER WORK SELECT 3 WORK SELECT 2 WORK SELECT 1 WORK SELECT 0
NO. PIN A6 PIN B6 PIN A5 PIN B5
1 OFF OFF OFF OFF
2 OFF OFF OFF ON
3 OFF OFF ON OFF
4 OFF OFF ON ON
5 OFF ON OFF OFF
6 OFF ON OFF ON
7 OFF ON ON OFF
8 OFF ON ON ON
9 ON OFF OFF OFF
10 ON OFF OFF ON
11 ON OFF ON OFF
12 ON OFF ON ON
13 ON ON OFF OFF
14 ON ON OFF ON
15 ON ON ON OFF
16 ON ON ON ON
OFF = Disabled ON =Enabled

Note: TB1 terminal must be enabled. (See Section 7.2.4)

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 FEC FUSION Operations Manual Chapter 4: System Setup and Wiring (Rev. 3)

4.7.3 Bank Select Table

Bank Select inputs are used to “multiplex” the output signals allowing up to 32 signals from
only 8 physical outputs. By changing the input conditions of the two Bank Select inputs, up
to four “Banks” may be selected, changing the definition of each output point.

BANK SEL.
PLC / CONTROLLER UNIT BANK DATA
INPUT

BANK SEL 1 SEL 0 Output NAME OF

DESCRIPTION
NO. B4 A4 A11~B14 SIGNAL

Output when the fastening result is a REJECT.

DATA 7 Indicates that the spindle has failed the fastening
REJECT
(A14) limits. This output remains active until the
START signal or RESET signal is input.
Output when the fastening result is a ACCEPT.
DATA 6 Indicates that the spindle is within the fastening
ACCEPT
(B14) limits. This output remains active until the START
signal or RESET signal is input.
Output when an Abnormal condition occurs,
indicates that the System has detected an internal
DATA 5
ABNORMAL fault, and can no longer proceed. An Abnormal
(A13)
condition must be corrected before the System
will resume normal operation.
1 OFF OFF
Output when the system is in READY condition to
DATA 4
READY operate, and inputs are enabled. This signal is
(B13)
inactive (off) when the BUSY output is active (on).
Output after a START signal is received, and
DATA 3
BUSY active until the fastening cycle is complete and
(A12)
the READY signal is output.
DATA 2 Output when Fastening resulted in a Torque High
TQ HIGH REJECT
(B12) Reject.
DATA 1 Output when Fastening resulted in a Torque Low
TORQUE LOW REJECT
(A11) Reject.
Output when the spindle is bypass either via
DATA 0
BYPASS PLC input or the Controller Unit front panel
(B11)
switch.
DATA 7
NOT USED
(A14)
DATA 6 Output when Fastening resulted in a 1st Time
1ST TIME OVER REJECT
(B14) Reject.
DATA 5 FINAL TIME OVER Output when Fastening resulted in a Final Time
(B13) REJECT Reject.
DATA 4
WORK 0
(B13)
2 OFF ON DATA 3
WORK 1
(A12)
DATA 2 Output confirmation of WORK SELECT 0~4 (Pins
WORK 2
(B12) A5,B5,A6,B6 & A7) input selections.
DATA 1
WORK 3
(A11)
DATA 0
WORK 4
(B11)

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 Chapter 4: System Setup and Wiring

BANK SEL.
PLC / CONTROLLER UNIT BANK DATA
INPUT

BANK SEL 1 SEL 0 Output NAME OF

DESCRIPTION
NO. B4 A4 A11~B14 SIGNAL

DATA 7 Output when Fastening resulted in an Angle High

ANGLE HIGH REJECT
(A14) Reject.

DATA 6 Output when Fastening resulted in an Angle Low

ANGLE LOW REJECT
(B14) Reject.

DATA 5 Output when Fastening resulted in a 1st Torque

1ST RATE HIGH REJECT
(B13) Rate High Reject.
3 ON OFF DATA 4 Output when Fastening resulted in a 1st Torque
1ST RATE LOW REJECT
(B13) Rate Low Reject.
DATA 3 Output when Fastening resulted in a 2nd Torque
2ND RATE HIGH REJECT
(A12) Rate High Reject.
DATA 2 Output when Fastening resulted in a 2nd Torque
2ND RATE LOW REJECT
(B12) Rate Low Reject.
DATA 1
NOT USED
(A11)
DATA 0
NOT USED
(B11)
DATA 7 Outputs when an abnormal condition occurs
ZERO CAL ERR
(A14) during the SELF CHECK (CAL and Zero).
DATA 6 Outputs when an abnormal condition occurs in
PSET ERR.
(B14) the parameter setting.
DATA 5 Outputs when an abnormal condition occurs in
RES ERR
(B13) the resolver.
DATA 4
TOOL ERR Outputs when a tool related abnormality occurs.
(B13)
4 ON ON
DATA 3 Outputs when a servo abnormality occurs, see
SV AMP ERR
(A12) SV ERR 0~2 codes below.
DATA 2
SV ERROR 0
(B12)
Outputs a detailed code when a SV AMP ERR is
DATA 1
SV ERROR 1 output. Error code is output in three bits. (See
(A11)
Section 4.7.4 ).
DATA 0
SV ERROR 2
(B11)

Page 4-14
FEC FUSION Operations Manual Chapter 4: System Setup and Wiring (Rev. 3)

4.7.4 Bank Output Servo Error Table

The Bank Servo Error Table defines the type of servo error (fault) output from Bank 4 Data
bits 4-7(see above)

SV ERR
SV AMP ERR 2 1 0
(Data 4) (Data 7) (Data 6) (Data 5) DESCRIPTION

ON OFF OFF OFF

Over current or Controller type mis-
ON OFF OFF ON
match.
ON OFF ON OFF Resolver abnormal.
ON OFF ON ON Controller unit overheated.
ON ON OFF OFF
ON ON OFF ON Internal voltage level abnormal.
ON ON ON OFF Input voltage abnormal.
ON ON ON ON Overload.
OFF - - - No error

Page 4-15
Chapter 4: System Setup and Wiring

4.7.5 PLC Wiring Sample

This diagram represents standard I/O connections to a PLC (NPN current sinking Active true
low). The 24VDC power can be supplied from the FUSION controller (terminals A10,B10) if
total consumption is less than 0.5A.

Standard current flow shown

FIG. 4-7-5 PLC Wiring Sample

The standard controller inputs and outputs (I/O) are active true low. All interface devices
must accommodate active true low logic for correct operation. Outputs are rated at +12~24
VDC, 40mA. When activated, open collector sinking outputs (normally high) pull the input
device signal low (0 VDC). Inputs are sourced (normally high) and activated when pulled
low (0 VDC).
Note: Optional PNP version I/O available – active true high, current sourcing (See next page
for wiring sample diagram)

Page 4-16
FEC FUSION Operations Manual Chapter 4: System Setup and Wiring (Rev. 3)

This diagram represents the OPTIONAL PNP version I/O connections to a PLC (PNP current
sourcing Active true high). The 24VDC power can be supplied from the FUSION controller
(terminals A10,B10) if total consumption is less than 0.5A.

FIG. 4-7-5a Optional PNP version PLC Wiring Sample

Page 4-17
Chapter 4: System Setup and Wiring

4.8 RS-232 Data communication ports.

The FUSION system programming and monitoring can be performed utilizing a PC, Laptop or
Industrial based system. Communication is performed via an RS232 port located on the front
of the unit. This port provides communication to the AFC User Console Software. (No cost
with a system purchase)

An additional port is available on the rear panel of the controller that can provide RS232 out-
put data to a variety of collection devices.

4.8.1 Front Panel DB9 RS232 PC Connection for AFC User Console Software

PIN SIGNAL DESCRIPTION

1 NOT USED
2 RXD RECEIVE DATA
3 TXD TRANSMIT DATA
4 DTR DATA TERMINAL READY (ALWAYS ON)
5 GND SIGNAL GROUND
6 DSR NOT USED
7 RTS REQUEST TO SEND (ALWAYS ON)
8 CTS CLEAR TO SEND
9 NOT USED

Note: Cabling length should be kept to a minimum (Max 50 Feet) and avoid routing
near high signal noise areas such as AC Motor invertors, speed controllers or strong
RF signals.

Standard DB9 Null Modem cables can be used for this connection (to a PC running the AFC
User Console Software). No special cabling is required. (These are standard Null Modem
cables which can be purchased at most computer stores)

See the AFC User Console Manual for more information. (Available for download on the FEC
website – www.fec-usa.com)

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 FEC FUSION Operations Manual Chapter 4: System Setup and Wiring (Rev. 3)

4.8.2 Rear Panel DB9 RS232 PC Connection (Fastening Data Output)

Connector: DB-9P (Male)
Mating Connector: DB-9S (Female)

PIN SIGNAL DESCRIPTION

1 NOT USED
2 RXD NOT USED
3 TXD TRANSMIT DATA
4 DTR DATA TERMINAL READY (ALWAYS ON)
5 GND SIGNAL GROUND
6 DSR NOT USED
7 RTS REQUEST TO SEND (ALWAYS ON)
8 CTS CLEAR TO SEND
9 NOT USED

Note: The CTS signal needs to be activated in order for the fastening data to be output. If it
the data will be overwritten in a First In, First Out (FIFO) process. The CTS signal may be
connected to the RTS signal if data is to be “dumped” at every fastening.

Connection with hardware handshake (with DTR signal)

U N IIT B A C K P A N EL U SER

Ｄ－ＳＵＢ ９P IN Ｄ－ＳＵＢ ２５P IN

ＴＸＤ 3 3 ＲＸＤ

ＲＸＤ 2

ＣＴＳ 8 20 ＤＴＲ

ＧＮＤ 5 7 ＧＮＤ

Connection without handshake – data “dumped” (without DTR signal)

U N IT B A C K P A N EL U SER

Ｄ－ＳＵＢ ９P IN Ｄ－ＳＵＢ ２５P IN

ＴＸＤ 3 3 ＲＸＤ

ＲＸＤ 2
ＲＴＳ 7
ＣＴＳ 8 20 ＤＴＲ

ＧＮＤ 5 7 ＧＮＤ

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 Chapter 4: System Setup and Wiring

4.8.3 Rear Panel RS232 Standard Communication Protocol

Communication protocol from the rear panel RS232 port is as follows;

Speed: 9600bps
Parity: None
Data Bits: 8 Bit
Start Bit: 1 Bit
Stop Bit: 2 Bit
Error Control: None

The data format from the Fusion system is a formatted ASCII output. This can be connected
to a serial printer, computer or other peripheral device. 214 bytes of data is output per fas-
tening using the Standard Format. The data format is described below.

Example Example Example

Byte Description Byte Description Byte Description
ASCII Data ASCII Data ASCII Data
1 Start Of Text 02H 35 Cycle Count 35H 5 69 1st Rate Incr. Ang. 32H 2
2 Parameter No. 20H 36 Cycle Count 37H 7 70 2nd Rate Incr. TQ. 30H 0
3 Parameter No. 31H 1 37 Peak Torque 31H 1 71 2nd Rate Incr. TQ. 30H 0
4 Clock – Year* 30H 0 38 Peak Torque 39H 9 72 2nd Rate Incr. TQ. 32H 2
5 Clock – Year* 37H 7 39 Peak Torque 39H 9 73 2nd Rate Incr. TQ. 35H 5
6 / 2FH / 40 Peak Torque 39H 9 74 2nd Rate Incr. Ang. 30H 0
7 Clock – Month* 30H 0 41 Final Torque 31H 1 75 2nd Rate Incr. Ang. 31H 1
8 Clock – Month* 38H 8 42 Final Torque 39H 9 76 2nd Rate Incr. Ang. 30H 0
9 / 2FH / 43 Final Torque 39H 9 77 2nd Rate Incr. Ang. 30H 0
10 Clock – Day* 31H 1 44 Final Torque 39H 9 78 3rd Rate Incr. TQ. 30H 0
11 Clock – Day* 35H 5 45 Final Angle 31H 1 79 3rd Rate Incr. TQ. 30H 0
12 Time – Hour* 31H 1 46 Final Angle 39H 9 80 3rd Rate Incr. TQ. 31H 1
13 Time – Hour* 32H 2 47 Final Angle 39H 9 81 3rd Rate Incr. TQ. 30H 0
14 : 3AH : 48 Final Angle 39H 9 82 3rd Rate Incr. Ang. 30H 0
15 Time – Minute* 34H 4 49 1st Rate 31H 1 83 3rd Rate Incr. Ang. 30H 0
16 Time – Minute* 35H 5 50 1st Rate 39H 9 84 3rd Rate Incr. Ang. 32H 2
17 : 3AH : 51 1st Rate 39H 9 85 3rd Rate Incr. Ang. 31H 1
18 Time – Second* 33H 3 52 1st Rate 39H 9 86 1st Time 30H 0
19 Time – Second* 30H 0 53 nd
2 Rate 31H 1 87 1st Time 30H 0
20 Spindle Number 30H 0 54 2nd Rate 39H 9 88 1st Time 36H 6
21 Spindle Number 31H 1 55 2nd Rate 39H 9 89 1st Time 35H 5
22 Judgment Flag1 4FH O 56 2nd Rate 39H 9 90 2nd Time 30H 0
23 Judgment Flag1 30H 0 57 3rd Rate 31H 1 91 2nd Time 30H 0
24 Judgment Flag1 30H 0 58 3rd Rate 39H 9 92 2nd Time 32H 2
25 Judgment Flag1 30H 0 59 3rd Rate 39H 9 93 2nd Time 37H 7
26 Judgment Flag1 30H 0 60 3rd
Rate 39H 9 94 Rundown Revs 30H 0
27 Judgment Flag1 30H 0 61 Rate Sign Flag4 30H 0 95 Rundown Revs 31H 1
28 Batch Count 30H 0 62 1st Rate Incr. TQ. 30H 0 96 Rundown Revs 31H 1
29 Batch Count 34H 4 63 1st Rate Incr. TQ. 30H 0 97 Rundown Revs 35H 5
30 Torque Unit2 30H 0 64 1st Rate Incr. TQ. 32H 2 98 Offset Torque 30H 0
31 Torque Decimal3 32H 2 65 1st Rate Incr. TQ. 30H 0 99 Offset Torque 30H 0
32 Rate Decimal3 33H 3 66 1st Rate Incr. Ang. 30H 0 100 Offset Torque 30H 0
33 Cycle Count 31H 1 67 1st Rate Incr. Ang. 31H 1 101 Offset Torque 30H 0
34 Cycle Count 33H 3 68 1st Rate Incr. Ang. 32H 2 102 Fastening Mode5 30H 0

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 FEC FUSION Operations Manual Chapter 4: System Setup and Wiring (Rev. 3)

Example Example Example

Byte Description Byte Description Byte Description
ASCII Data ASCII Data ASCII Data
103 Cal Value 32H 2 141 Crossover Torque 30H 0 179 1st Rate Lo Limit 30H 0
104 Cal Value 34H 4 142 Crossover Torque 30H 0 180 1st Rate Lo Limit 30H 0
105 Cal Value 35H 5 143 2nd Rate Start TQ 30H 0 181 1st Rate Lo Limit 31H 1
106 Cal Value 32H 2 144 2nd Rate Start TQ 36H 6 182 1st Rate Lo Limit 30H 0
107 Peak TQ. Lo Limit 31H 1 145 2nd Rate Start TQ 30H 0 183 1st Rate Hi Limit 30H 0
108 Peak TQ. Lo Limit 31H 1 146 2nd Rate Start TQ 30H 0 184 1st Rate Hi Limit 35H 5
109 Peak TQ. Lo Limit 30H 0 147 Angle Low Limit 30H 0 185 1st Rate Hi Limit 30H 0
110 Peak TQ. Lo Limit 30H 0 148 Angle Low Limit 30H 0 186 1st Rate Hi Limit 30H 0
111 Peak TQ. Hi Limit 31H 1 149 Angle Low Limit 30H 0 187 1st Rt. Sign Flag4 30H 0
112 Peak TQ. Hi Limit 34H 4 150 Angle Low Limit 35H 5 188 2nd Rate Lo Limit 30H 0
113 Peak TQ. Hi Limit 30H 0 151 Angle High Limit 30H 0 189 2nd Rate Lo Limit 30H 0
114 Peak TQ. Hi Limit 30H 0 152 Angle High Limit 31H 1 190 2nd Rate Lo Limit 31H 1
115 Final TQ. Lo Limit 30H 0 153 Angle High Limit 30H 0 191 2nd Rate Lo Limit 30H 0
116 Final TQ. Lo Limit 30H 0 154 Angle High Limit 30H 0 192 2nd Rate Hi Limit 30H 0
117 Final TQ. Lo Limit 30H 0 155 Standard Angle 30H 0 193 2nd Rate Hi Limit 35H 5
118 Final TQ. Lo Limit 30H 0 156 Standard Angle 30H 0 194 2nd Rate Hi Limit 30H 0
119 Final TQ. Hi Limit 32H 2 157 Standard Angle 30H 0 195 2nd Rate Hi Limit 30H 0
120 Final TQ. Hi Limit 34H 4 158 Standard Angle 30H 0 196 2nd Rt. Sign Flag4 30H 0
121 Final TQ. Hi Limit 39H 9 159 1st Angle 30H 0 197 3rd Rate Lo Limit 30H 0
122 Final TQ. Hi Limit 38H 8 160 1st Angle 30H 0 198 3rd Rate Lo Limit 30H 0
123 Standard Torque 31H 1 161 1st Angle 30H 0 199 3rd Rate Lo Limit 30H 0
124 Standard Torque 32H 2 162 1st Angle 30H 0 200 3rd Rate Lo Limit 30H 0
125 Standard Torque 30H 0 163 Crossover Angle 30H 0 201 3rd Rate Hi Limit 31H 1
126 Standard Torque 30H 0 164 Crossover Angle 30H 0 202 3rd Rate Hi Limit 39H 9
127 1st Torque 30H 0 165 Crossover Angle 30H 0 203 3rd Rate Hi Limit 39H 9
128 1st Torque 36H 6 166 Crossover Angle 30H 0 204 3rd Rate Hi Limit 39H 9
129 1st Torque 30H 0 167 Correction Angle 30H 0 205 3rd Rt. Sign Flag4 30H 0
130 1st Torque 30H 0 168 Correction Angle 30H 0 206 R/D Rev Lo Limit 30H 0
131 Snug Torque 30H 0 169 Correction Angle 30H 0 207 R/D Rev Lo Limit 30H 0
132 Snug Torque 35H 5 170 Correction Angle 30H 0 208 R/D Rev Lo Limit 30H 0
133 Snug Torque 30H 0 171 2nd
Rate Start Ang. 30H 0 209 R/D Rev Lo Limit 30H 0
134 Snug Torque 30H 0 172 2nd Rate Start Ang. 30H 0 210 R/D Rev Hi Limit 30H 0
135 Threshold Torque 30H 0 173 2nd Rate Start Ang. 30H 0 211 R/D Rev Hi Limit 30H 0
136 Threshold Torque 32H 2 174 2nd Rate Start Ang. 30H 0 212 R/D Rev Hi Limit 30H 0
137 Threshold Torque 30H 0 175 3rd Rate Start Ang. 30H 0 213 R/D Rev Hi Limit 30H 0
138 Threshold Torque 30H 0 176 3rd Rate Start Ang. 30H 0 214 End Of Text 03H
139 Crossover Torque 30H 0 177 3rd
Rate Start Ang. 30H 0
140 Crossover Torque 36H 6 178 3rd Rate Start Ang. 30H 0

Byte Numbers 2 – 106 = actual fastening data

Byte Numbers 107 – 213 = PRESET (limit) data

*Date & Time only with clock (RTC) module installed in Fusion Controller

1-5See next page(s) for explanation

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Chapter 4: System Setup and Wiring

Rear Panel RS232 Standard Communication Protocol (Continued)

1
Judgment Flag
The Judgment Flag uses (6) ASCII bytes for detailed information to identify specific REJECT causes.
Below is the definition of byte 1-6 of the Judgment Flag.

Byte 1

Output ASCII
Status
Data (Hex)
Accept O 4F
Reject N 4E
Stop S 53
Bypass B 42
Abnormal A 41

Bytes 2-6 use flags to identify reject causes. It uses an ASCII coded hexadecimal format where the
upper bits (of the byte) automatically consider an ASCII “3” or “4” for conversion purposes. (hex
numbers 0-9 will automatically generate an ASCII “3x”, and hex letters A-F will automatically generate
an ASCII “4x”)

Byte 2
Torque Reject Byte

MSB LSB
LSB 1 : Peak Torque Low Reject
1 : Peak Torque High Reject
1 : Final Torque Low Reject
MSB 1 : Final Torque High Reject
Byte 3
Angle / Rev Reject Byte
LSB 1 : Angle Low Reject
1 : Angle High Reject
1 : Rundown Revolution Low Reject
MSB 1 : Rundown Revolution High Reject
Byte 4
Time Reject Byte
LSB 1 : 1st Time Reject
1 : 1st Time Low Reject
1 : Final Time Reject
MSB 1 : Final Time Low Reject
Byte 5
Torque Rate Reject Byte
LSB 1 : 1st Rate Low Reject
1 : 1st Rate High Reject
1 : 2nd Rate Low Reject
MSB 1 : 2nd Rate High Reject
Byte 6
Torque Rate Reject Byte
LSB 1 : 3rd Rate Low Reject
1 : 3rd Rate High
1 : Not Used
MSB 1 : Not Used

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 FEC FUSION Operations Manual Chapter 4: System Setup and Wiring (Rev. 3)

Rear Panel RS232 Standard Communication Protocol (Continued)

2
Torque Unit

Output ASCII
Unit
Data (Hex)
Nm 0 30
Kgm 1 31
Kgcm 2 32
Ft. Lb. 3 33
In. Lb. 4 34

3
Torque / Rate Decimal

Decimal Output ASCII

Place Data (Hex)
0000. 0 30
000.0 1 31
00.00 2 32
0.000 3 33

4
Rate Sign Flag

MSB LSB
LSB 1 : 1st Rate Negative
1 : 2nd Rate Negative
1 : 3rd Rate Negative
MSB 1 : Not Used

5
Fastening Mode

Fastening Output ASCII

Method Data (Hex)
Torque
0 30
Control
Angle
1 31
Control

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Chapter 4: System Setup and Wiring

4.8.4 Rear Panel RS232 Abbreviated Communication Protocol

The RS232C output format can be switched between the standard format (preceding page)
and the abbreviated format shown below. This function is available in firmware versions
2.22 or later. The table below describes the data set-up for enabling and configuring the
abbreviated output format.

Work # Data # Item Setting

00 40 Format selection 0: Standard (214 bytes) Data # 41 ~ 49 Disabled
1:Abbreviated (32bytes) Data # 41 ~ 49 Enabled
00 41 End data selection 0: 0Dh (CR) 1: 0Ah (LF) 3: 0Dh+0Ah (CR & LF)
00 42 Comm. Speed 1: 9600 BPS 2: 19200BPS 3: 38400BPS
00 43 Data bit 0: 7Bit 1: 8 Bit
00 44 Stop bit 0: 1 Bit 1: 2 Bit
00 45 Parity 0: None 1: Even 2: Odd
00 46 Torque data 0: No data 1:Enable data
00 47 Angle data 0: No data 1:Enable data
00 48 Cycle Time data 0: No data 1:Enable data
00 49 Judgment 0: No data 1:Enable data

Example of abbreviated format:

Byte 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Desc. Spindle # Work Cycle Count Peak Torque Final Angle
ASCII
23H 31H 31H 30H 31H 32H 31H 32H 2EH 33H 34H 31H 31H 32H 2EH 33H
Hex
Data # 1 1 0 1 2 1 2 . 3 4 1 1 2 . 3

Byte 17 18 19 20 21 22 23 24 25 26 27 28 29 30
Desc. Not Used Cycle Time Judge
ASCII
30H 30H 30H 30H 30H 30H 30H 30H 30H 31H 32H 2EH 33H 40H
Hex
Data 0 0 0 0 0 0 0 0 0 1 2 . 3 @

Byte 31 31 31 32
Desc.
ASCII
0DH OR 0AH OR 0DH 0AH
Hex
Data CR LF CR LF

Definition of “Judge” (Byte 30):

@ = Accept G = Stop
E = Low Time Reject F = Time Reject
P = Bypass
K = Angle High Reject J = Angle Low Reject
I = Torque High Reject H = Torque Low Reject
A = Abnormal X = Other Reject

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 FEC FUSION Operations Manual Chapter 4: System Setup and Wiring (Rev. 3)

4.8.5 Rear Panel RS232 Alternate Communication Protocol

An alternate communication protocol is available upon set-up in a different “Fastening Func-
tion Mode” (See 7.2.5 Fastening Function Version [Work]-00, [D-No]-03) If the system is set-
up in a “DDK” mode, this protocol becomes the Standard Communication Protocol.
This alternate protocol has 79 bytes of data per fastening.

Byte 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Spindle Work
Desc. Cycle Count
Number Number
ASCII
30H 30H 30H 31H 20H 20H 30H 31H 20H 20H 20H 31H 20H 20H
Hex
Data 0 0 0 1 0 1 1

Byte 15 16 17 18 19 20 21 22 23 24 25 26 27 28
Desc. Peak Torque Judge Final Angle Judge
ASCII
31H 32H 2EH 33H 34H 4CH 20H 20H 20H 20H 35H 30H 48H 20H
Hex
Data 1 2 . 3 4 L 5 0 H

Byte 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44
Desc. Final Torque Judge 1st Rate Judge
ASCII
31H 32H 2EH 33H 34H 20H 20H 20H 30H 2EH 31H 32H 33H 20H 20H 20H
Hex
Data 1 2 . 3 4 0 . 1 2 3

Byte 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60
Desc. 2nd Rate Judge 3rd Rate Judge
ASCII
30H 2EH 31H 32H 33H 20H 20H 20H 30H 2EH 31H 32H 33H 20H 20H 20H
Hex
Data 0 . 1 2 3 0 . 1 2 3

Byte 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79
1st Time Judge 2nd Time Judge Final CR LF
Desc.
Judge
ASCII
20H 31H 30H 2EH 30H 20H 20H 20H 20H 20H 32H 2EH 30H 20H 20H 20H 58H 0DH 0AH
Hex
Data 1 0 . 0 2 . 0 X
Final Judgment: “X” Reject = 58H, “O” Accept = 4FH, “A” Abnormal = 41H, “S” Stop=53H, “B” Bypass=42H
Judge: “H” High Reject= 48H, “L” Low Reject= 4CH (H = Hex)

Page 4-25
Chapter 4: System Setup and Wiring

4.9 T/A MON. DB9 Connector - External Torque/Angle/Current/Speed Output

This auxiliary connector is used to output Torque, Angle, Current & Speed signals to external
equipment for monitoring purposes (X-Y Plotter, etc). The signals output from this con-
nector are the same signals that the system receives during the fastening process. This
connector is not required for the system to operate.

No Signal In/Out Description

1 None
2 None
3 Angle Pulse Out Angle Pulse Monitor TTL
4 Angle CW/CCW Out CW/CCW Monitor TTL
5 GND Out Ground
6 None
7 Current Monitor Out -10V～+10V 10V=(HFC-EC-16 16A )
Speed Voltage
8 Out -10V～+10V 10V=Max Speed
Monitor
9 Torque Monitor Out Max Torque=2.5V

Torque voltage (Analog voltage)

Monitor voltage represents zero torque to full-scale torque by an electric
potential difference of 2.5V.
Zero Level voltage is voltage measured with the nutrunner stopped with no load.
Angle pulse (TTL signal 0V or 5V)
Angle pulse is output at 1 pulse per degree.
It differs slightly from the actual angle of rotation displayed from the controller.
Normal/reverse revolution pulse (TTL signal 0V or 5V)
A 5v (High) signal is output during CW revolution, and 0V (Low) signal is output during CCW
revolution.

Angle and direction are output as shown below;

TOOL CW STOP
ROTATION

CCW

ANGLE
PULSES

CW/CCW

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 FEC FUSION Operations Manual Chapter 4: System Setup and Wiring (Rev. 3)

4.10 Controller Unit DIP Switch Setting.

In a multiple controller unit system, it may be beneficial to address the controllers for organi-
zational purposes. The number is set using the DIP switch located behind the access panel
on the back panel of the unit.

DIP switch located on printed

circuit board through access
panel at the back of unit.

FIG. 4-10 Dip Switch settings

4.10.1 Controller Unit DIP Switch positions 1 ~ 3

 DIP switch positions 1 ~ 3 are used for setting the special configuration features as defined in
the following explanation. The DEFAULT setting is switch 1 – 3 OFF.
 DIP Switch 1 - Zero Check acceptance window selection.
o ON – Expanded Zero Check acceptance window
o OFF – Normal Zero Check acceptance window
 DIP Switch 2 - NOT USED
o ON – Not Used
o OFF – Not Used
 DIP Switch 3 - Disable Motor Ramp Down.
o ON - Enables dynamic brake for motor speed changes.
- Used for applications which overshoot standard torque
- Will reduce Motor/Tool life
o OFF - Disables Dynamic brake during speed changes (Default)

Note: The Controller unit must be powered off and on again for the DIP switch changes to be
initialized.

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Chapter 4: System Setup and Wiring

4.10.2 Controller Unit DIP Switch positions 4 ~ 8

DIP switch positions 4 ~ 8 are used for setting the Controller unit spindle address number as
described in the following table. This can be beneficial if fastening data is being collected
from multiple spindles whereas the data needs to be identified differently between each spin-
dle. Do not set two spindles with the same address.

Note: The Controller unit must be powered off and on again for the DIP switch changes
to be initialized

Unit DIP SWITCH NUMBER Unit DIP SWITCH NUMBER

No. No.
4 5 6 7 8 4 5 6 7 8
1 OFF OFF OFF OFF ON 16 ON OFF OFF OFF OFF
2 OFF OFF OFF ON OFF 17 ON OFF OFF OFF ON
3 OFF OFF OFF ON ON 18 ON OFF OFF ON OFF
4 OFF OFF ON OFF OFF 19 ON OFF OFF ON ON
5 OFF OFF ON OFF ON 20 ON OFF ON OFF OFF
6 OFF OFF ON ON OFF 21 ON OFF ON OFF ON
7 OFF OFF ON ON ON 22 ON OFF ON ON OFF
8 OFF ON OFF OFF OFF 23 ON OFF ON ON ON
9 OFF ON OFF OFF ON 24 ON ON OFF OFF OFF
10 OFF ON OFF ON OFF 25 ON ON OFF OFF ON
11 OFF ON OFF ON ON 26 ON ON OFF ON OFF
12 OFF ON ON OFF OFF 27 ON ON OFF ON ON
13 OFF ON ON OFF ON 28 ON ON ON OFF OFF
14 OFF ON ON ON OFF 29 ON ON ON OFF ON
15 OFF ON ON ON ON 30 ON ON ON ON OFF
31 ON ON ON ON ON

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 FEC FUSION Operations Manual Chapter 4: System Setup and Wiring (Rev. 3)

4.11 Tool Cable Connection

 Tools are connected to the controller using one cable. One cable connects to the torque trans-
ducer preamp, motor and resolver. Each cable should be labeled with a specific spindle or iden-
tification number and should be connected to the corresponding controller and tool.
 Cables should be supported to reduce fatigue points. Cable tie points should be loose enough
to allow the cable to move, but yet hold it in place. Cable tie points that are too tight cause a
stress point leading to premature cable failure.

WARNING: Do not make motor connections with the power on. Turn off all controller power
before attempting to connect or disconnect any motor cables or tool damage may occur.

Recommended cable length: 75’ or less.

Maximum cable length: 100’ (must be free from Electrical Noise)

SILVER Tool Style Cables (“-01” Model designation)

FEC Part # Cable Description Length

FEB-1309-M5 Main Cable Straight Female Plug 5 meter
FEB-1309-M10 Main Cable Straight Female Plug 10 meter
FEB-1309-M15 Main Cable Straight Female Plug 15 meter

FEB-1311-M5 Main Cable 90 Degree Female Plug 5 meter

FEB-1311-M10 Main Cable 90 Degree Female Plug 10 meter
FEB-1311-M15 Main Cable 90 Degree Female Plug 15 meter

FEB-1310-M1 Extension Cable Straight Female Plug 1 meter

FEB-1310-M2 Extension Cable Straight Female Plug 2 meter
FEB-1310-M3 Extension Cable Straight Female Plug 3 meter
FEB-1310-M5 Extension Cable Straight Female Plug 5 meter
FEB-1310-M10 Extension Cable Straight Female Plug 10 meter

FEB-1312-M1 Extension Cable 90 Degree Female Plug 1 meter

FEB-1312-M2 Extension Cable 90 Degree Female Plug 2 meter
FEB-1312-M3 Extension Cable 90 Degree Female Plug 3 meter
FEB-1312-M5 Extension Cable 90 Degree Female Plug 5 meter
FEB-1312-M10 Extension Cable 90 Degree Female Plug 10 meter
Wave Washer (Part # WAV-25036) can be used to tighten the tool side twist lock connector. The
washer must be split and inserted by threading the washer underneath the twist lock rollers.

GOLD Tool Style Cables (“-10” model designation)

FEC Part # Cable Description Length

C15-F7-M05 Main Cable Straight Female Plug 5 meter
C15-F7-M10 Main Cable Straight Female Plug 10 meter
C15-F7-M15 Main Cable Straight Female Plug 15 meter

C15-EF7-M05 Extension Cable Straight Female Plug 5 meter

C15-EF7-M10 Extension Cable Straight Female Plug 10 meter
C15-EF7-M15 Extension Cable Straight Female Plug 15 meter

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Chapter 4: System Setup and Wiring

4.11.1 Cable Installation Guidelines

Improper installation of cables can reduce cable life expectancy drastically. The following guide-
lines should be used when installing cables.
 The cables must be prepared for installation without twists, bends or kinks. Upon unpack-
ing the cables, any tie wraps used in shipping should be removed.
 Before inserting the cables in the cable tray, cable track or other overhead suspension, it
is important that the cables be laid out or hung prior to installation long enough to relax
any stresses and remove any “memory” resulting from packaging, transit or storage. If the
cables cannot be relaxed, they should be shook out by grasping the cable length at its mid
point and shaking the cables as you move to each end. Then, wrap the end of each cable
with masking tape and make alignment marks on the top of each end. Maintain this align-
ment throughout the installation to assure cable is not being twisted.
 The minimum recommended bending radius of the cable should not be exceeded. The
minimum bend radius is calculated by multiplying the cable’s outer diameter by ten
(Rmin = O.D. x 10). When multiple cables are run together, the largest diameter cable in
the bundle should be used for calculating bend radius. Minimum bend radius must be in-
creased when repeated flexing occurs at a given point on the cables.
 Use the most direct path when routing cables.
 Do not weave cables between or wrap around one another.
 Route cables and connectors away from liquid of any type.
 Protect cable connectors from any impact or abrasion that may cause damage (IE: pulling
cables through cable tray and dropping cables to the floor).
 Check cable route for possible chafing or abrasion points. Re-route or protect cable at
these points with a nylon cable wrap or similar means to avoid future cable damage.
 The use of plastic cable ties (ty-wraps) should be avoided if possible. The use of Velcro
straps is preferable. If the use of plastic cable ties cannot be avoided, the following prac-
tices should be followed:
o Cables should not be tied so tight as to cause indentations in the cable jack-
et. Flexible cables are designed to move inside their cable jacket. If this
movement is restricted, wires in the cable may become stressed and break.
o Plastic cable ties around grouped cables should be used minimally so that
cables have the ability to move individually rather than all as one.
o An acceptable method is to include the use of a flexible tubing or sleeve be-
tween the plastic cable tie and the cable(s).
 Do not tie or hang anything, whatsoever, from tool cables.
 Avoid running cables directly next to high voltage or high frequency lines.
 Cables must be supported near connectors in panel and at tool to avoid strain on connec-
tion points.
 Certain tool operations may have foreseeable cable damaging aspects which are una-
voidable. In these situations a shorter “extension” cable can be provided with the expecta-
tion of replacing this intermediate, less expensive cable as required. The use and proper
placement of an “extension” cable will also make cable replacement less time consuming.

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 FEC FUSION Operations Manual Chapter 4: System Setup and Wiring (Rev. 3)

4.11.2 Considerations for Cable Trolleys

 Cables hung by festooning type systems must be secured to the individual cable trolley
and positioned to avoid sharp bends and eliminate or minimize any torsion twisting.
 Restraint cords should be used in between cable trolleys to limit movement and reduce
the stress on cables as they are extended. Restraint cord lengths must always be shorter
than the length of cable hung between trolleys.
 Cable loops should be consistent in length,typically not exceeding 5 feet in depth between
trolleys. Sufficient number of trolleys should be used in a system to support the entire
length of moving cable and to allow relaxed stacking/festooning of cable loops when tool is
in the retracted position.
 One trolley should be fixed to the runway rail to eliminate tugging on or stretching of ca-
bles.

4.11.3 Considerations for Flexible Cable Tracks

 Cables must under no circumstances have the opportunity to tangle. Therefore the
clearance height of a track compartment with several similar cables next to one another
must not amount to more that one and a half times the cable diameter.
 There should be an “all around” minimum clearance between cables of 10% of the cable’s
diameter.
 Cables and hoses with very different diameters should be laid separately. Separation is
achieved by using Flexible Track separators. The following rules should be followed for
cable separation:
o If (Cable 1 Diameter) + (Cable 2 Diameter) > 1.2 x Track Inner Height, then
no separation is necessary.
o If (Cable 1 Diameter) + (Cable 2 Diameter) ≤ 1.2 x Track Inner Height, then a
horizontal or vertical separator must be used to reduce the inner height,
thereby preventing the entanglement of the cables.
 The cable weight should be symmetrically distributed along the width of the track.
 Cables must be able to move freely along the radius.
 The cables must be secured with strain relief at both ends. In exceptional cases, the ca-
bles may be fixed with strain relief at the moving end only. Unless using a Flexible Cable
Track with integrated strain relief, a gap of 10~30 x cable diameter between the end of the
bending segment and the fixed point is recommended for most cables.
 Under no circumstances should excess cable be put into a Flexible Cable Track.

4.11.4 Considerations for Cable Trays & Ladders

 Cable drop out panels should be used where cables enter and exit a tray or ladder sys-
tem. Sharp bends need to be avoided whenever possible.
 Cables should be secured at both entry and exit points of a tray or ladder.
 Avoid running high voltage or high frequency cables in the same tray or ladder as signal or
control cables unless cables are designed for such environments.
 If excess cable is to be stored in a tray or ladder, do not tightly coil cable. Cable should be
laid in as large of a loop as possible.

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Chapter 4: System Setup and Wiring

4.11.5 Tool Cable - Preamplifier Pins.

The preamplifier connection links the controller to the tool torque transducer to:
a) Read the torque voltage values from the preamplifier.
b) Test the preamplifier full scale torque via the calibration function.
c) Test the preamplifier zero level by the zero level check function.
d) Read and Write the EEPROM memory located in the preamplifier.

PIN DESCRIPTION
T TRx +
J TRx -
G GND
F +12VDC
H TORQUE OUT
E -12VDC

4.11.6 Tool Cable - Motor Pins

The Motor connection provides control power to the motor.

PIN DESCRIPTION
N FRAME GROUND
L W PHASE
M V PHASE
A U PHASE

4.11.7 Tool Cable - Resolver Pins

The resolver connection handles the signals which define the rotation of the motor.
The controller provides a signal to the winding of the rotor. As the rotor spins, two sets of sta-
tors electrically shifted 90 degrees generate a sine wave and a cosine wave signal. Both sig-
nals are processed by the controller to define position and speed of the motor.

PIN DESCRIPTION
C ROTOR (R1)
P STATOR (S2)
V STATOR (S1)
D ROTOR R2
R STATOR S4
S STATOR S3
N SHIELD

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FEC FUSION Operations Manual Chapter 4: System Setup and Wiring (Rev. 3)

4.12 Firmware Flash Connector (CN8)

Upgrades or revisions to Firmware are handled easily with the on board Flash connector lo-
cated behind the access panel on the bottom of each controller Unit. There is no need to
remove or disassemble the unit. A Flash adapter (CONTROLLER-ROM) containing the new
firmware can be connected to connector CN8 with the power off to the unit. The power is
then cycled on until the ACCEPT LED is blinking indicating the firmware upload is complete.
Turn off power and remove the flash adapter. The firmware update is now complete.
Note: This connector is for FEC use only and it is not recommended for use other than
FEC.

FIG 4-12: CN8 location (CONTROLLER) unit bottom view).

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Chapter 4: System Setup and Wiring

4.13 SYNC Connector

The Sync connector is provided for a means to synchronize more than one spindle during the
fastening process. Synchronized fastening allows spindles to synchronize at a preset torque
before attempting to reach the next target or final torque. For synchronized fastening opera-
tion using individual Fusion controllers, the SYNC terminals must be wired between all affect-
ed spindles.

The SYNC signals are Bi-directional signals for synchronized fastening (5V, TTL signal).

1. At the start of the cycle until reaching the synchronization point (1st torque), the SYNC
signal is ON (LOW condition) to stop other Fusion Units from continuing to the second
step (wired OR).
2. When the 1st torque is reached, the signal works as an input signal. If it reads LOW -
meaning that other Fusion units have not reached 1st torque yet - the Fusion unit stays in
the standby state waiting for all connected spindles to reach first torque.
When the SYNC signal is HIGH (all Fusion units have completed the first step), all units
simultaneously start the second step.

Spindle SYNC signals are connected in series from

one spindle to the next.

Fig. 4.13 Sync Connector

CN6 (Sync Connector)

PIN DESCRIPTION
1 Sync Signal (5V TTL)
2 Not Used
3 Sync Common (0v)
4 Frame Ground (FG)

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FEC FUSION Operations Manual Chapter 4: System Setup and Wiring (Rev. 3)

4.14 Options – Ethernet card

An optional Ethernet card is available for “AFC Programming / Monitoring software” connec-
tion as well as fastening data communication over an Ethernet network (TCP/IP – 10 /
100BaseT). Current developed communication protocols include ToolsNet Open Protocol
(Atlas Copco), Q-DAS (Qs-Stat), FECNet (proprietary protocol), Part ID / Model select via
Ethernet as well as custom protocols as required by customer specifications.

The Ethernet module is installed in the back of the controller located in the top right auxiliary
opening. (The Real Time Clock module (RTC) should be removed when using an Ethernet
card module.) Connections are made to the RS232 port as well as the TB1 terminal strip.

The Ethernet module is set-up using an onboard browser - based configuration firmware that
allows a laptop to connect to the module by an Ethernet connection and set-up the module
without installing additional software. This configuration allows you to set-up the Ethernet
module to communicate over various networks (described above).

For configuration, an Ethernet CROSSOVER cable (FEC Part # A3X126-07-YLW-M) must

be used between the configuration computer and the Ethernet module.

Fig. 4.14 Ethernet Configuration

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Chapter 4: System Setup and Wiring

4.14.1 Ethernet Set-up of PC to Communicate to Ethernet Module

The PC used to configure the Ethernet module must have the Ethernet TCP/IP settings con-
figured for the following to communicate to the Fusion Ethernet module.
(See you network administrator or Windows® support for detailed information to set-up your
Ethernet port if you are unfamiliar with Ethernet port set-up. You may also request the “Fu-
sion Ethernet Module Set-Up Procedure” from FEC for more detail)

PC Ethernet Set-up
IP address: 192.168.10.40
Subnet mask: 255.255.255.0
Default Gateway:192.168.10.1

Once the PC is configured and connected to the Ethernet Module using an Ethernet cross-
over cable, you can use your web browser (Ex. Internet Explorer) to configure the Ethernet
module including the network IP address , Station Name, etc.

Open the web browser and put this address in the address bar ;

This screen should appear:

If this screen does not appear, re-check your cables and connection. (See the “Fusion Ethernet
Module Set-Up Procedure” from FEC for more detail)

Note: If this screen does not show up, the IP address setup of the Fusion Ethernet module
may have already been changed. The IP configuration setup of the Fusion Ethernet Module
can be reset to default by putting a jumper wire between pin 3 and 5 of the Fusion Ethernet I/O
“Power & I/O” connector at power up. (Power down, put jumper in and power up – jumper can
be removed after resetting IP address)

Once the Ethernet module is configured for the network you are connecting to, you can disconnect
the PC and cycle power. Upon the next power-up, the Ethernet module can be connected to the
configured network using the IP address that was configured. (Tag the Ethernet port with the con-
figured IP address for future easy reference)

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 FEC FUSION Operations Manual Chapter 4: System Setup and Wiring (Rev. 3)

4.14.2 Ethernet Module Connection

The Ethernet Module connections are shown below. Note that the power for the module is
supplied from the Fusion controller TB1 terminal. Optional Work Select terminations only
need to be made if the desired Ethernet protocol requires selection of work selects by Ether-
net.

Fig. 4.14.2 Ethernet Module Connection

Connection to an Ethernet network is done by using the RJ-45 Ethernet port on the Ethernet
module. (Set-up of the TCP/IP configuration must be completed in the module set-up before
communication can take place) After Connection to an Ethernet network, the Ethernet sta-
tus is displayed on the Ethernet Status display LED’s located just above the RJ-45 Ethernet
connection port (shown to the left of the Ethernet port on the drawing above)

Ethernet Status LED

Link

Active

Link: LED is “ON” (solid) when link is established

Active: LED flashes during data transmission

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Chapter 4: System Setup and Wiring

4.15 Options – Fieldbus Interfaces

The Fusion controller is able to operate under different Input/Output control structures
through use of a modular I/O interface board installed in the rear of the unit. With the intro-
duction of “Open” communication networks known as “Fieldbus”, the direct interfacing to
these networks became necessary. FEC integrated many of these Fieldbus interfaces di-
rectly into our system through use of a modular I/O board interfacing these networks directly
to our I/O.
The available I/O interfaces are: Profibus, Devicenet, Ethernet I/P, CClink & Allen Bradley
Remote I/O. (others available - Contact FEC for additional Fieldbus requirements) The
fieldbus interface boards are integrated directly to internal I/O signals which eliminate associ-
ated I/O wiring thus reducing overall assembly labor. In fieldbus systems, the communica-
tion is typically of the Master/Slave format in which the FEC unit is a slave to the master
PLC/CPU. Some of the Fieldbus interfaces are also capable of sending limited fastening
data as well as I/O control.
The Fieldbus interface module is factory installed in the rear auxiliary opening (where the real
time clock (RTC) module normally resides). With a fieldbus interface installed, the real time
clock is installed internally with the RTC cable extending through the fieldbus cover plate for
connection to the rear real time clock connector.

Fieldbus interface module is

factory-installed in this auxiliary slot.

Note: With the fieldbus module installed for

I/O control, the I/O on Terminal TB1 is still enabled

Fieldbus Link Status

The Fusion controller display has a special function for displaying the Fieldbus
link status whether the controller is connected and active on the fieldbus net-
work or not.

The COUNT/D-NO LED on the front of

Count / D-NO.
the controller indicates the fieldbus link
status. The two decimal points will il-
luminate when the Fieldbus link is
DISABLED. Check all connections
and configurations for proper set-up.

Page 4-38
 FEC FUSION Operations Manual Chapter 4: System Setup and Wiring (Rev. 3)

4.15.1 Fieldbus Interfaces – Profibus-DP

The Profibus-DP communication interface allows slave connection to an industrial Profibus-

DP network. Profibus-DP allows industrial devices to be controlled over an open network
architecture enabling device connection at various locations in the field. This “Fieldbus”
technology reduces hardwiring/cabling & provides ease of installation. It can interface to
many devices such as limit switches, sensors, directional valves, motor starters, bar code
readers, process sensors, frequency drives, etc. The network can have up to 126 nodes. Its
maximum communication baud rate is 12M baud and its minimum baud rate is 9.6K baud.
Node addressing is selectable using the address selection switch. Baud rate is auto detect-
ed rom the master and no user setup is required. Module & Network status LED’s provide
network diagnostics.

The Fusion Profibus supports Cyclic I/O only. Messaging (CIP) is not supported.

Maximum configurable I/O is 32 bytes (256bits) input / 32 bytes (256 bits) output.
FEC uses 16 Bytes (128bits) for Fusion OUTPUTS (Fusion to PLC) which includes Binary In-
teger output of both Fastening Torque & Angle. Fusion INPUTS (PLC to Fusion) uses 4
Bytes (32 bits). The I/O signal map defines the signals/data for each address. (See below)

Note: The Profibus-DP interface is implemented according to the Profibus-DP EN 50 170

(DIN 19245 Part 1) specification.

FEC integrates the Profibus-DP board manufactured by HMS Fieldbus Systems AB into the
Fusion modular I/O board. For further technical information on the Profibus-DP interface go
to the HMS website. (www.hms.se)
Further Profibus information can be found on the Profibus website at www.profibus..com.

PLC
ＰＬＣ(PROFIBUS
（Profibusﾏｽ ﾀｰmaster)
）

サイクリックＩ ／Ｏ通信
Cyclic
メッセージ通信I/O communication

Profibus
ｽ ﾚｰ ﾌﾞ
PROFIBUS
M ULTIユニット
slave 他社製Profi
Other busｽ ﾚｰ ﾌﾞ
PROFIBUS slave
M ULTI-2ユニット

1軸 2軸 31軸

HFC-EC-16-BUS

ＡＦＣ１５００ＭＵＬＴＩ
システム
ＡＦＣ１５００ＭＵＬＴＩ
－２システム

Page 4-39
Chapter 4: System Setup and Wiring

Termination
Termination of the fieldbus requires a terminating resistor at each end of the fieldbus. A
termination switch is provided on the Profibus-DP interface board. Set the switch to “ON”, if
termination is required. If external terminators are used, the switch must be in the off posi-
tion.

GSD File
Each device on a Profibus network is associated with a GSD file containing all necessary in-
formation about the device to be connected. The network configuration program uses this
file during configuration of the network.
The GSD file associated with the FEC device can be downloaded from the FEC website.
www.fec-usa.com (See Support/Download area) (File : hms_1003.gsd)
(the file can also be downloaded directly from HMS - www.hms.se)

Profibus Specifications
Speed 9.6K - 12M baud – auto-selected
Nodes 126 Note: Node 126 is reserved for commissioning
purposes only
Distance 200m max. at 1.5Mbit/s extendable with repeaters.
Cable Shielded Copper Twisted Pair or fiber optic
Communications Type Master/Slave - EIA RS485
Protocol Version Ver. 1.10
Maximum Cyclic I/O Size 244bytes In, 244 bytes out max. 416 total
bytes max.
Data transmission The module only supports cyclic I/O data transmis-
sion.
Note: Limited Coded Binary Integer data is sent in the
cyclic I/O data

Profibus Connector

Termination Switch

Node Address Switch

LED Status Indicator

Page 4-40
FEC FUSION Operations Manual Chapter 4: System Setup and Wiring (Rev. 3)

Profibus Status LED

Profibus connector - D-Sub

Pin 1 Not Connected
Pin 2 Not Connected
Pin 3 B- Line Positive RxD/TxD accord-
ing to RS485 Spec.
Pin 4 RTS Request to send
Pin 5 GND Bus Isolated GND from RS
485 side
Pin 6 +5V Bus Isolated +5V from RS 485
side
Pin 7 Not connected
Pin 8 A- Line Negative RxD/TxD ac-
cording to RS485 Spec.
Pin 9 Not Connected
Housing Shield Connected to PE

Profibus Status LED

Status LEDs
Red Indicates faults on fieldbus side
LED #4 Flashing Red - Config. Error - in/out length set
Fieldbus Diagnostics 1sec at module initialization does not
match length in network config.
Flashing Red - Error in user parameter data -
2sec parameter length/content does
not match network
length/content
Flashing Red - Error in initialization of Profibus
4sec communication ASIC
On-Line Off Module not online
LED #2 Green Module online and Normal
Communication - OK
Off- Line Off Module is not offline
LED #3 Red Module is offline on the fieldbus
Note: LED #1- Not Used

Page 4-41
Chapter 4: System Setup and Wiring

Node Address
Before configuring the Profibus-DP module the node address has to be set. This is done
with two rotary switches on the module which can set the node address 1-99 in decimal for-
mat. The Upper rotary switch (closest to the D-sub) sets the “ten” digit (X 10), and the bot-
tom rotary switch sets the single digit. Example: To set node 37, place the “ten” switch on 3,
and the single digit switch on 7.
This switch must be set before power is on, and cannot be changed during operation.

Configuration
FEC Profibus I/O is pre-configured according to the I/O Signal Map (See below). Configura-
tion of the Profibus Master MUST match the configuration of the FEC Profibus slave. In the
Profibus Master set-up, input size and output size is set as “byte” ordering. (Do not use
“word” ordering. This will inverse the I/O location) When setting the Profibus Master con-
figuration, PLC input size refers to FEC output size (ie. Accept, Reject, Busy, etc.) and PLC
output size refers to FEC inputs (ie. Start, Stop, Reset, etc.). FEC will show up as 2 mod-
ules. Module 1 is inputs, module 2 is outputs.

Profibus I/O Signal Mapping

Input number: 8 bytes (64 bits) Permanently set
Output number: 16 bytes (128 bits) Permanently set

Input Signals
From PLC to Fusion: 4 Words (8 Bytes – 64bits)
Word Byte Bit No. Description Comment
0 1
1 2
2 3
3 4
0
4 5
5 6
6 7 Reset/Abort Job Resets initial condition
7 8
01
0 9
1 10
2 11
3 12
1
4 13 Work Select 0
5 14 Work Select 1
6 15 Work Select 2
7 16 Work Select 3
0 17 Stop
1 18 Reset
2 19 Reverse
3 20 Start
2
4 21 Bypass
5 22 Disable Self-check
6 23
7 24
02
0 25
1 26
2 27
3 28
3
4 29 Batch OK Reset
5 30 Work Select 4
6 31
7 32
Input Word 03 ~ 04 have no signals assigned and are not shown.

Page 4-42
 FEC FUSION Operations Manual Chapter 4: System Setup and Wiring (Rev. 3)

Output Signals
From Fusion to PLC : 8 Words (16 Bytes – 128 Bits)
Word Byte Bit No. Signal Description Comment
0 1 End
1 2 Accept
2 3 Reject
3 4
0
4 5
5 6 Job Cycle Accepted Total Accept for Sequence Function
6 7
7 8
01
0 9 Work Select 4 Selected (echo)
1 10
2 11 Time 1 Reject
3 12 Time 2 Reject
1
4 13 Work Select Bit 0 Selected (echo)
5 14 Work Select Bit 1 Selected (echo)
6 15 Work Select Bit 2 Selected (echo)
7 16 Work Select Bit 3 Selected (echo)
0 17 Reject
1 18 Accept
2 19 Abnormal
3 20 Ready
2
4 21 Busy
5 22 Torque High Reject
6 23 Torque Low Reject
7 24 Bypass
02
0 25 Angle High Reject
1 26 Angle Low Reject
2 27 Rate1 High Reject
3 28 Rate1 Low Reject
3
4 29 Rate2 High Reject
5 30 Rate2 Low Reject
6 31 Rate3 High Reject
7 32 Rate3 Low Reject
0 33 Torque Integer bit 0 Outputs Fastening Torque using bi-
1 34 Torque Integer bit 1 nary integer
2 35 Torque Integer bit 2 0 - 999 max.
3 36 Torque Integer bit 3 (number LEFT of decimal only)
4
4 37 Torque Integer bit 4 Example:
5 38 Torque Integer bit 5 Torque Integer bit 2, 4, 7 Logical "1"
6 39 Torque Integer bit 6 = 148
7 40 Torque Integer bit 7
03 Total Torque including Torque deci-
0 41 Torque Integer bit 8
1 42 Torque Integer bit 9 mal (word3) = 148.38
2 43
3 44
5
4 45
5 46
6 47
7 48
0 49 Torque Decimal bit 0 Outputs Fastening Torque Decimal
1 50 Torque Decimal bit 1 value using binary integer
2 51 Torque Decimal bit 2 0 - 99 max.
3 52 Torque Decimal bit 3 (number RIGHT of decimal only)
6
4 53 Torque Decimal bit 4 Example:
5 54 Torque Decimal bit 5 Torque Decimal bit 1, 2, 5 Logical
6 55 Torque Decimal bit 6 "1" = 38
7 56
04
0 57
1 58
2 59
3 60
7
4 61
5 62
6 63
7 64

Page 4-43
Chapter 4: System Setup and Wiring

Profibus I/O Signal Mapping

(Continued)
Word Byte Bit No. Signal Description Comment
0 65 Angle Integer bit 0
1 66 Angle Integer bit 1
2 67 Angle Integer bit 2
3 68 Angle Integer bit 3
8 Outputs Fastening Angle value using
4 69 Angle Integer bit 4
5 70 Angle Integer bit 5 binary integer
0 - 9999 max.
6 71 Angle Integer bit 6
7 72 Angle Integer bit 7
05 Example:
0 73 Angle Integer bit 8 Angle Integer bit 1, 2, 5, 7 Logical
1 74 Angle Integer bit 9 "1" = 166
2 75 Angle Integer bit 10
3 76 Angle Integer bit 11
9
4 77 Angle Integer bit 12
5 78 Angle Integer bit 13
6 79
7 80
06- Byte 81
Not Used
08 10-15 128

Page 4-44
FEC FUSION Operations Manual Chapter 4: System Setup and Wiring (Rev. 3)

Profibus AFC Software Configuration

Use the AFC User Console software to configure the Fusion controller Fieldbus Setup.

HFC-EC-16-BUS-PB is preset with the standard Fieldbus setting values.

Before changing the settings inside, please make backups.
Caution

[Fieldbus Setup screen – AFC software]

BROWSE: Browse Fieldbus configuration files.

SAVE: Save Fieldbus configuration files.
UPLOAD: Upload Fieldbus set up from Fusion controller.
（BUS TYPE will automatically switch per uploaded type）
DOWNLOAD: Download Fieldbus set up to Fusion controller.
(*Cycle power after download.)
VERIFY: Verify Fusion controller set up with AFC software set up.
BUS TYPE: Choose PROFIBUS

When Fieldbus setting is finished, hit the “SAVE” button to save to a file
The Fieldbus setting is downloaded using the “DOWNLOAD” button and/or can
be downloaded from the "PARAMETER COMMUNICATIONS" screen by select-
Caution ing the “Fieldbus Configuration” checkbox (*Cycle power after download.)

・File Extension Information

Item Extension
Parameter .PAR
Fieldbus setting .FCF

Page 4-45
Chapter 4: System Setup and Wiring

Profibus I/O Size Setting

The “SETUP” tab allows you to set the size of the I/O.
Once the size of I/O is set, you must DOWNLOAD the setting to the Fusion Controller. (See
above)

●Default set up
Input data length : 16bytes (128bits)
Output data length : 8bytes ( 64bits)

●Available I/O setup

Input data length : 1byte (8bits) ～ 32bytes (256bits)
Output data length : 1byte (8bits) ～ 32bytes (256bits)

Page 4-46
 FEC FUSION Operations Manual Chapter 4: System Setup and Wiring (Rev. 3)

4.15.2 Fieldbus Interfaces – Allen Bradley Remote I/O

The Allen Bradley (AB) Remote I/O communication interface allows slave connection to an
AB Remote I/O network. FEC has licensed (Lic. #199906006) the use of the AB Remote I/O
interface board (through HMS Fieldbus Systems). AB Remote I/O is a proprietary Fieldbus
of Allen Bradley. AB - RIO allows industrial devices to be controlled over a network architec-
ture enabling device connection at various locations in the field. The network can have up
to 240 nodes with valid rack addresses of 0-59. Its maximum communication baud rate is
230K baud with two other settings of 115K & 57.6K baud.
Rack addressing & baud rate is selectable using the baud/address selection DIP switch.
Module status LED’s provide network diagnostics.
Maximum FEC I/O data is 32 inputs & 32 outputs (1/4 Rack). 1/2, 3/4 & Full rack configura-
tion are not supported by the Fusion system.

FEC integrates the AB Remote I/O board manufactured by HMS Fieldbus Systems into the
Multi-Unit modular I/O board. For further technical information on the AB Remote I/O inter-
face see the AnyBus -DT reference found at the end of this chapter or go to the HMS web-
site. (www.hms.se)
Further AB Remote I/O information can be found through Allen Bradley’s website.
(www.ab.com)

BAUD/ADDRESS
SETTING

LED
INDICATION

TERMINATION
SWITCH

REMOTE I/O
CONNECTOR

Allen Bradley Remote I/O interface Board

Page 4-47
Chapter 4: System Setup and Wiring

Termination
Termination of the RIO network requires a terminating resistor at each end of the network. If
this is the last module on the network, turn “ON” the terminating switch located on the inter-
face board.

Specifications
AB Remote I/O Specifications
Speed 57.6, 115, 230K baud - Selectable
Rack Addresses 0-59
Nodes up to 240 1/4 racks
Rack Configuration supported 1/4
Distance 57.6k - 3048 meter
115K - 1524 meter
230K - 762 meter
Cable 78 ohm Twinax
Belden #9463 or equivalent
Communications Type Master/Slave

AB Remote I/O connector

Pin 1 COM line Blue
Pin 2 GND Shield
Pin 3 COM line Clear

Status LED

Status LEDs
Error OFF Normal Operation
ON - Red Bus off / Error
Active OFF No Communication
ON - Green Communication Active
Power OFF Power Off
ON - Green Power On

Page 4-48
 FEC FUSION Operations Manual Chapter 4: System Setup and Wiring (Rev. 3)

Dip Switch Setting

Address setting (DIP switch)
SW-3 SW-4 SW-5 SW-6 SW-7 SW-8 MAC ID
(LSB)
OFF OFF OFF OFF OFF OFF Address 0*
ON OFF OFF OFF OFF OFF Address 1
OFF ON OFF OFF OFF OFF Address 2
ON ON OFF OFF OFF OFF Address 3
. . . . . . .
ON OFF OFF ON ON ON Address 57
OFF ON OFF ON ON ON Address 58
ON ON OFF ON ON ON Address 59
This switch must be set before power is on, and cannot be changed during operation.
*Address should be set to “0” if this is the only device on the network.

Baud rate setting (DIP switch)

SW-1 SW-2 Baud rate
OFF OFF 57.6K
ON OFF 115K
OFF ON 230K
ON ON Reserved
Baud rate must match the settings of the Remote I/O scanner.
This switch must be set before power is on, and cannot be changed during operation.

I/O Signal Map

From Fusion to PLC – (4 Bytes – 32 Bits)
Octal Bit Signal Description Comment
0 0 End
1 1 Accept
2 2 Reject
3 3
I:00
4 4
5 5 Job Cycle Accepted Total Accept for Sequence Function
6 6
7 7
10 8 Work Select 4 Selected (echo)
11 9
12 10 Time 1 Reject
13 11 Time 2 Reject
I:00
14 12 Work Select Bit 0 Selected (echo)
15 13 Work Select Bit 1 Selected (echo)
16 14 Work Select Bit 2 Selected (echo)
17 15 Work Select Bit 3 Selected (echo)
0 0 Reject
1 1 Accept
2 2 Abnormal
3 3 Ready
I:01
4 4 Busy
5 5 Torque High Reject
6 6 Torque Low Reject
7 7 Bypass
10 8 Angle High Reject
11 9 Angle Low Reject
12 10 Rate1 High Reject
13 11 Rate1 Low Reject
I:01
14 12 Rate2 High Reject
15 13 Rate2 Low Reject
16 14 Rate3 High Reject
17 15 Rate3 Low Reject

Page 4-49
Chapter 4: System Setup and Wiring

I/O Signal Map

(Continued)

From PLC to Fusion – (4 Bytes – 32 Bits)

Octal Bit Description Comment
0 0
1 1
2 2
3 3
O:00
4 4
5 5
6 6 Reset
7 7
10 8
11 9
12 10
13 11
O:00
14 12 Work Select 0
15 13 Work Select 1
16 14 Work Select 2
17 15 Work Select 3
0 0 Stop
1 1 Reset
2 2 Reverse
3 3 Start
O:01
4 4 Bypass
5 5 Disable Self-check
6 6
7 7
10 8
11 9
12 10
13 11
O:01
14 12 Batch OK Reset
15 13 Work Select 4
16 14
17 15

Software Configuration
Configuration related to Allen Bradley Remote I/O is configurable using the AFC User Con-
sole Software. Configuration should be set as required by your Remote I/O network and
downloaded to the Fusion controller.

Page 4-50
 FEC FUSION Operations Manual Chapter 4: System Setup and Wiring (Rev. 3)

4.15.3 Fieldbus Interfaces – DeviceNet®

DeviceNet® Interface
The DeviceNet communication interface allows slave connection to an industrial DeviceNet net-
work. DeviceNet allows industrial devices to be controlled over an open network architecture
enabling device connection at various locations in the field. This “fieldbus” technology reduces
hard wiring/cabling & provides ease of installation. It uses a broadcast-oriented protocol -the CAN
(Controller Area Network)- that can interface to many devices such as limit switches, sensors, di-
rectional valves, motor starters, bar code readers, process sensors, frequency drives, etc. The
network can have up to 64 nodes.
Maximum I/O data is 512 input bytes & 512 output bytes. FEC Inputs/Outputs are shown in the
following I/O signal map layout.
Note: The DeviceNet interface is implemented according to the ODVA specification for a commu-
nications adapter (profile no.12). It is acting as a “group two only server” on the DeviceNet net-
work.
FEC integrates the DeviceNet board manufactured by HMS Fieldbus Systems into the Multi-Unit
modular I/O board. For further technical information on the DeviceNet interface go to the HMS
website. (www.hms.se)
Further DeviceNet information can be found through the Open DeviceNet Vendors Association
(ODVA). (www.ODVA.org)

System Structure
ＰＬＣ
PLC （DeviceNetﾏｽ
(DeviceNet ﾀｰ ）
master)

リモートＩ
Remote ／Ｏ通信
I/O communication
メッセージ通信

D eviceN et
DeviceNet
ｽ ﾚｰ ﾌﾞ
slave
M ULTIユニット Other DeviceNet slave
他社製D eviceN etｽ ﾚｰ ﾌﾞ
M ULTI-2ユニット

1軸
No.1 2軸 31軸
No.31
HFC-EC-16-BUS
No.2
No.1

ＡＦＣ１５００ＭＵＬＴＩ
システム
ＡＦＣ１５００ＭＵＬＴＩ
－２システム

Page 4-51
 Chapter 4: System Setup and Wiring

Devicenet Hardware

DEVICENET
CONNECTOR
1
DEVICENET DEVICENET
CONNECTOR CONNECTOR
2

BAUD/MAC ID BAUD/MAC ID BAUD/MAC ID

SETTING SETTING
SETTING 3

LED LED
INDICATORS INDICATORS 4

LED
INDICATORS

Interface Board with DeviceNet Daughter Board

Item Description
1 Application Connector
2 DeviceNet Connector
3 Configuration Switches
4 Status LEDs (4)
Red - (flashing @ 2Hz) - ASIC and FLASH ROM check fault.
Green (flashing @ 2Hz) - module not initialized.
5 Watchdog LED Green (flashing @ 1Hz) - module initialized and running OK.
Red (flashing @ 1Hz) - RAM check fault.
Red (flashing @ 4Hz) - DPRAM check fault.

DeviceNet Specifications
Speed 125K, 250K and 500K baud
Nodes 64
500 meters at 125K baud
Maximum Distance 250 meters at 250K baud
100 meters at 500K baud
Twisted pair for signal and power
Allen Bradley or equivalent ;
Cable
Thin Cable #1485C-P1-C
Thick Cable # 1485C-P1-A
Communications Type Master/Slave

Page 4-52
FEC FUSION Operations Manual Chapter 4: System Setup and Wiring (Rev. 3)

Interface Board Specifications

Operating Voltage +5V, 200 ma
Output data bytes 512 max.*
Input data bytes 512 max.*
Servers per group 2 Maximum
Interface type Dual Port RAM or Serial Interface
* Actual FUSION Configuration only requires 16 Bytes of OUTPUTS (128 points) and 4 Bytes
of INPUTS (32 points). Maximum settable size for the FEC board is 32 bytes (256 bits) Input /
Output each (See DeviceNet Signal Reference at the end of this chapter for I/O Signal map)
NOTE: Devicenet also support the data Messaging function (CIP) for resultant data transfer.
See the Ethernet I/P chapter below for more detail (Devicenet uses similar setup)

EDS File
Each device on a DeviceNet network is associated with an EDS file containing all necessary
information about the device to be connected. The network configuration program uses this
file during configuration of the network.
The EDS file associated with the FEC device can be downloaded from the FEC website sup-
port & downloads pages. www.fec-usa.com (file: abs.eds)
(the file can also be downloaded directly from HMS - www.hms.se)

Note: The FEC system will appear in the network Vendor list as “HMS Fieldbus Systems” and
in the network as “Anybus-S DeviceNet” adapter. This is the manufacturer of the interface
board which is integrated into the Multi-2 Unit.

Configuration
FEC DeviceNet I/O is pre-configured according to the I/O Signal Map (See below). Configu-
ration of the DeviceNet Master MUST match the size configuration of the FEC DeviceNet
slave or the network will not connect/operate properly. In the DeviceNet Master set-up using
RSNetworx, set the Input/Output length using the “Polled” option. When setting the De-
viceNet Master I/O configuration, Input size refers to FEC output size (ie. Accept, Reject,
Busy, etc.) and Output size refers to FEC inputs (ie. Start, Stop, Reset, etc.). See the be-
low screen shots of this configuration using RSNetworx.

Termination
Termination of the DeviceNet network requires a terminating resistor at each end of the net-
work. These resistors should have a value of 121 ohms.

Page 4-53
Chapter 4: System Setup and Wiring

DeviceNet Interface Connections

Pin No. Signal Wire Color

1 V- Black
2 CAN_L Blue
3 Drain/Shield See “Termination”
4 CAN_H White
5 V+ Red

Configuration Switches
On a DeviceNet network, each node must be assigned its own unique Mac ID. The Mac ID is
a value between 0 and 63 used to identify each node. The Mac ID and Baud Rate are set us-
ing the DIP switches on the front of the module.
These switches must be set before power is on and cannot be changed during opera-
tion.

Baud Rate Settings

Baud Rate SW-1 SW-2
125K OFF OFF
ON 250K OFF ON
1 500K ON OFF
2 Reserved ON ON
3 Mac ID Settings
4 Mac ID SW-3 (MSB) SW-4 SW-5 SW-6 SW-7 SW-8 (LSB)
5 Address 0 OFF OFF OFF OFF OFF OFF
6 Address 1 OFF OFF OFF OFF OFF ON
7 Address 2 OFF OFF OFF OFF ON OFF
Address 3 OFF OFF OFF OFF ON ON
8
… … … … … … …
Address 61 ON ON ON ON OFF ON
Address 62 ON ON ON ON ON OFF
Address 63 ON ON ON ON ON ON

Status LEDs

LED State Description

1 - Reserved - Reserved for future use.
Off Not Powered / Not Online
Green solid Link OK, Online, Connected
2 - Network Status Green flashing Online, Not connected
Red solid Critical Link Failure
Red flashing Connection Timeout
4 1 Off No power to device
3 2 Green solid Device operational
3 - Module Status Green flashing Data size bigger than configured
Red solid Unrecoverable fault
Red flashing Minor fault
4 - Reserved - Reserved for future use.

Page 4-54
 FEC FUSION Operations Manual Chapter 4: System Setup and Wiring (Rev. 3)

DeviceNet Signal I/O Map

From Fusion to PLC : 8 Words (16 Bytes – 128 Bits)
Data Bit No. Signal Description Comment
0 1 End
1 2 Accept
2 3 Reject
3 4
0
4 5
5 6 Job Cycle Accepted Total Accept for Sequence Function
6 7
7 8
8 9 Work Select Bit 4 (echo)
9 10
10 11 Time 1 Reject
11 12 Time 2 Reject
0
12 13 Work Select Bit 0 (echo)
13 14 Work Select Bit 1 (echo)
14 15 Work Select Bit 2 (echo)
15 16 Work Select Bit 3 (echo)
16 17 Reject
17 18 Accept
18 19 Abnormal
19 20 Ready
0
20 21 Busy
21 22 Torque High Reject
22 23 Torque Low Reject
23 24 Bypass
24 25 Angle High Reject
25 26 Angle Low Reject
26 27 Rate1 High Reject
27 28 Rate1 Low Reject
0
28 29 Rate2 High Reject
29 30 Rate2 Low Reject
30 31 Rate3 High Reject
31 32 Rate3 Low Reject
0 33 Torque Integer bit 0 Outputs Fastening Torque using bi-
1 34 Torque Integer bit 1 nary integer
2 35 Torque Integer bit 2 0 - 999 max.
3 36 Torque Integer bit 3 (number LEFT of decimal only)
1
4 37 Torque Integer bit 4 Example:
5 38 Torque Integer bit 5 Torque Integer bit 2, 4, 7 Logical "1"
6 39 Torque Integer bit 6 = 148
7 40 Torque Integer bit 7
8 41 Torque Integer bit 8 Total Torque including Torque deci-
9 42 Torque Integer bit 9 mal (word3) = 148.38
10 43
11 44
1
12 45
13 46
14 47
15 48
16 49 Torque Decimal bit 0 Outputs Fastening Torque Decimal
17 50 Torque Decimal bit 1 value using binary integer
18 51 Torque Decimal bit 2 0 - 99 max.
19 52 Torque Decimal bit 3 (number RIGHT of decimal only)
1
20 53 Torque Decimal bit 4 Example:
21 54 Torque Decimal bit 5 Torque Decimal bit 1, 2, 5 Logical
22 55 Torque Decimal bit 6 "1" = 38
23 56
24 57
25 58
26 59
27 60
1
28 61
29 62
30 63
31 64

Page 4-55
Chapter 4: System Setup and Wiring

DeviceNet Signal I/O Map

(Continued)
Data Bit No. Signal Description Comment
0 65 Angle Integer bit 0
1 66 Angle Integer bit 1
2 67 Angle Integer bit 2
3 68 Angle Integer bit 3
2
4 69 Angle Integer bit 4 Outputs Fastening Angle value using binary
5 70 Angle Integer bit 5 integer
6 71 Angle Integer bit 6 0 - 9999 max.
7 72 Angle Integer bit 7
8 73 Angle Integer bit 8 Example:
9 74 Angle Integer bit 9 Angle Integer bit 1, 2, 5, 7 Logical "1" = 166
10 75 Angle Integer bit 10
11 76 Angle Integer bit 11
2
12 77 Angle Integer bit 12
13 78 Angle Integer bit 13
14 79
15 80
Data 16 81
2-3 31 128

From PLC to Fusion: 2 Words (4 Bytes – 32bits)

Data Bit No. Description Comment
0 1
1 2
2 3
3 4
0
4 5
5 6
6 7 Reset
7 8
8 9
9 10
10 11
11 12
0
12 13 Work Select 0
13 14 Work Select 1
14 15 Work Select 2
15 16 Work Select 3
16 17 Stop
17 18 Reset
18 19 Reverse
19 20 Start
0
20 21 Bypass
21 22 Disable Self-check
22 23
23 24
24 25
25 26
26 27
27 28
0
28 29 Batch OK Reset
29 30 Work Select 4
30 31
31 32

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 FEC FUSION Operations Manual Chapter 4: System Setup and Wiring (Rev. 3)

4.15.4 Fieldbus Interfaces – Ethernet I/P

The Ethernet-I/P communication interface allows slave connection to PLC networks that support
Ethernet communication via TCP/IP.
Maximum I/O data is 256 input bits & 256 output bits. FEC Inputs match the discrete input layout.
FEC Output location is programmed using the AFC User Console Software. Communication
speeds of 10/100M baud (auto-selectable) are supported.

FEC integrates the Ethernet-I/P board manufactured by HMS Fieldbus Systems AB into the
Multi-2 Unit’s modular I/O board. For further technical information on the Ethernet-I/P interface go
to the HMS website. (www.hms.se)

Ethernet I/P Hardware

Item Description
1 Ethernet Connector
2 Configuration Switches
3 Status LEDs (4)

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Chapter 4: System Setup and Wiring

Fieldbus Interface Connection

Pin Signal Note

1 TD+
2 TD-
3 RD+
4 - Normally left unused; to ensure signal integrity, these pins are tied
5 - together and terminated to PE via a filter circuit in the module.
6 RD-
7 - Normally left unused; to ensure signal integrity, these pins are tied
8 - together and terminated to PE via a filter circuit in the module.

Configuration DIP Switch

This switch is not used for FEC IP configuration and should be

set to all OFF. The IP address is set-up using the AFC Software
(see below) “Fieldbus Configuration” feature

Status LEDs

LED State Description

Off No Link Established
1 - Link
On Link Established
Off Not Powered / Not Online
Green solid Controlled by scanner in run state
Green flashing Not configured or scanner in idle state
2 - Module Status A major unrecoverable fault has been
4 1 Red solid
detected.
3 2 A minor recoverable fault has been
Red flashing
detected.
No power to device or no IP ad-
Off
dress has been set.
Online. One or more connections es-
Green solid
tablished.
3 - Network Status
Green flashing Data size bigger than configured.
Red solid Duplicate IP address. Fatal error.
Red flashing One or more connections timed out.
Green / Red Self test in progress
Flashes each time a packet is trans-
4 - Activity Green
mitted or received.

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 FEC FUSION Operations Manual Chapter 4: System Setup and Wiring (Rev. 3)

Input / Output Signal Mapping

Input Signals
From PLC to Fusion: 4 Words (8 Bytes – 64bits)
Word Byte Bit No. Description Comment
0 1
1 2
2 3
3 4
0
4 5
5 6
6 7 Reset/Abort Job Resets initial condition
7 8
01
0 9
1 10
2 11
3 12
1
4 13 Work Select 0
5 14 Work Select 1
6 15 Work Select 2
7 16 Work Select 3
0 17 Stop
1 18 Reset
2 19 Reverse
3 20 Start
2
4 21 Bypass
5 22 Disable Self-check
6 23
7 24
02
0 25
1 26
2 27
3 28
3
4 29 Batch OK Reset
5 30 Work Select 4
6 31
7 32
Input Word 03 ~ 04 have no signals assigned and are not shown.

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Chapter 4: System Setup and Wiring

Output Signals
From Fusion to PLC : 8 Words (16 Bytes – 128 Bits)
Word Byte Bit No. Signal Description Comment
0 1 End
1 2 Accept
2 3 Reject
3 4
0
4 5
5 6 Job Cycle Accepted Total Accept for Sequence Function
6 7
7 8
01
0 9 Work Select 4 Selected (echo)
1 10
2 11 Time 1 Reject
3 12 Time 2 Reject
1
4 13 Work Select Bit 0 Selected (echo)
5 14 Work Select Bit 1 Selected (echo)
6 15 Work Select Bit 2 Selected (echo)
7 16 Work Select Bit 3 Selected (echo)
0 17 Reject
1 18 Accept
2 19 Abnormal
3 20 Ready
2
4 21 Busy
5 22 Torque High Reject
6 23 Torque Low Reject
7 24 Bypass
02
0 25 Angle High Reject
1 26 Angle Low Reject
2 27 Rate1 High Reject
3 28 Rate1 Low Reject
3
4 29 Rate2 High Reject
5 30 Rate2 Low Reject
6 31 Rate3 High Reject
7 32 Rate3 Low Reject
0 33 Torque Integer bit 0
1 34 Torque Integer bit 1 Outputs Fastening Torque using binary in-
2 35 Torque Integer bit 2 teger
3 36 Torque Integer bit 3 0 - 999 max.
4 (number LEFT of decimal only)
4 37 Torque Integer bit 4
Example:
5 38 Torque Integer bit 5
Torque integer bit 2, 4, 7 Logical "1" = 148
6 39 Torque Integer bit 6
7 40 Torque Integer bit 7 Total Torque including Torque decimal
03
0 41 Torque Integer bit 8 (word3) = 148.38
1 42 Torque Integer bit 9
2 43
3 44
5
4 45
5 46
6 47
7 48
0 49 Torque Decimal bit 0
1 50 Torque Decimal bit 1 Outputs Fastening Torque Decimal value
using binary integer
2 51 Torque Decimal bit 2
0 - 99 max.
3 52 Torque Decimal bit 3
6 (number RIGHT of decimal only)
4 53 Torque Decimal bit 4
Example:
5 54 Torque Decimal bit 5 Torque Decimal bit 1, 2, 5 Logical "1" = 38
6 55 Torque Decimal bit 6
7 56
04
0 57
1 58
2 59
3 60
7
4 61
5 62
6 63
7 64

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FEC FUSION Operations Manual Chapter 4: System Setup and Wiring (Rev. 3)

Data Bit No. Signal Description Comment

0 65 Angle Integer bit 0
1 66 Angle Integer bit 1
2 67 Angle Integer bit 2
3 68 Angle Integer bit 3
8
4 69 Angle Integer bit 4 Outputs Fastening Angle value using binary
5 70 Angle Integer bit 5 integer
6 71 Angle Integer bit 6 0 - 9999 max.
7 72 Angle Integer bit 7
8 73 Angle Integer bit 8 Example:
9 74 Angle Integer bit 9 Angle Integer bit 1, 2, 5, 7 Logical "1" = 166
10 75 Angle Integer bit 10
11 76 Angle Integer bit 11
9
12 77 Angle Integer bit 12
13 78 Angle Integer bit 13
14 79
15 80
Data 16 81
10-15 31 128

AFC Software Configuration

The Anybus board is set up by sending a Fieldbus Configuration File (*.fcf) containing ini-
tialization messages from the Fusion Unit to the board during power up. This string of da-
ta initializes different characteristics required for the board to communicate over the
Ethernet-I/P network. In this string is configuration data which sets the length of I/O data
as well as length of messages (Resultant Fastening data). Since the board is only initial-
ized during power-up, the Fusion Unit MUST have the power cycled OFF/ON after the
“fcf” file is downloaded.

To download the fcf file, select “Field Bus Setup” from the “Axis” pull down menu. Select
the appropriate “Bus Type” and click “Browse” to locate the correct fcf file. After the file
has been selected, click “download” to send the file data to the Anybus board.

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Chapter 4: System Setup and Wiring

If no file exists, (or if the settings need to be changed) after the Bus Type has been se-
lected, click on the “Setup” Tab.

In NETWORK SETUP, input all of the IP settings required by the host PLC. In I/O
SETUP, select the “Input Data Length” and “Output Data Length” as required by you ap-
plication. Data lengths MUST MATCH the PLC’s same I/O length setup otherwise con-
nection will not be possible.

The Ethernet-I/P interface also has the ability to transfer resultant fastening data using
the message data Transfer (CIP) function. The MESSAGE INPUT (Fusion to PLC) de-
fault setting is 200bytes. MESSAGE OUTPUT is currently not used. Refer to “Message
Output Format” for message data information.

PLC Setting

The setup procedure of “Rockwell Automation RXLogix5000 V15.02.00” and “Allen Bradley
CompactLogix L32E” is described.
Please inquire to each manufacturer when you use other PLC (Note: Some PLC manufac-
turers may not support this Messaging (CIP) function)

Connection with HFC-EC-16-BUS-FEI

[I/O Configuration] right-click => [1769-L32E Ethernet Port Local ENB] => [New Module]

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FEC FUSION Operations Manual Chapter 4: System Setup and Wiring (Rev. 3)

Please select [Generic Ethernet Module] from among the module list, and click OK.

[Module Property] General

Name:
Inputs the “Station Name”.
IP Address:
Inputs the same “IP address” as you configured the Ethernet I/P module.
Input Size, Output Size:
Inputs the same “Input Size” and “Output Size” as the Ethernet I/P is configured.
Assembly Instance:
Inputs the same value as the following setting.

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Chapter 4: System Setup and Wiring

[Module Property] Connection

Request Packet Interval: Inputs 50.0ms.

The input signal and the output signal are added to Tag.

FEC_2:I
Input Signals PLC <= Fusion
FEC_2:O
Output Signals PLC => Fusion

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 FEC FUSION Operations Manual Chapter 4: System Setup and Wiring (Rev. 3)

Receiving message communication (FUSION OUTPUT -> PLC INPUT)

● Generation of Tag
When you perform message communication, a “Read_Tag” is necessary. Generate a “Read_Tag” us-
ing the PLC software.

● Message Command (MSG)

With the PLC ladder editing screen, a MSG message command must be used to get transfer the
Message data.

● Properties of the MSG command

MSG properties are set using Message Configuration and Communication. Please refer to the following
list for Configuration. Establish Communication by pointing the message path to the (FUSION) Ethernet
Module.

Message Type CIP Generic

Service Type Get Attribute Single
Service Code E
Class B0
Instance 1
Attribute 1~5
Destination The controller tag “C” should be selected

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Chapter 4: System Setup and Wiring

4-15-5 CC-Link® Interface (Version 2)

FEC integrates the CC-Link board (Version 2 setting) manufactured by HMS Fieldbus Sys-
tems AB into the Fusion Unit’s modular I/O board when CC-link must send both I/O and
Message Data. For further technical information on the CC-Link (Version 2) interface go to
the HMS website. (www.hms.se)

NOTE: The FEC CC-Link (V2) module is configured as a “Remote Device Station” when set-
ting up the parameters in the PLC program.
For detailed information on the Mitsubishi CC-Link Network, see the Mitsubishi User Manual #
13J872 Control & Communication - Link System Master / Local Module.

CCLink V2 Hardware

Item Description
1 Station Number Setting Switch
2 Communication Speed Setting Switch
3 Status LEDs (4)
4 CC-Link Connector

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 FEC FUSION Operations Manual Chapter 4: System Setup and Wiring (Rev. 3)

CC-Link Specifications
Speed 156K - 10M baud - selectable
Stations 64 Max.
Distance 1200m max. at 156K baud / 50m max. at 10Mbit/s
Cable Shielded Copper Twisted Pair
Mitsubishi BA1SJ61-(m) m=Meters
Belden 8102 or equivalent
Communications Type Master/Slave - EIA RS485
Transmission Format HDLC Standard
Maximum Cyclic I/O 896 inputs, 896 outputs max. Size set in groups of 256 I/O
Size (Occupied Stations)
I/O Configuration* I/O addressing set by PLC TO / FROM commands in Logic
* Actual I/O addressing must be assigned in the PLC logic. See the Mitsubishi User Manual # 13J872
Control & Communication - Link System Master / Local Module for logic reference. (Ref. Section 10)

Configuration
Configuration of the CC-Link system is done in the PLC Logic. It is essential that this configuration
matches the Dip Switch settings of the FEC CC-Link slave. FEC is considered a “Remote Device” in
the PLC configuration. The number of “Occupied Stations” set in the PLC must also match the set-
tings in the AFC User Console set-up. (Note: The last 16 output addresses are used by the CC-
Link communication & cannot be used by the user)

FEC CC-Link (Version 2) I/O configuration is programmable using the AFC User Console software.
I/O can be set as required by the application according to parameter limits set forth by the CC-Link
System Profile (CSP file). The AFC Software allows configuration of the number of Occupied Stations
and Extended Cyclic Settings in the Multi Unit. Configuration of the CC-Link Master MUST match the
configuration of the FEC CC-Link slave.

CSP File
To simplify network configuration, CC-Link devices may be associated with a CC-Link System Profile,
also known as a CSP-file. This file contains a description of the device and can be used by some CC-
Link system utilities to simplify the configuration process.
The CSP file associated with the FEC device can be downloaded directly from HMS - www.hms.se.

5.9.1 Component Descriptions

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Chapter 4: System Setup and Wiring

Fieldbus Interface Connection

Pin 1 DA Communication Line See

Pin 2 DB Communication Line “Termination”
Pin 3 DG Digital Ground
Pin 4 SHIELD Connect cable shield
Pin 5 FG Field Ground

Mating Connector: Allows in-line “series” connection

Manufacturer：Phoenix Contact
Model Name ：TMSTBP 2.5/5-ST-5.08

*Connector is attached.

Wiring of the CC-Link network should be performed by using the cable listed above in the
CC-Link Specifications. The three twisted conductors should be wired in series to each CC-
Link device, using a terminating resistor at the Master end and on the last Remote/Local de-
vice between the DA & DB terminals.

Termination
Termination of the CC-Link requires a terminating resistor at each end of the fieldbus.
Connect 120 ohm resistor between the DA & DB terminals if this is the last connection. (Re-
member that the CC-Link master also needs to be terminated)

Baud Rate Switch

This rotary switch is used to specify the baud rate of the

module. This can also be specified in the FB_INIT mailbox
command. In this case, the switch must be set to “9”.
This setting MUST match the setting of the Master
module. This switch must be set before power is on and
cannot be changed during operation.

Station Number Switches

These two rotary switches are used to specify the station number of the
module (Two digit decimal). The Upper rotary switch (closest to the Baud
Rate Switch) sets the “tens” digit (10x), and the bottom rotary switch sets
the “ones” digit (1x). Valid settings range from 1 up to 641.
Example: To set station number 24, place the “tens” digit switch on 2 and
the “ones” digit switch on 4.
This can also be specified in the FB_INIT mailbox command. In this case,
the switches must be set to “99”.
This switch must be set before power is on, and cannot be changed
during operation.

1) If more than one station is occupied by the module, the highest possible station number is
reduced by the number of occupied stations minus one.
Status LEDs

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FEC FUSION Operations Manual Chapter 4: System Setup and Wiring (Rev. 3)

LED Color State Description

ON Normal Operation
1
Green Network non-participating or timeout status
(RUN) OFF
No power on module
CRC error detection
ON
2 Illegal station number or illegal baud rate selected
Red
(ERRL) Normal Operation
OFF
4 1
No power on module
ON Data being received
3 2 3
Green No data reception
(RDLED) OFF
No power on module
ON Data being transmitted
4
Green No data transmission
(SDLED) OFF
No power on module

〇：On ●：Off ◎：Blinking

RUN ERRL SD RD Operation
Communication is normal. However, CRC error is occurred from
〇 ◎ ◎ 〇
time to time due to noise.
〇 ◎ ◎ 〇
Baud rate or station number setting have been changed when
0.4 SEC baud rate/ station number setting released at reset.
〇 ◎ ● 〇 Received data is CRC error and can’t respond
〇 ● ◎ 〇 Normal communication.
〇 ● ● 〇 Data can’ t be received to the station.
● ◎ ◎ 〇 Poling is responding or CRC error is occurred to refresh reception.
● ◎ ● 〇 CRC error occurred to the station data.
● ● ◎ 〇 Link does not work properly.
● ● ● 〇 No station data or station data can’t be received due to noise.
Data isn’t received due to disconnection, etc.
● ● ● ●
Power source is disconnected to H/W is in the reset process.
● 〇 ● 〇 Illegality of communication speed and station number setting up.

CC-Link Specification

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Chapter 4: System Setup and Wiring

I/O MESSAGE
FUSION=>PLC PLC=>FUSION FUSION=>PLC PLC=>FUSION
MAXIMUM 32BYTES(256BIT) 8BYTES(64BIT) 128WORDS(256BYTES)
DEFAULT 32BYTES(256BIT) 8BYTES(64BIT) 128WORDS(256BYTES)

Number of Input： 64points Fixed assignment ※Can’t be changed

Making Secure RY(n+4)0～RY(n+7)F territory not used.

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FEC FUSION Operations Manual Chapter 4: System Setup and Wiring (Rev. 3)

FUSION CC-LINK V2 INPUT SIGNAL

NC：Normal Close、NO：Normal Open

Remote Remote
Output Signal Name Connection output Signal Name Connection
RY RY
RY(n+0h)0h NO RY(n+2h)0h NO
RY(n+0h)1h NO RY(n+2h)1h NO
RY(n+0h)2h NO RY(n+2h)2h NO
RY(n+0h)3h NO RY(n+2h)3h NO
RY(n+0h)4h NO RY(n+2h)4h NO
RY(n+0h)5h NO RY(n+2h)5h NO
RY(n+0h)6h RESET NO RY(n+2h)6h NO
RY(n+0h)7h NO RY(n+2h)7h NO
RY(n+0h)8h NO RY(n+2h)8h NO
RY(n+0h)9h NO RY(n+2h)9h NO
RY(n+0h)Ah NO RY(n+2h)Ah NO
RY(n+0h)Bh NO RY(n+2h)Bh NO
RY(n+0h)Ch WORK SELECT 0 NO RY(n+2h)Ch NO
RY(n+0h)Dh WORK SELECT 1 NO RY(n+2h)Dh NO
RY(n+0h)Eh WORK SELECT 2 NO RY(n+2h)Eh NO
RY(n+0h)Fh WORK SELECT 3 NO RY(n+2h)Fh NO
RY(n+1h)0h STOP NO RY(n+3h)0h NO
RY(n+1h)1h RESET NO RY(n+3h)1h NO
RY(n+1h)2h REVERSE NO RY(n+3h)2h NO
RY(n+1h)3h START NO RY(n+3h)3h NO
RY(n+1h)4h BYPASS NO RY(n+3h)4h NO
SELF CHECK
RY(n+1h)5h NO RY(n+3h)5h NO
OFF
RY(n+1h)6h NO RY(n+3h)6h NO
RY(n+1h)7h NO RY(n+3h)7h NO
RY(n+1h)8h NO RY(n+3h)8h NO
RY(n+1h)9h NO RY(n+3h)9h NO
RY(n+1h)Ah NO RY(n+3h)Ah NO
RY(n+1h)Bh NO RY(n+3h)Bh NO
BATCH OK
RY(n+1h)Ch NO RY(n+3h)Ch NO
RESET
RY(n+1h)Dh WORK SELECT 4 NO RY(n+3h)Dh NO
RY(n+1h)Eh NO RY(n+3h)Eh NO
RY(n+1h)Fh NO RY(n+3h)Fh NO

Input signals are permanently set. (Cannot be changed)

Unused range in RY (n+4h) 0h to RY (n+37h) Fh is also reserved.
Caution

“WORK SELECT 4” is effective after Fusion Firmware V5.00.

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FUSION CC-LINK V2 INPUT SIGNAL

Remote Remote
Input Signal Name Connection Input Signal Name Connection
RX RX
RXn0 END NO RX(n+2)0 Torque Integer bit0 NO
RXn1 ACCEPT NO RX(n+2)1 Torque Integer bit1 NO
RXn2 REJECT NO RX(n+2)2 Torque Integer bit2 NO
RXn3 NO RX(n+2)3 Torque Integer bit3 NO
RXn4 NO RX(n+2)4 Torque Integer bit4 NO
RXn5 Job Cycle Accept NO RX(n+2)5 Torque Integer bit5 NO
RXn6 NO RX(n+2)6 Torque Integer bit6 NO
RXn7 NO RX(n+2)7 Torque Integer bit7 NO
RXn8 WORK SELECT 4 NO RX(n+2)8 Torque Integer bit8 NO
RXn9 NO RX(n+2)9 Torque Integer bit9 NO
RXnA Time 1 Reject NO RX(n+2)A NO
RXnB Time 2 Reject NO RX(n+2)B NO
RXnC WORK SELECT 0 NO RX(n+2)C NO
RXnD WORK SELECT 1 NO RX(n+2)D NO
RXnE WORK SELECT 2 NO RX(n+2)E NO
RXnF WORK SELECT 3 NO RX(n+2)F NO
RX(n+1)0 REJECT NO RX(n+3)0 Torque Decimal bit0 NO
RX(n+1)1 ACCEPT NO RX(n+3)1 Torque Decimal bit1 NO
RX(n+1)2 ABNORMAL NO RX(n+3)2 Torque Decimal bit2 NO
RX(n+1)3 READY NO RX(n+3)3 Torque Decimal bit3 NO
RX(n+1)4 BUSY NO RX(n+3)4 Torque Decimal bit4 NO
RX(n+1)5 Torque Hi Reject NO RX(n+3)5 Torque Decimal bit5 NO
RX(n+1)6 Torque Low Reject NO RX(n+3)6 Torque Decimal bit6 NO
RX(n+1)7 BYPASS NO RX(n+3)7 NO
RX(n+1)8 Angle Hi Reject NO RX(n+3)8 NO
RX(n+1)9 Angle Low Reject NO RX(n+3)9 NO
RX(n+1)A Rate 1 Hi Reject NO RX(n+3)A NO
RX(n+1)B Rate 1 Low Reject NO RX(n+3)B NO
RX(n+1)C Rate 2 Hi Reject NO RX(n+3)C NO
RX(n+1)D Rate 2 Low Reject NO RX(n+3)D NO
RX(n+1)E Rate 3 Hi Reject NO RX(n+3)E NO
RX(n+1)F Rate 3 Low Reject NO RX(n+3)F NO

Example of Torque data

Peak Torque Integer Portion Decimal Portion

12.34 Nm 000C 0022
Peak Torque Integer Portion Decimal Portion
123.4 Nm 007B 0004

* Integer portion is LEFT of decimal. Decimal Portion is Right of Decimal

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FEC FUSION Operations Manual Chapter 4: System Setup and Wiring (Rev. 3)

Remote In-
Remote In-
put
Signal Name Connection put Signal Name Connection
RX
RX
RX(n+4)0 Angle Integer bit0 NO RX(n+6)0 NO
RX(n+4)1 Angle Integer bit1 NO RX(n+6)1 NO
RX(n+4)2 Angle Integer bit2 NO RX(n+6)2 NO
RX(n+4)3 Angle Integer bit3 NO RX(n+6)3 NO
RX(n+4)4 Angle Integer bit4 NO RX(n+6)4 NO
RX(n+4)5 Angle Integer bit5 NO RX(n+6)5 NO
RX(n+4)6 Angle Integer bit6 NO RX(n+6)6 NO
RX(n+4)7 Angle Integer bit7 NO RX(n+6)7 NO
RX(n+4)8 Angle Integer bit8 NO RX(n+6)8 NO
RX(n+4)9 Angle Integer bit9 NO RX(n+6)9 NO
RX(n+4)A Angle Integer bit10 NO RX(n+6)A NO
RX(n+4)B Angle Integer bit11 NO RX(n+6)B NO
RX(n+4)C Angle Integer bit12 NO RX(n+6)C NO
RX(n+4)D Angle Integer bit13 NO RX(n+6)D NO
RX(n+4)E NO RX(n+6)E NO
RX(n+4)F NO RX(n+6)F NO
RX(n+5)0 NO RX(n+7)0 NO
RX(n+5)1 NO RX(n+7)1 NO
RX(n+5)2 NO RX(n+7)2 NO
RX(n+5)3 NO RX(n+7)3 NO
RX(n+5)4 NO RX(n+7)4 NO
RX(n+5)5 NO RX(n+7)5 NO
RX(n+5)6 NO RX(n+7)6 NO
RX(n+5)7 NO RX(n+7)7 NO
RX(n+5)8 NO RX(n+7)8 NO
RX(n+5)9 NO RX(n+7)9 NO
RX(n+5)A NO RX(n+7)A NO
RX(n+5)B NO RX(n+7)B NO
RX(n+5)C NO RX(n+7)C NO
RX(n+5)D NO RX(n+7)D NO
RX(n+5)E NO RX(n+7)E NO
RX(n+5)F NO RX(n+7)F NO

Final Angle Integer Portion

1234 deg 04D2

Output signals are permanently set. (Cannot be changed)

Unused range in RX (n+8h) 0h to RX (n+37h) Fh is also reserved.
Caution

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Chapter 4: System Setup and Wiring

CCLink V2 AFC Software Configuration

Use the AFC user console software to configure the CCLink V2 in the Fusion Controller.

[Configuration file]

BROWSE: Browse Fieldbus configuration files.

SAVE: Save Fieldbus configuration files.
UPLOAD: Upload Fieldbus set up from Fusion controller.
（BUS TYPE automatically.）
DOWNLOAD: Download open net set up to Fusion controller.
(*Cycle power after download.)
VERIFY: Verify Fusion controllerset up vs AFC User Console Software set up.
BUS TYPE: Choose CC-LINK VER2

Once Fieldbus setting is configured, hit “SAVE” to SAVE the configuration to a file
The Fieldbus setting is downloaded using the "PARAMETER COMMUNICATIONS"
Caution screen. (*Cycle power after download.)

・File Extension Information

Item Extension
Parameter .PAR
Fieldbus setting .FCF

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 FEC FUSION Operations Manual Chapter 4: System Setup and Wiring (Rev. 3)

CCLink SETUP Tab

●Extended cyclic setting

8 cycles

●Occupied station
4 stations

●Remote I/O（RX/RY）
896 points

●Remote Register（RWw/RWr）
128 words（256 bytes）

When PLC master module is CC-Link Ver1.00, check the “PLC CC-Link Ver.1 Master
Station” box in the setup screen.
Caution

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Chapter 4: System Setup and Wiring

MELSEC-Q Series Parameter Setting (Example)

Start up GX Developer  Prepare PC Series QCPU (Q mode) Project 

Parameter  Network Parameter  Set List of CC-Link

Example of PLC setting using (3) Fusion systems (3 CCLINK connections)

1 2

4
5

1. Select “Remote Net (Ver. 2 Mode)” at Mode Select.

2. Set the All Connect Count (3) for number of connected Remote Device stations
3. Set the refresh device Remote Input (X100) / Output (Y100) at “Remote Output (RX / RY).”
4. Set the refresh device Remote Register read (D1000) at “Remote Register (RWr).”
5. Set the refresh device Remote Register write (D4000) at “Remote Register (RWw).”
* The allocated set values differ according to the station No. of the Controller used.
6. Set the station information at Station Information Setting (the picture below shows an ex-
ample for reference).

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FEC FUSION Operations Manual Chapter 4: System Setup and Wiring (Rev. 3)

Station information Setting example (#6 above)

Enabling the CC-Link connection to the PLC

PLC Ladder logic is required to enable the CC-Link communication link. The logic must address
the enable bit (Initial Data Processing Request) of which the address changes based on the size
setting used. The last 16 bits of both the Inputs and outputs (no matter what size is configured)
is the CCLINK system setting area and this is where the link must be enabled.

Below is an example of CC-Link configuration settings made by GX Developer software and how
memory is allocated. This configuration has 3 sets of AFC3000 controllers connected with 4 oc-
cupied stations / 8 extended cyclic cycles. (I/O 896 Points, Message 72 Words)

Item Fusion Fusion Fusion

(System 1) (System 2) (System 3)
CC-Link Station Number 1 5 9
Configured Size (4 occupied stations/8Cyclic cy- 896 (880 896 (880 896 (880
cles) useable) useable) useable)
EM-STOP (First bit of PLC output) Y100 Y480 Y800
Total Reject (First bit of AFC3000 Output) X100 X480 X800
Part ID message output to AFC3000 Controllers D4000 D4072 D4144
Fastening result message from AFC3000 con- D1000 D1072 D1144
trollers
CC-Link Request address X478 X7F8 XB78
CC-Link Enable address Y478 Y7F8 YB78

In the case of the first Fusion System (1) (shown in the table above), the PLC program is set so
that when the 888th (378h) bit (“Initial Data Processing Request”) in the (CC-Link Reserved) sys-
tem area (X area) is turned “ON”, the output at the 888th (378h) bit (“Initial Data Processing
Complete”) of the system area (Y area) is set “ON”. (Note: See pages 8 & 14 for CCLINK
handshaking signal location)

Since the X/Y starting address of (System 1) is configured to start at X100 and Y100, this must
be added to the addresses and therefore (100h+378h) 478h is specified for the X area and the Y
area as shown in the PLC Logic diagram below to enable Station 1’s link.
For Station 2’s link, the starting address (X/Y480) is added to the 888th (378h) bit for that station
which is address (480h + 378h) X/Y7F8.
For Station 3’s link, the starting address (X/Y800) is added to the 888th (378h) bit for that station
which is address X/YB78.

Page 4-77
Chapter 4: System Setup and Wiring

PLC Logic example that would be required to enable the CC-Link in the three systems listed
above

X area
Y area

● Location of Handshaking Bits According to Size Configuration

Cyclic Cy-
1 Occupied Station 2 Occupied Stations 3 Occupied Stations 4 Occupied Stations
cles Setting
24th bit 56th bit 88th bit 120th bit
1
18h 38h 58h 78h
24th bit 88th bit 152th bit 216th bit
2
18h 58h 98h D8h
56th bit 184th bit 312th bit 440th bit
4
38h B8h 138h 1B8h
120th bit 376th bit 632th bit 888th bit
8
78h 178h 278h 378h
(Location of “Initial Data Processing Request” and “Initial Data Processing Complete” Bits)
“h” = hexadecimal

Page 4-78
FEC FUSION Operations Manual Chapter 4: System Setup and Wiring (Rev. 3)

4-15-6 Profinet Interface

The Profinet communication interface allows slave connection to PLC networks that support
Profinet communication via TCP/IP.
Maximum I/O data is 512 input bits & 512 output bits. FEC Inputs match the discrete input lay-
out. FEC Output location is programmed using the AFC User Console Software.

FEC integrates the Profinet board manufactured by HMS Fieldbus Systems AB into the Multi-2
Unit’s modular I/O board. For further technical information on the Ethernet-I/P interface go to the
HMS website. (www.hms.se)

Profinet Structure

PLC (PROFINET IO master)

I/O communication
HUB

PROFINET IO
PROFINET
slave IO
slave
Other PROFINET IO slaves

HFC-EC-16-BUS
HFC-EC-16-BUS
No.1 No.2 No.31

Page 4-79
Chapter 4: System Setup and Wiring

Profinet Hardware

①Cable connector

②Status LED Indicator

Profinet Interface Connections

Pin Signal Note

1 TD+
2 TD-
3 RD+
4 - Normally left unused; to ensure signal integrity, these pins are tied
5 - together and terminated to PE via a filter circuit in the module.
6 RD-
7 - Normally left unused; to ensure signal integrity, these pins are tied
8 - together and terminated to PE via a filter circuit in the module.

Page 4-80
FEC FUSION Operations Manual Chapter 4: System Setup and Wiring (Rev. 3)

Status LEDs

LED State Description

Green Link Established
1 – Link/Activity Green, Flashing Receiving/Transmitting data
Off No Link Established or power off
Off Offline
Online, Run
Green solid - Connection established
4 1
2 - Communication
- IO controller in RUN
Status
3 2 Online, Stop
Green, 1 flash - Connection Established
- IO controller in STOP
Off No power or not initialized
Green solid Initialized, no error
Green, 1 flash Diagnostic data available
Green, 2 flashes Blink. Factory ID tool
Configuration Error
- Too many modules
3 - Module Status - I/O from IO controller config.
Red, 1 flash
Too large
- Configuration Mismatch (no
module, wrong module)
No station name or no IP address as-
Red 3 flashes
signed
Red, 4 flashes Internal error
4 – Not
Used

Page 4-81
Chapter 4: System Setup and Wiring

5.12.2 User Console Software Settings

The Anybus board is set up by sending a Fieldbus Configuration File (*.fcf) containing ini-
tialization messages from the Fusion Controller to the Profinet board during power up.
This string of data initializes different characteristics required for the board to communi-
cate over the Profinet network. In this string, is data which sets the length of I/O data as
well as length of messages (Resultant Fastening data). Since the board is only initialized
during power-up, the controller MUST have the power cycled OFF/ON after the “fcf” file
is downloaded.

To download the fcf file, select “Field Bus Setup” from the “AXIS” pull down menu. Select
the appropriate “Bus Type” and click “Browse” to locate the correct fcf file. (if one has
previously been saved) After the file has been selected, click “download” to send the
file data to the Anybus Profinet board.

If no file exists, (or if the settings need to be changed) after the Bus Type has been se-
lected click on the Setup Tab.

In NETWORK SETUP, input all of the IP settings required by the host PLC. In I/O
SETUP, select the “Input Data Length” and “Output Data Length” as required by you ap-
plication. (INPUT & OUTPUT in this screen refer to PLC side I/O, INPUT = FEC Output
size, OUTPUT = FEC Input size) Data lengths MUST MATCH the PLC’s same I/O
length setup otherwise connection will not be possible.

The Ethernet-I/P interface also has the ability to transfer resultant fastening data using
the message data. Set the MESSAGE INPUT (AFC1500 to PLC) settings according to
the PLC settings. MESSAGE OUTPUT is currently not used. Refer to Page 5.11.5 for
message setup information.

Page 4-82
FEC FUSION Operations Manual Chapter 4: System Setup and Wiring (Rev. 3)

I/O Signal Specification

Input number: 32 bytes (256 bits) Input map is permanently set
Output number: 32 bytes (256 bits) Output map is permanently set

Input Map
CH. No. Bit Signal Connection Comment
0bit NO
1bit NO
2bit NO
Input 3bit NO
4bit NO
No.01 5bit NO
6bit RESET NO
7bit NO
CH. No. Bit Signal Connection Comment
0bit NO
1bit NO
2bit NO
Input
3bit NO
No.02 4bit WORK SELECT 0 NO
5bit WORK SELECT 1 NO
6bit WORK SELECT 2 NO
7bit WORK SELECT 3 NO
CH. No. Bit Signal Connection Comment
0bit STOP NO
1bit RESET NO
2bit REVERSE NO
Input 3bit START NO
4bit BYPASS NO
No.03
5bit SELF CHECK OFF NO
6bit NO
7bit NO
CH. No. Bit Signal Connection Comment
0bit NO
1bit NO
Input 2bit NO
3bit NO
No.04 4bit BATCH OK RESET NO
5bit WORK SELECT 4 NO
6bit NO
7bit NO

Page 4-83
Chapter 4: System Setup and Wiring

CH. No. Bit Signal Connection Comment

0bit NO
1bit NO
2bit NO
Input
3bit NO
4bit NO
No.05
5bit NO
6bit NO
7bit NO

CH. No. Bit Signal Connection Comment

0bit NO
1bit NO
2bit NO
Input
3bit NO
4bit NO
No.32
5bit NO
6bit NO
7bit NO

Note) NC: Normal Closed, NO: Normal Open

(Example) Siemens PLC

SFC15 is used.
32 bytes are stored from M70.0.

LADDR : Output address set by H/W configuration

Hexadecimal WORD form

RET_VAL : Memory address when error occurs

RECORD : Read output signal from PLC

Page 4-84
 FEC FUSION Operations Manual Chapter 4: System Setup and Wiring (Rev. 3)

Output Signal Specification

Output number: 32 bytes (256 bits) Output map is permanently set

Output Map
No. Bit Signal Connection Comment
0bit END NO
1bit ACCEPT NO
2bit REJECT NO
Output
3bit NO
No.01
4bit NO
5bit Job Cycle Accept NO
6bit NO
7bit NO
0bit WORK SELECT 4 NO
1bit NO
2bit Time 1 Reject NO
Output
3bit Time 2 Reject NO
No.02
4bit WORK SELECT 0 NO
5bit WORK SELECT 1 NO
6bit WORK SELECT 2 NO
7bit WORK SELECT 3 NO
0bit REJECT NO
1bit ACCEPT NO
2bit ABNORMAL NO
Output
3bit READY NO
No.03
4bit BUSY NO
5bit Torque Hi Reject NO
6bit Torque Low Reject NO
7bit BYPASS NO
0bit Angle Hi Reject NO
1bit Angle Low Reject NO
2bit Rate 1 Hi Reject NO
Output
3bit Rate 1 Low Reject NO
No.04
4bit Rate 2 Hi Reject NO
5bit Rate 2 Low Reject NO
6bit Rate 3 Hi Reject NO
7bit Rate 3 Low Reject NO

Page 4-85
Chapter 4: System Setup and Wiring

No. Bit Signal Connection Comment

0bit Torque Integer bit0 NO
1bit Torque Integer bit1 NO
2bit Torque Integer bit2 NO Outputs Fastening Torque using binary integer
Output 0 - 999 max.
3bit Torque Integer bit3 NO (number LEFT of decimal only)
No.05
4bit Torque Integer bit4 NO Example:
5bit Torque Integer bit5 NO Torque integer bit 2, 4, 7 Logical "1" = 148
6bit Torque Integer bit6 NO Total Torque including Torque decimal (Output No. 7
7bit Torque Integer bit7 NO below) = 148.38
0bit Torque Integer bit8 NO
1bit Torque Integer bit9 NO
2bit NO
Output
3bit NO
No.06
4bit NO
5bit NO
6bit NO
7bit NO
0bit Torque Decimal bit0 NO
1bit Torque Decimal bit1 NO Outputs Fastening Torque Decimal value using bina-
2bit Torque Decimal bit2 NO ry integer
Output 0 - 99 max.
3bit Torque Decimal bit3 NO (number RIGHT of decimal only)
No.07
4bit Torque Decimal bit4 NO Example:
5bit Torque Decimal bit5 NO Torque Decimal bit 1, 2, 5 Logical "1" = 38
6bit Torque Decimal bit6 NO
7bit NO
0bit NO
1bit NO
2bit NO
Output
3bit NO
No.08
4bit NO
5bit NO
6bit NO
7bit NO

Page 4-86
FEC FUSION Operations Manual Chapter 4: System Setup and Wiring (Rev. 3)

No. Bit Signal Connection Comment

0bit Angle Integer bit0 NO
1bit Angle Integer bit1 NO
2bit Angle Integer bit2 NO
Output
3bit Angle Integer bit3 NO
No.09
4bit Angle Integer bit4 NO
5bit Angle Integer bit5 NO Outputs Fastening Angle value using binary integer
6bit Angle Integer bit6 NO 0 - 9999 max.
7bit Angle Integer bit7 NO Example:
0bit Angle Integer bit8 NO Angle Integer bit 1, 2, 5, 7 Logical "1" = 166
1bit Angle Integer bit9 NO
2bit Angle Integer bit10 NO
Output
3bit Angle Integer bit11 NO
No.10
4bit Angle Integer bit12 NO
5bit Angle Integer bit13 NO
6bit NO
7bit NO
0bit NO
1bit NO
2bit NO
Output
3bit NO
No.11
4bit NO
5bit NO
6bit NO
7bit NO
0bit NO
1bit NO
2bit NO
Output
3bit NO
No.12
4bit NO
5bit NO
6bit NO
7bit NO

Final Angle Integer

1234 deg 04D2

Page 4-87
Chapter 4: System Setup and Wiring

No. Bit Signal Connection Comment

0bit NO
1bit NO
2bit NO
Output
3bit NO
No.13
4bit NO
5bit NO
6bit NO
7bit NO
0bit NO
1bit NO
2bit NO
Output
3bit NO
No.14
4bit NO
5bit NO
6bit NO
7bit NO
0bit NO
1bit NO
2bit NO
Output
3bit NO
No.15
4bit NO
5bit NO
6bit NO
7bit NO
0bit NO
1bit NO
2bit NO
Output
3bit NO
No.16
4bit NO
5bit NO
6bit NO
7bit NO

(Example) Siemens PLC

SFC14 is used.
32 bytes are stored from M30.0.

LADDR : Input address set by HW configuration

Hexadecimal WORD form

RET_VAL : Storage place when error occurs

RECORD : Read output signal from FUSION

Page 4-88
 FEC FUSION Operations Manual Chapter 4: System Setup and Wiring (Rev. 3)

Receive in Fastening Data message communication

2 CPU-315-PN/DP S7 Version5.4 result data entry example made in Siemens

Reception circuit of the STL form

Message Communication PLC
Receive declaration (Fusion → PLC)

M30.0
M30.0

M30.0

M30.0

The detailed explanation looks at programming manual or a system function block

manuals of the PLC, and please refer to the PLC maker for any questions.

REQREQ=1: Transfer data record

(use 1 by transmission start and make it 0 by the completion of Transmission).
ID: Set the Fusion unit slave module address assigned by the hardware configuration.
INDEX: Data record number - set to 4096.
MLEN: Set message block length. A preset value is 480 at the time of factory shipment.
RECORD: Target area for the fetched data record. In the example, it is 480 bytes from M300.0.
VALID: New data record was received and valid.
BUSYBUSY=1: The read process is not yet terminated.
ERRORERROR=1: A read error has occurred.
STATUS: Call ID (bytes 2 and 3) or error code. Please read PLC manual.
LEN: Length of the fetched data record information.

Page 4-89
Chapter 4: System Setup and Wiring

4-15-7 Message Output Format

Resultant fastening data can be output to the PLC via the Fieldbus connection after the end of each
fastening cycle. This is done using the Messaging function (CIP) in the PLC. (Each PLC uses a
different method to acquire the data – please see the PLC manuals on how to program the PLC to re-
ceive the data)
The output message format is preset and cannot be changed. See the following for an example of
the message format.

Note: The message data is available only on the Fieldbus type below.

DeviceNet
CC-Link V2
EtherNet/IP
Profinet-IO
Profibus-DPV1

Fastening result data DeviceNet

CC-Link V2
EtherNet/IP
Profinet-IO
Profibus-DPV1

Page 4-90
 FEC FUSION Operations Manual Chapter 4: System Setup and Wiring (Rev. 3)

Fastening Message Output Format ASCII 182bytes (Fixed Length)

“Accept” Fastening (Normal Format)

Page 4-91
Chapter 4: System Setup and Wiring

“Reject” Fastening: (Reject or Abnormal)

Page 4-92
FEC FUSION Operations Manual Chapter 5: Power Up and Initial Checks (Rev. 3)

Chapter 5: Power Up and Initial Checks

Page 5-1
Chapter 5: Power Up and Initial Checks

5.1 Before Powering On

WARNING:Follow Lockout / Tag out and other safety precautions when connecting or
disconnecting cabling, wiring, and equipment.
Each item below lists the manual Section(s) that will provide a reference for that specific item.
Also refer to Section 4.5 Connection Diagram.
Caution: Damage may occur if the 24 VDC and 0 VDC Commons are improperly connect-
ed.
1. Verify CONTROLLER Unit DIP switch settings (4.10)
 Verify that the eight (8) DIP switches visible through the rear panel removable plate of
each unit are set to indicate the appropriate spindle number and options. Section 4.10
CONTROLLER DIP Switch setting.

2. Confirm Interface (PLC) connection (4.7)

 Verify that the CONTROLLER unit I/O Interface wiring is connected to the corresponding
PLC terminals.

3. Check connections between the tool and the CONTROLLER unit (section 3.1.2)
 Verify that the Single cable (resolver/ motor and transducer) connecting the tool and
CONTROLLER unit is secure. If using multiple systems, ensure that the correct cable is
connected to the appropriate TOOL and CONTROLLER unit.
 If the layout contains moveable parts, visually inspect all components to ensure that
there is proper clearance and that cables have sufficient length. If movement would
create any excessive stress on a cable, or create any potential for damage to the system
or other components in the layout, then make appropriate adjustments.

WARNING: Do not make motor connections with the power on. Turn off all controller
power before attempting to connect or disconnect any motor cables or tool damage may
occur.

4. Check the input voltage (3.1.2, 4.6)

 Verify input power is properly connected (4.6.1).
 Ensure input power voltage to the CONTROLLER Units is 100~230 VAC.

NOTE:After a CONTROLLER unit is powered down, the power must not be applied again
for at least five (5) seconds. Repeated power up and power down, may temporarily disa-
ble the CONTROLLER unit as a safety precaution. If a CONTROLLER unit does become
disabled, keep the power off for five (5) minutes, then power on again to reset the fault.

Page 5-2
 FEC FUSION Operations Manual Chapter 5: Power Up and Initial Checks (Rev. 3)

5.2 Initial Data Setting

After completion of the System verification/power on procedure in Section 5.1, the system is
ready for the input of data required for the fastening operation. Chapters 6 and 7 give details on
the types of information required, and the procedure for entering data into the System. The sys-
tem will not run until this data is correctly set-up.

NOTE: Most FUSION systems are delivered with application-specific fastening data already
setup (if provided by customer). This set-up data is considered preliminary and should be ad-
justed according to actual process / part runs for optimal performance.

After the system is setup with the appropriate data, perform the following procedure.
1. Check the transducer ZERO output.
Press the RESET button on front of the Keyboard-display Unit. The
CONTROLLER unit will output a number (voltage) to the DATA display WITHOUT
the “ABN” LED displayed (See NOTE 1 below.)
2. Check the transducer CAL output.
 Press the CAL button on front of the Keyboard-display Unit. The CONTROLLER
Unit will output a number (voltage) to the DATA display WITHOUT the “ABN” LED
displayed (See NOTE 1 below.)

NOTE 1: If the Zero and/or Cal check results in an "ABNORMAL" LED output from the
CONTROLLER unit refer to Section 9 for guidance.

WARNING: VERIFY THERE ARE NO PERSONNEL OR OBSTRUCTIONS IN THE TOOL AREA

PRIOR TO ACTIVATING A SPINDLE OR OTHER MOVEABLE COMPONENT.
3. Check manual reverse operation.

A. Set the Tool assembly to Reverse Mode.

1. Momentarily depress the Reverse pushbutton switch on the Tool Assembly.
2. The Tool Assembly light ring should be flashing to indicate Reverse Mode
has been selected.
B. Press the manual Start switch on the Tool Assembly while the tool is in Reverse
Mode.
1. Verify that the spindle is turning in the appropriate direction (opposite the
preset (parameter) direction),

4. Verify operation of manual start.

A. Set the Tool assembly to Fastening Mode.
1. Momentarily depress the Reverse pushbutton switch on the Tool Assembly.
2. The Tool Assembly light ring should not be flashing (flashing indicates Re-
verse Mode has been selected)
B. Press the manual Start switch on the Tool Assembly while the tool is in Fastening
Mode.
1. Verify that the spindle is turning in the appropriate direction for fastening.

5. Verify System operation by external commands (not required for normal operation).
 Confirm that the equipment operates correctly when PLC inputs are activated (as
required). Use the PLC to perform all of the functions (Start, Work Sel, etc.) that
will be utilized in system operation.
 Confirm all PLC Output signals (Accept, Reject, Ready,etc.) that will be used in
system operation.

Page 5-3
Chapter 5: Power Up and Initial Checks

(Blank Page)

Page 5-4
FEC Fusion Operations Manual Chapter 6: Fastening Instructions (Rev.3)

Chapter 6: Fastening Instructions

Page 6-1
Chapter 6: Fastening Instructions

6.1 Fastening Control.

The Fusion system is user programmable to select from two different fastening methods, re-
ferred to as Torque Control and Angle Control methods. Each control method can be per-
formed in 1 to 3 incremental steps, which will successively secure the fastener to the speci-
fied torque or angle values.

NOTE: All setting recommendations are based upon common fastening applications.
Applications that experience high Prevailing torque, excessive joint compression or
other unique characteristics must be set with these characteristics in mind.

6.1.1 Torque Control Method.

In Torque Control method, fastening is performed based upon attaining a desired torque val-
ue within one to three incremental steps, while monitoring the degrees of rotation (Angle) of
the fastener and time. Additional monitor items (limits) can be set to enhance the systems
ability to determine if the fastener was properly secured (Section 6.2).

◆ One-Step Fastening
One-step fastening will be used primarily for joints which have no requirement to synchronize
with another spindle during the final stage of the rundown. Examples: Pipe Plugs, Spark
Plugs, single spindle applications.
1. Once SPEED CHANGE TORQUE is reached or FREERUN REVOLUTIONS expires, the sys-
tem will switch from FREERUN SPEED to SLOWDOWN SPEED and continue to fasten to
1ST TORQUE.
2. The system will fasten to the 1ST TORQUE value during the specified 1ST TIME. 1ST
TORQUE must be reached within the 1ST TIME limits or a reject will occur.
3. Upon reaching 1ST TORQUE, 1ST TIME ends and FINAL TIME begins. 1ST TORQUE is
the shift point to TORQUE SPEED.
4. The system will fasten to STANDARD TORQUE using TORQUE SPEED during FINAL TIME.
STANDARD TORQUE must be reached within the FINAL TIME limits or a reject will occur.

FUNCTION RECOMMENDATION / COMMENT

SPEED CHANGE TORQUE 10% of STANDARD TORQUE
THRESHOLD TORQUE Start point of 1st torque rate monitoring (section 6.2)
30% of STANDARD TORQUE
1ST TORQUE
Used for RATE/TIME settings and TORQUE SPEED initiation.
SNUG TORQUE Angle Monitoring Start Point (section 6.2)
CROSSOVER TORQUE Start point of 3RD torque rate monitoring (section 6.2)
STANDARD TORQUE Engineered product fastening specification
1ST TIME HIGH/LOW LIMIT Acceptance range to reach 1ST TORQUE setting
Acceptance range to go from 1ST TORQUE to STANDARD
FINAL TIME HIGH/LOW LIMIT
TORQUE

Page 6-2
FEC Fusion Operations Manual Chapter 6: Fastening Instructions (Rev.3)

Torque

Standard Torque

Crossover Torque

Snug Torque

1st Torque

Threshold Torque

Speed Change Torque

Angle/Time

1st Time Final Time

FIG. 6-1-1a Torque Control Functions for One-Step Fastening

Page 6-3
Chapter 6: Fastening Instructions

◆ Two-Step Fastening
Two-step fastening will be used primarily for joints that have a requirement to synchronize
with another spindle during the final stage of the rundown or require joint conditioning. Ex-
amples: Connecting Rod, Main Bearing Cap, any multiple-spindle application.
1. Once SPEED CHANGE TORQUE is reached or FREERUN REVOLUTIONS expires, the sys-
tem will switch from FREERUN SPEED to SLOWDOWN SPEED and continue to fasten to
1ST TORQUE.
2. The system will fasten to the 1ST TORQUE value during the specified 1ST TIME. 1ST
TORQUE must be reached within the 1ST TIME limits or a reject will occur.
3. Upon reaching 1ST TORQUE, 1ST TIME ends and FINAL TIME begins. 1ST TORQUE is
the shift point to TORQUE SPEED and the synchronization point prior to commencing the
next step. (See 4.13 for Sync. info)
4. The system will fasten to STANDARD TORQUE using TORQUE SPEED during FINAL TIME.
STANDARD TORQUE must be reached within the FINAL TIME limits or a reject will occur.

FUNCTION RECOMMENDATION / COMMENT

SPEED CHANGE TORQUE 10% of STANDARD TORQUE
THRESHOLD TORQUE Start point of 1st torque rate monitoring (section 6.2)
30% of STANDARD TORQUE
1ST TORQUE Used for RATE/TIME settings and TORQUE SPEED initiation.
Synchronization point for 2ND STEP
SNUG TORQUE Angle Monitoring Start Point (section 6.2)
CROSSOVER TORQUE Start point of 3RD torque rate monitoring (section 6.2)
STANDARD TORQUE Engineered product fastening specification
1ST TIME HIGH/LOW LIMIT Acceptance range to reach 1ST TORQUE setting
Acceptance range to go from 1ST TORQUE to STANDARD
FINAL TIME HIGH/LOW LIMIT
TORQUE

Torque

Standard Torque

Crossover Torque

Snug Torque

1st Torque

Threshold Torque

Speed Change Torque

Angle/Time

1st Time Final Time

FIG. 6-1-1b Torque Control Functions for Two-Step Fastening

Page 6-4
FEC Fusion Operations Manual Chapter 6: Fastening Instructions (Rev.3)

◆ Three-Step Fastening
Three-step fastening will be used primarily for joints that have a requirement to synchronize
with another spindle during the incremental stages of the rundown to crush/compress a gas-
ket or grommet or for special joint conditioning (valve cover, oil pan, or body assembly, for
example).
1. The system will fasten to the 1ST TORQUE value during the specified 1ST TIME. 1ST
TORQUE must be reached within the 1ST TIME limits or a reject will occur.
2. Once SPEED CHANGE TORQUE is reached or FREERUN REVOLUTIONS expires, the sys-
tem will switch from FREERUN SPEED to SLOWDOWN SPEED and continue to fasten to
1ST TORQUE.
3. Upon reaching 1ST TORQUE, 1ST TIME ends and FINAL TIME begins. 1ST TORQUE is
the shift point to TORQUE SPEED and the synchronization point prior to commencing the
next step. (See 4.13 for Sync. info)
4. The system will fasten to CROSSOVER TORQUE, synchronize with other spindles and then
fasten to STANDARD TORQUE using TORQUE SPEED during FINAL TIME. STANDARD
TORQUE must be reached within the FINAL TIME limits or a reject will occur.

FUNCTION RECOMMENDATION / COMMENT

SPEED CHANGE TORQUE 10% of STANDARD TORQUE
THRESHOLD TORQUE Start point of 1st torque rate monitoring (section 6.2)
30% of STANDARD TORQUE
1ST TORQUE Used for RATE/TIME settings and TORQUE SPEED initiation.
Synchronization point for 2nd STEP
SNUG TORQUE Angle Monitoring Start Point (section 6.2)
Start point of 3RD torque rate monitoring (section 6.2)
CROSSOVER TORQUE
Synchronization point for 3rd STEP
STANDARD TORQUE Engineered product fastening specification
1ST TIME HIGH/LOW LIMIT Acceptance range to reach 1ST TORQUE setting
Acceptance range to go from 1ST TORQUE to STANDARD
FINAL TIME HIGH/LOW LIMIT
TORQUE

Torque

Standard Torque

Crossover Torque

Snug Torque

1st Torque

Threshold Torque

Speed Change Torque

Angle/Time

1st Time Final Time

FIG. 6-1-1c Torque Control Functions for Three-Step Fastening

Page 6-5
Chapter 6: Fastening Instructions

6.1.2 Angle Control Method.

In Angle Control method, fastening is performed based upon attaining a desired torque value
and then rotating the fastener a specified number of degrees, while monitoring the Torque of the
fastener and time. Additional monitor items (limits) can be set to enhance the systems ability to deter-
mine if the fastener was properly secured (Section 6.2). Fastening can be performed from 1 to 3
incremental steps that will successively secure the fastener to a specified torque or angle
value before attaining the final number of degrees of rotation.

Angle Control method is primarily used when greater control of clamp load is required. (Angle
Control specs. are developed through testing of the joint and fastener characteristics and
therefore should not be attempted unless testing is performed)

NOTE: All setting recommendations are based upon common fastening applications.
Applications that experience high Prevailing torque, excessive joint compression or
other unique characteristics must be set with these characteristics in mind.

NOTE: When performing multiple step Angle control fastening, the rotation Angle
should be performed as one continuous operation. There should be no intermediate
stop/synchronization points once Snug Torque has been sensed and rotation angle is
being controlled. Under special conditions multiple steps can be performed using in-
termediate Torque or Angle stop/synchronization points.

◆ One-Step Fastening
One-Step fastening will be used primarily for joints that have no requirement to synchronize
with another spindle during the final stage of the rundown.
1. Angle control commences at SNUG TORQUE. All angle values are referenced from this point.
2. Once SPEED CHANGE TORQUE is reached or FREERUN REVOLUTIONS expires, the system will
switch from FREERUN SPEED to SLOWDOWN SPEED and continue to fasten to 1ST
TORQUE/ANGLE.
3. The system will fasten to the 1ST TORQUE/ANGLE value during the specified 1ST TIME. 1ST
TORQUE/ANGLE must be reached within the 1ST TIME limits or a reject will occur.
4. Upon reaching 1ST TORQUE/ANGLE, 1ST TIME ends and FINAL TIME begins. 1ST
TORQUE/ANGLE is the shift point to TORQUE SPEED.
5. The system will fasten to STANDARD ANGLE using TORQUE SPEED during FINAL TIME.
STANDARD ANGLE must be reached within the FINAL TIME limits or a reject will occur.

FUNCTION RECOMMENDATION / COMMENT

SPEED CHANGE TORQUE 30% of SNUG TORQUE
THRESHOLD TORQUE Start point of 1st torque rate monitoring (section 6.2)
80% of SNUG TORQUE
1ST TORQUE/ANGLE
Used for RATE/TIME settings and TORQUE SPEED initiation.
SNUG TORQUE Angle Control Start Point
CROSSOVER
Start point of 3RD torque rate monitoring (section 6.2)
TORQUE/ANGLE
STANDARD ANGLE Engineered product fastening specification
1ST TIME HIGH/LOW LIMIT Acceptance range to reach 1ST TORQUE/ANGLE setting
Acceptance range to go from 1ST TORQUE/ANGLE to
FINAL TIME HIGH/LOW LIMIT
STANDARD ANGLE

Page 6-6
FEC Fusion Operations Manual Chapter 6: Fastening Instructions (Rev.3)

Torque

Crossover Torque

Snug Torque

1st Torque

Threshold Torque

Speed Change Torque

Angle/Time

Standard
Angle

1st Time Final Time

FIG. 6-1-2a Angle Control Functions for One-Step Fastening

Page 6-7
Chapter 6: Fastening Instructions

◆ Two-Step Fastening
Two-Step fastening will be used primarily for joints that have a requirement to synchronize
with another spindle during the final stage of the rundown.
1. Angle control commences at SNUG TORQUE. All angle values are referenced from this point.
2. Once SPEED CHANGE TORQUE is reached or FREERUN REVOLUTIONS expires, the system will
switch from FREERUN SPEED to SLOWDOWN SPEED and continue to fasten to 1ST
TORQUE/ANGLE.
3. The system will fasten to the 1ST TORQUE/ANGLE value during the specified 1ST TIME. 1ST
TORQUE/ANGLE must be reached within the 1ST TIME limits or a reject will occur.
4. Upon reaching 1ST TORQUE/ANGLE, 1ST TIME ends and FINAL TIME begins. 1ST
TORQUE/ANGLE is the shift point to TORQUE SPEED and the synchronization point prior to com-
mencing the next step. (See 4.13 for Sync. info).
5. The system will fasten to STANDARD ANGLE using TORQUE SPEED during FINAL TIME.
STANDARD ANGLE must be reached within the FINAL TIME limits or a reject will occur.

NOTE: When performing multiple step Angle control fastening, the rotation Angle
should be performed as one continuous operation. There should be no intermediate
stop / synchronization points once Snug Torque has been sensed and rotation angle is
being controlled. Under special conditions multiple steps can be performed using in-
termediate Torque or Angle stop/synchronization points.

FUNCTION RECOMMENDATION / COMMENT

SPEED CHANGE TORQUE 30% of SNUG TORQUE
THRESHOLD TORQUE Start point of 1st torque rate monitoring (section 6.2)
80% of SNUG TORQUE
1ST TORQUE/ANGLE
Used for RATE/TIME settings and TORQUE SPEED initiation.
SNUG TORQUE Angle Control Start Point
CROSSOVER
Start point of 3RD torque rate monitoring (section 6.2)
TORQUE/ANGLE
STANDARD ANGLE Engineered product fastening specification
1ST TIME HIGH/LOW LIMIT Acceptance range to reach 1ST TORQUE/ANGLE setting
Acceptance range to go from 1ST TORQUE/ANGLE to
FINAL TIME HIGH/LOW LIMIT
STANDARD ANGLE

Page 6-8
FEC Fusion Operations Manual Torque Chapter 6: Fastening Instructions (Rev.3)

Crossover Torque

Snug Torque

1st Torque

Threshold Torque

Speed Change Torque

Angle/Time

Standard
Angle

1st Time Final Time

FIG. 6-1-2b Angle Control Functions for Two-Step Fastening (1st step Torque)

NOTE: When performing multiple step Angle control fastening, the rotation Angle should be
performed as one continuous operation. There should be no intermediate stop / synchroniza-
tion points once Snug Torque has been sensed and rotation angle is being controlled.

Under special conditions multiple steps can be performed using intermediate Torque or Angle
stop/synchronization points as shown below.

Torque

Crossover Torque

1st Angle

Snug Torque
Threshold Torque
Speed Change Torque
Angle/Time

Standard
Angle

1st Time Final Time

FIG. 6-1-2c Angle Control Functions for Two-Step Fastening (1st step Angle)

Page 6-9
Chapter 6: Fastening Instructions

◆ Three-Step Fastening
Three-step fastening will be used primarily for joints that have a requirement to synchronize
with another spindle during the incremental stages of the rundown to crush/compress a gas-
ket or grommet or for special joint conditioning (valve cover, oil pan, or body assembly, for
example).

1. Angle control commences at SNUG TORQUE. All angle values are referenced from this point.
2. Once SPEED CHANGE TORQUE is reached or FREERUN REVOLUTIONS expires, the system will
switch from FREERUN SPEED to SLOWDOWN SPEED and continue to fasten to 1ST
TORQUE/ANGLE.
3. The system will fasten to the 1ST TORQUE/ANGLE value during the specified 1ST TIME. 1ST
TORQUE/ANGLE must be reached within the 1ST TIME limits or a reject will occur.
4. Upon reaching 1ST TORQUE/ANGLE, 1ST TIME ends and FINAL TIME begins. 1ST
TORQUE/ANGLE is the shift point to TORQUE SPEED and the synchronization point prior to com-
mencing the next step. (See 4.13 for Sync. info).
5. The system will fasten to CROSSOVER TORQUE/ANGLE, synchronize with other spindles
and then fasten to STANDARD ANGLE using TORQUE SPEED during FINAL TIME.
STANDARD ANGLE must be reached within the FINAL TIME limits or a reject will occur.

NOTE: When performing multiple step Angle control fastening, the rotation Angle
should be performed as one continuous operation. There should be no intermediate
stop / synchronization points once Snug Torque has been sensed and rotation angle is
being controlled. Under special conditions multiple steps can be performed using in-
termediate Torque or Angle stop/synchronization points.

FUNCTION RECOMMENDATION / COMMENT

SPEED CHANGE TORQUE 30% of SNUG TORQUE
THRESHOLD TORQUE Start point of 1st torque rate monitoring (section 6.2)
80% of SNUG TORQUE
1ST TORQUE/ANGLE
Used for RATE/TIME settings and TORQUE SPEED initiation.
SNUG TORQUE Angle Control Start Point
CROSSOVER Start point of 3RD torque rate monitoring (section 6.2)
TORQUE/ANGLE Synchronization point for 3rd Step
STANDARD ANGLE Engineered product fastening specification
1ST TIME HIGH/LOW LIMIT Acceptance range to reach 1ST TORQUE/ANGLE setting
Acceptance range to go from 1ST TORQUE/ANGLE to
FINAL TIME HIGH/LOW LIMIT
STANDARD ANGLE

Page 6-10
FEC Fusion Operations Manual Chapter 6: Fastening Instructions (Rev.3)

NOTE: When performing multiple step Angle control fastening, the rotation Angle should be
performed as one continuous operation. There should be no intermediate stop / synchroniza-
tion points once Snug Torque has been sensed and rotation angle is being controlled.

Under special conditions multiple steps can be performed using intermediate Torque or Angle
stop/synchronization points as shown below.

Crossover Torque/Angle

Snug Torque

1st Torque

Threshold Torque

Speed Change Torque

Standard
Angle

1st Time Final Time

FIG. 6-1-2d Angle Control Functions for Three-Step Fastening

Page 6-11
Chapter 6: Fastening Instructions

6.2 Monitoring Functions

The Fusion System is user programmable to select and set the monitoring limits for torque, angle,
time, up to three independent torque rate areas, and special functions describe below.

6.2.1 Peak Torque Monitoring

Torque Monitoring is a continuous process whenever the System is operating. Peak Torque monitor-
ing uses the maximum torque value detected during Fastening.

 In Torque Control method, the Peak Torque High and Low Torque limits are set based upon the
engineering specification for the specific fastener.

TORQUE CONTROL
REJECT TYPE CAUSES
Re-hit of pre-secured fastener.
PEAK TORQUE HIGH LIMIT
Incorrect parameter set-up.
PEAK TORQUE LOW LIMIT Reject condition caused by another monitor item reject.

Torque

Peak Torque High Limit

Standard Torque
Peak Torque Low Limit

Crossover Torque

Snug Torque

1st Torque

Threshold Torque

Speed Change Torque

Angle/Time

1st Time Final Time

FIG. 6-2-1a Peak Torque Monitor – Torque Control

Page 6-12
FEC Fusion Operations Manual Chapter 6: Fastening Instructions (Rev.3)

 For Angle Control operations, the High and Low Torque limits are either set by the engineer-
ing specification for that specific fastener, or by determining the acceptable limits from a
study of known good and bad assemblies. The High Torque limit will stop the fastening pro-
cess for Angle Control operations if it is reached before attaining the desired angle.

ANGLE CONTROL
REJECT TYPE CAUSES
Reduced joint compression.
PEAK TORQUE HIGH LIMIT Increased joint friction.
Incorrect parameter set-up.
Increased joint compression.
Reduced joint friction.
PEAK TORQUE LOW LIMIT High initial prevailing torque.
Incorrect parameter set-up.
Reject condition caused by another monitor item reject.

Torque

Peak Torque High Limit

Peak Torque Low Limit

Crossover Torque

Snug Torque

1st Torque

Threshold Torque

Speed Change Torque

Angle/Time

Standard
Angle

1st Time Final Time

FIG. 6-2-1b Peak Torque Monitor – Angle Control

Page 6-13
Chapter 6: Fastening Instructions

6.2.2Final Torque Monitoring

Torque Monitoring is a continuous process whenever the system is operating. Final Torque monitor-
ing uses the torque value detected at the completion of fastening.

 In Torque Control method, the Final Torque value and Peak Torque values will be identical except
in cases where Torque Recovery (Section 6.5) is enabled. In Torque Control method, the Final
Torque High and Low Torque limits are only selectable when Torque Recovery is enabled, and are
typically set based upon the engineering specification for that specific fastener.

TORQUE CONTROL – TORQUE RECOVERY ENABLED

REJECT TYPE CAUSES
Excessive chatter of the torque signal due to slip stick friction.
FINAL TORQUE HIGH LIMIT
Incorrect parameter set-up.
FINAL TORQUE LOW LIMIT Reject condition caused by another monitor item reject.

Torque Recovery Pulse Time

Torque

Peak Torque High Limit

Final Torque High Limit

Standard Torque
Peak Torque Low Limit
Final Torque Low Limit

Crossover Torque

Snug Torque

1st Torque

Threshold Torque

Speed Change Torque

Time Only

1st Time Final Time

FIG. 6-2-2a Final Torque Monitor – Torque Control W/ Torque Recovery

Page 6-14
FEC Fusion Operations Manual Chapter 6: Fastening Instructions (Rev.3)

 For Angle Control operations, the Torque value may reach a peak value and then drop to a lower
value as the fastener is stretched beyond the point of yielding. Final Torque High and Low Limits are
either set by the engineering specification for that specific fastener, or by determining the acceptable
limits from a study of known good and bad assemblies.

ANGLE CONTROL
REJECT TYPE CAUSES
Reduced joint compression.
Increased joint friction.
FINAL TORQUE HIGH LIMIT
Excessive chatter of the torque signal due to slip stick friction.
Incorrect parameter set-up.
Increased joint compression.
Reduced joint friction.
Excessive yield of fastener.
FINAL TORQUE LOW LIMIT
High initial prevailing torque.
Incorrect parameter set-up.
Reject condition caused by another monitor item reject.

Torque

Peak Torque High Limit

Final Torque High Limit

Peak Torque Low Limit

Final Torque Low Limit

Crossover Torque

Snug Torque

1st Torque

Threshold Torque

Speed Change Torque

Angle/Time

Standard
Angle

1st Time Final Time

FIG. 6-2-2b Final Torque Monitor – Angle Control

Page 6-15
Chapter 6: Fastening Instructions

6.2.3 Angle Monitoring

Angle Monitoring commences upon reaching the preset SNUG TORQUE value, and continues until
completion of the fastening process.

 In Angle Control method, the Angle High and Low Limits are set based upon the engineering
specification for that specific fastener.

ANGLE CONTROL
REJECT TYPE CAUSES
ANGLE HIGH LIMIT Incorrect parameter set-up.
ANGLE LOW LIMIT Reject condition caused by another monitor item reject.

Torque Angle Low Limit Angle High Limit

Peak Torque High Limit

Final Torque High Limit

Peak Torque Low Limit

Final Torque Low Limit

Crossover Torque

Snug Torque

1st Torque

Threshold Torque

Speed Change Torque

Angle/Time

Standard
Angle

1st Time Final Time

FIG. 6-2-3a Angle Monitoring – Angle Control

Page 6-16
FEC Fusion Operations Manual Chapter 6: Fastening Instructions (Rev.3)

For Torque Control operations, the High and Low Angle limits are either set by the engineering speci-
fication for that specific fastener, or by determining the acceptable limits from a study of known good
and bad assemblies. The High Angle limit will stop the fastening process for Torque Control opera-
tions if it is reached before attaining the desired torque.

TORQUE CONTROL
REJECT TYPE CAUSES
Increased joint compression.
Reduced joint friction.
HIGH ANGLE LIMIT
High initial prevailing torque.
Incorrect parameter set-up.
Reduced joint compression.
LOW ANGLE LIMIT Increased joint friction.
Reject condition caused by another monitor item reject.

Torque
Angle Low Limit Angle High Limit

Peak Torque High Limit

Standard Torque
Peak Torque Low Limit

Crossover Torque

Snug Torque

1st Torque

Threshold Torque

Speed Change Torque

Angle/Time

1st Time Final Time

FIG. 6-2-3b Angle Monitoring – Torque Control

Page 6-17
Chapter 6: Fastening Instructions

6.2.4 Point-to-Point Torque Rate Monitoring

The Fusion System is capable of performing 3 torque rate calculations. The Point-to-Point torque
rate method performs the calculation based upon completing a step of the process, and then calculat-
ing the rate for the full duration of that step. The chart below identifies the different areas that torque
rate can be calculated. Each Torque Rate is calculated by dividing the change in torque during the
specific period by the change in angle.

Example: 25Nm / 100deg. = 0.25 Nm/Deg. (rate)

NOTE: Setting any of the Torque Rate START POINTS above the FASTENING
END TORQUE will eliminate the torque rate calculation for that stage.

Torque Rate Calculation Areas (Typical for 1 or 2 step)

(CROSSOVER TORQUE set above FASTENING END TORQUE)
Refer to Fig. 6-2-4a
STAGE START POINT STOP POINT
1ST TORQUE RATE THRESHOLD TORQUE 1ST TORQUE
2ND TORQUE RATE 2ND RATE START TORQUE FASTENING END

Torque Rate Calculation Areas (Typical for 3 step, however can be used on 1 or 2 step)
Refer to Fig. 6-2-4b
STAGE START POINT STOP POINT
1ST TORQUE RATE THRESHOLD TORQUE 1ST TORQUE
2ND TORQUE RATE 2ND RATE START TORQUE CROSSOVER TORQUE
3RD TORQUE RATE CROSSOVER TORQUE FASTENING END

In the case that Torque Rate Stop Points are not set incrementally larger from THRESHOLD
to 2ND RATE START TORQUE and then to CROSSOVER TORQUE, the rate calculation will
be performed at the next successive available stop point prior to fastening end.

STAGE START POINT AVAILABLE STOP POINTS

1ST TORQUE
1ST TORQUE RATE THRESHOLD CROSSOVER TORQUE
FASTENING END
CROSSOVER TORQUE
2ND TORQUE RATE 2ND RATE START
FASTENING END
3RD TORQUE RATE CROSSOVER TORQUE FASTENING END

For all control operations, the High and Low Torque Rate limits are set by determining the
acceptable limits from a study of known good and bad assemblies.

Page 6-18
FEC Fusion Operations Manual Chapter 6: Fastening Instructions (Rev.3)

Torque

Crossover Torque

Standard Torque

2nd Rate
High Limit

2nd Rate
Low Limit

2nd Rate Start Torque

1st Torque
1st Rate 1st Rate
High Limit Low Limit
Threshold Torque

Angle/Time

1st Time Final Time

FIG. 6-2-4a Two Stage Point-to-Point Torque Rate Monitoring

Torque

Standard Torque

3rd Rate
3rd Rate
High Limit Low Limit

Crossover Torque

2nd Rate
2nd Rate
High Limit
Low Limit
2nd Rate Start Torque
1st Torque
1st Rate 1ST Rate
Low Limit
High Limit
Threshold Torque

Angle/Time

1st Time Final Time

FIG. 6-2-4b Three Stage Point-to-Point Torque Rate Monitoring

Page 6-19
Chapter 6: Fastening Instructions

6.2.5 Time Monitoring

◆ Time High Limits
As outlined in the Fastening Control Methods portion of this chapter, this system is capable of
performing multiple-step fastening operations. The duration of each of these steps is gov-
erned by one of two independent watchdog time settings. If the step fails to attain the desired
result before the completion of the specified time, a TIME HIGH reject condition will occur.

◆ Time Low Limits

Low time limit settings for both 1st and Final steps are available for special applications. This
allows the setting of a low time limit which can be used to detect conditions in which the fas-
tening reaches a given point before it would have under normal conditions. Short bolts, short
threads, blind holes, cross threads, etc. are all conditions which may be detected with this
setting. Times under the low limit will produce a reject for that fastening.

1 Step Fastening
Function Start Point Stop Point Time Preset Limits
START 1ST TORQUE 1ST TIME HIGH/LOW LIMIT
1ST STEP
1ST TORQUE FASTENING END FINAL TIME HIGH/LOW LIMIT
1st TORQUE also serves as a shift point to TORQUE SPEED and the monitoring stop point for 1 st
TORQUE RATE. The system does not stop or synchronize at this point.

2 Step Fastening
Function Start Point Stop Point Time Preset Limits
1ST STEP START 1ST TORQUE 1ST TIME HIGH/LOW LIMIT
2ND STEP 1ST TORQUE FASTENING END FINAL TIME HIGH/LOW LIMIT
1st TORQUE also serves as a shift point to TORQUE SPEED and the monitoring stop point for 1 st
TORQUE RATE. The system will temporarily stop at this point and can be set to synchronize with
other spindles.

3 Step Fastening
Function Start Point Stop Point Time Preset Limits
1ST STEP START 1ST TORQUE 1ST TIME HIGH/LOW LIMIT
1st TORQUE also serves as a shift point to TORQUE SPEED and the monitoring stop point for 1 st
TORQUE RATE. The system will temporarily stop at this point and can be set to synchronize with
other spindles.
2ND STEP 1ST TORQUE CROSSOVER TORQUE
FINAL TIME HIGH/LOW LIMIT
3RD STEP CROSSOVER TORQUE FASTENING END
For 3 Step Fastening, 2ND STEP and 3RD STEP are performed with the same preset FINAL TIME
HIGH/LOW LIMITS. (both must finish within the same combined timeframe)

Page 6-20
FEC Fusion Operations Manual Chapter 6: Fastening Instructions (Rev.3)

6.3 Speed Functions

The Fusion system is user-programmable for operations involving multiple speed settings. The use
of multiple speeds during the fastening process aids in socket engagement, achieving cycle time, op-
erator ergonomic issues and controlling the applied torque during all stages. Speed functions work
the same for Torque control and Angle control, using any of the previously stated standard monitoring
function. Special conditions that affect these operations will be identified in the appropriate section.

1. The system will fasten to the 1ST TORQUE/ANGLE value during the specified 1ST TIME.
During 1ST time the following steps occur:
a. The system starts off running at INITIAL SPEED for the period specified by INITIAL
TIME. This segment is intended to be used for initial fastener engagement.
b. Upon completion of INITIAL TIME the system switches to FREERUN SPEED for the
period specified by FREERUN REVOLUTIONS. The number of revolutions required
to complete INITIAL TIME will be deducted from the number of revolutions run at
FREERUN SPEED.
c. Once SPEED CHANGE TORQUE is reached or FREERUN REVOLUTIONS expires,
the system will switch from FREERUN SPEED to SLOWDOWN SPEED and continue
to fasten until 1ST TORQUE/ANGLE is attained or the 1ST TIME HIGH LIMIT (1ST
time reject) is reached. SLOW DOWN SPEED is intended to provide a slower, more
controlled speed to seat the fastener.
2. Upon reaching 1ST TORQUE/ANGLE, 1ST TIME ends and FINAL TIME begins. 1ST
TORQUE/ANGLE is the shift point to TORQUE SPEED and the synchronization point prior to
commencing the next step. (See 4.13 for Sync. info).
3. For a 2 step fastening, the system will fasten to STANDARD TORQUE/ANGLE, using
TORQUE SPEED during FINAL TIME. STANDARD TORQUE/ANGLE must be reached
within the FINAL TIME limits or a reject will occur.
4. For a 3 step fastening, the system will fasten to CROSSOVER TORQUE/ANGLE, synchro-
nize with other spindles and than fasten to STANDARD TORQUE/ANGLE using TORQUE
SPEED during FINAL TIME. STANDARD TORQUE/ANGLE must be reached within the
FINAL TIME limits or a reject will occur.

FUNCTION RECOMMENDATION
INITIAL TIME Set to a duration which will provide sufficient time for the socket to en-
gage the fastener. Set in seconds.
INITIAL SPEED Set to the rpm which will allow for easy socket to fastener engagement.
FREERUN For joints that do not react properly to high speed seating, the Freerun
REVOLUTIONS revolutions should be set to end prior to the fastener seating.
FREERUN SPEED Set based upon cycle time requirements. This speed is used to run
down the bolt quickly.
SLOW DOWN SPEED First torque fastening speed. SET based upon the joint type to allow
for a controlled seating. LESS THAN 200 RPM.
TORQUE SPEED Final torque speed to which the nutrunner will shift once 1st TORQUE
is reached. SET based upon the joint type to allow for a controlled final
fastening. LESS THAN 50 RPM.
REVERSE SPEED Speed used to reverse or back - out a fastener. Typically ¼ of full
speed. Additional reverse functions exist when a MULTI unit is used.

Page 6-21
 Chapter 6: Fastening Instructions

The graphic below describes the ideal relationship between torque and speed. Typically for high mo-
tor durability, High speed (FREERUN speed) should slow to SLOWDOWN speed before the fastener
seats. Final torque speed should not exceed 50 RPM.

Speed

Freerun Revolutions

Freerun Speed

Initial Time

Torque Inhibit
Revolutions Slow Down
Speed
Initial Speed
Torque Speed
Time/Revolution
s

1st Time Final Time

Torque

Standard
Torque

1st Torque

Speed Change
Torque Angle/Time

1st Time Final Time

FIG. 6-3b Ideal Relationship of Speed and Torque

Page 6-22
FEC Fusion Operations Manual Chapter 6: Fastening Instructions (Rev.3)

6.4 Reverse Functions

The Fusion system is capable of reverse operations using the reverse pushbutton on the Fusion tool
or via the PLC input at TB1 Terminal. The PLC input can be used for automated reverse operations.
The motor will reverse as long as the reverse signal or manual button is enabled.
One reverse speed is available per parameter (up to 16).

Time/Revolutions

Reverse Speed

RPM

FIG. 6-4a Fusion Reverse Function

The reverse function on a stand alone SAN Unit is set with one speed setting (Reverse Speed). The
duration of the reverse would be controlled from an external source (PLC) using the “Reverse” input
or manual reverse pushbutton & trigger combination. (The Reverse pushbutton must first be enabled.
Then depress the start trigger for the desired reverse duration. Depress the Reverse pushbutton
again to disable the reverse mode)

FIG. 6-4b Tool LED Function

Page 6-23
Chapter 6: Fastening Instructions

6.5 Torque Recovery

The Torque Recovery function is used when the potential for joint relaxation and interaction exists.
Under this control method, the fasteners are secured to Standard Torque, and then held at Standard
Torque for a programmed duration of “pulses”. This “pulse” setting can be between 0-50 pulses.
Power is applied to the motor for this duration, “holding” torque at the specified STD (Standard)
Torque. During Torque Recovery the tool will use Recovery Speed as its maximum Speed, but will
only rotate as a result of a drop in the Torque. Torque Recovery is only available in Torque Con-
trolled Fastening due the fact that the use of Torque Recovery may cause addition rotation (Angle) of
the fastener.

WARNING: The Torque Recovery function will cause the motor to heat up at a rate
faster than normal fastening due to high amperage draw. Particular attention to mini-
mized duty cycle is recommended if using this function or premature motor failure
could result. Torque Recovery Pulses should be kept to a minimum for the application
requirements.

Torque Recovery Pulses

Torque

Peak Torque High Limit

Final Torque High Limit

Standard Torque
Peak Torque Low Limit
Final Torque Low Limit

Crossover Torque

Snug Torque

1st Torque

Threshold Torque

Speed Change Torque

Time Only

1st Time Final Time

FIG. 6-5 Torque Recovery

WARNING: When a Fusion tool is held in the hand of an operator, the Torque Recov-
ery function will cause additional or unexpected torque reaction to be applied to the
operator. Be careful when using this function when held in the hand of an operator or
operator harm may result.

Page 6-24
FEC Fusion Operations Manual Chapter 6: Fastening Instructions (Rev.3)

6.6 Added Functions

Additional functions are available as standard features integrated within the Fusion controller. These
functions may be helpful in special applications or for maintenance reasons. See below for additional
functions.

6.6.1 Current Monitoring / Control

The current monitoring function works as a redundant protection for the torque transducer operations.
By sensing the current drawn by the motor, the system can establish an alternate reference to the
signals generated by the torque transducer preamplifier. It is intended to detect problems with the mo-
tor that would not be detected by the torque transducer and also as a maintenance tool to determine
if there is a problem before the system will shut down.

This function allows the user to set Low Current and High Current Limits. If the current drawn by the
motor overrides the High Current Limit or does not achieve the Low Current Limit, the System acti-
vates the Current Warning PLC Output Signal, without halting the System's operation. This current
warning signal prompts of a potential failure in the system that requires inspection, but allows the sys-
tem to continue until a suitable time is available to inspect the system.

The Fastening current limit allows a limit for maximum current draw during a fastening cycle. If this is
set below Full Scale Current, then the current will not exceed this value during a fastening cycle. This
function is mainly for protecting a motor during Torque recovery applications. If the Fastening Current
Limit is exceeded and the motor stops turning, a Resolver Abnormal fault may occur.

The Full scale current limit is an automatically set reference value. This is generated based upon the
motor/servo used and should not be changed.

FULL SCALE CURRENT

HIGH CURRENT LIMIT

FASTENING CURRENT LIMIT
LOW CURRENT LIMIT
CURRENT

TIME / ANGLE

Fig. 6-6-1 Current Monitor function

Page 6-25
Chapter 6: Fastening Instructions

6.6.2 Angle Correction

An Angle Correction preset is available for correcting angle reading disparities during calibration us-
ing a certified master transducer with Angle Monitoring capabilities. Under normal conditions this is
not used. This may be necessary in applications requiring crowsfeet, right angle drives, belt or chain
drives, etc.

Setting range is from -99 to +99 degrees.

See the AFC User Console software manual for additional set-up information.

6.6.3 Reduced Fastening Reaction

This function is mainly for manual or hand held applications where torque reaction during motor stop-
ping is too extreme for an operator to handle. The motor ramp down time is extended allowing a
gradual relief of the applied torque to the operator’s hands, thus reducing the affect and fatigue of di-
rect torque reaction.

See the AFC User Console software manual for additional set-up information.

6.6.4 VariSpeed
Varispeed automatically adjusts the fastening speed based on the type of joint that is being fastened.
This eliminates motor overload conditions typically on very soft joints (high rotational angle) and de-
creases system cycle time. When the system senses a decreasing torque rate (soft joint) prior to
reaching 1st Torque/Angle, the motor speed is automatically increased to an optimal speed for that
particular torque rate. When the system senses an increasing torque rate (hard joint) prior to reach-
ing 1st Torque/Angle, the motor speed is automatically decreased to an optimal speed for that particu-
lar torque rate. The speed is automatically controlled during the fastening process based on the
torque rate.

See the AFC User Console software manual for additional set-up information.

6.6.5 Work Count (Batch Counting)

For applications requiring multiple “Accept” fastenings for a given part before a total “Work”
(work piece) accept is output, the Work Accept count function can be used. This allows an
operator to fasten multiple times, (the number of accepts is programmable) before a total
WORK ACCEPT is output & displayed on the WORK ACCEPT LED.
To use the WORK count function, program the number of desired Acceptable fastenings you
wish in PARM. 1-16 D-NO. 74 (0 – 99 max.). Only acceptable fastenings will be counted
towards the WORK ACCEPT. If a fastening cannot be accepted during the course of the
work piece fastening, the WORK ACCEPT will NOT light, and the input WORK OK RESET
(input B7 on TB1 terminal) will have to be activated before starting the next work piece.
Once the WORK ACCEPT has been activated, it will automatically be reset upon the next
start signal.

Page 6-26
FEC Fusion Operations Manual Chapter 6: Fastening Instructions (Rev.3)

6.6.6 Torque Inhibit

The Torque Inhibit function is used to ignore high torque spikes during initial starting of the motor or
fastening process. Under normal fastening operations, peak torque will stop the fastening process (if
Standard Torque is reached). This may not be desirable for applications with high starting torque and
lower fastening torque. Applications such as self tapping screws, nylok nuts, crushed fasteners, and
application with high starting inertia may require this function.

Torque Inhibit is set by the number of revolutions that is required to be “ignored” during the process.
The Torque Inhibit Limit is a torque limit used as protection in case the amount of torque monitored
during the Torque Inhibit Revolution is too high. If this torque limit is hit during the Torque Inhibit pro-
cess, then the spindle will stop and an Abnormal is output.

Speed

Freerun
Revolutions

Freerun
Speed

Initial Time

Torque Inhibit
Slow Down
Revolutions
Speed
Initial
Speed Torque
Speed

1st Time Final

Time

Fig. 6-6-9 Torque Inhibit Function

WARNING: The Torque Inhibit Rev setting should be set as low as possible for the intended
application to avoid ignoring torque readings as the fastener approaches the seating point. If
the fastener seats and the system is still in Torque Inhibit mode, possible fastener/part and/or
system damage may occur.

Page 6-27
Chapter 6: Fastening Instructions

(Blank Page)

Page 6-28
FUSION Operations Manual Chapter 7: System Operations (Rev.3a)

Chapter 7: System Operations

Page 7-1
Chapter 7: System Operations

7.1 FUSION Display and Programming unit operation.

The FUSION system can be programmed and monitored using the AFC Software package or
through use of the keypad and LED display on the front panel. While the AFC software of-
fers an easy to use Windows based software, especially for multiples of spindles, the keypad
and display offer an economical alternative.

FIG. 7-1 Operational controls and indicators

7.1.1 Manual Fastening controls.

 START
The Start switch for the FUSION Controller is located on the Handheld tool. This Trigger-
switch initiates the fastening cycle. When partially depressed, the tool will run in a slow start
speed; until the trigger is fully depressed, until the trigger is released, or until the fastening
cycle is complete. When the trigger is fully depressed the tool will operate as programmed,
completing each speed change step that has not elapsed.

(Alternative Start input available though use of PLC inputs on terminal TB1)

 REVERSE
The Reverse switch for the FUSION Controller is located on the Handheld tool. This push-
button switch enables Reverse/back-out operations. When depressed, the Tool LED display
will flash to indicate Reverse/back-out mode selection. Depressing the Start trigger switch,
while in Reverse/back-out mode, will cause the tool to run the opposite direction of the Fas-
tening operation

(Alternative Reverse input available though use of PLC inputs on terminal TB1)

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

 CAL (Calibration).
Transducer calibration check push-button. Depress this push-button to obtain the CAL volt-
age level from the tool pre-amplifier. This level is compared to the data stored in memory.
The calibration voltage level is converted to the full-scale torque, according to the parameter
setting and is shown in the "DATA" display.

 RESET
Used to reset the FUSION controller unit. If this key is pressed during fastening, the process
will stop, and all the fastening data and output signals will be reset. At the same time, the Ze-
ro level of the torque transducer will be checked.

(Alternative Reset input available though use of PLC inputs on terminal TB1)

7.1.2 Fastening Indicators.

 ACCEPT LED (Green).

Solid Light indicates when the fastening results are within the defined limits.
Flashing Light indicates when the fastening results, for a batch fastening step, are within the
defined limits. The Batch fastening count will be displayed in the [COUNT / D-NO] display.

 WORK ACCEPT LED (Green).

Indicates when the fastening results for a batch fastening operation are within the defined lim-
its for all steps of the batch operation. For Batch count settings of 1 or more (99max.).

 REJECT LED (Red).

Indicates when the fastening results are out the defined limits, or that an Abnormal has oc-
curred (refer to Display for Abnormal code)

 TORQUE (Yellow).
Indicates when the Data Display is set for viewing of Fastening Peak Torque. [COUNT / D-
NO] is set to _0 while in the Run State.

 ANGLE (Yellow).
Indicates when the Data Display is set for viewing of Final Angle. [COUNT / D-NO] is set to
_1 while in the Run State.

7.1.3 Fastening Preset / Result displays.

 [COUNT/D-NO] Data number indicator (2 digits).

Indicates the Display mode and data type (number)
Indicates the Current Fastening count during a Batch count fastening operation. Count reset
performed via PLC input
Displays the Unit number during power up (U.01 ~ U.32)

 [DATA] Data value indicator (4 digits).

During the Run State, the display mainly shows the results of fastening, abnormalities, preset
values, etc.

. During the Bypass State, the controller displays and allows setting of all available parame-
ter presets.

 [WORK] Parameter number/Abnormal number indicator (2 digits).

Display for the parameter number of the last fastening. Also displays an abnormal code dur-
ing an abnormal condition. When the CAL switch is pressed, "E" is shown if the FULL-SCALE
preset value is missing or a wrong tool is connected (Refer to Chapter 9).

Page 7-3
Chapter 7: System Operations

Abnormal “A9” Display Parameter No. 1 Cal “E” Fault

Calibration not set after pressing CAL
switch or tool number mis-match

FIG. 7-1-3 Fastening Displays

7.1.4 Fastening Presetting / Result Display Controls

 MODE button
Used to change modes while in the Run state. (Refer to 7.2)
Used to move the cursor while in the Bypass (program) state. (Refer to 7.3)

 SET button
Used to enter the data in edit mode, and to confirm data setting change.

 MODE and SET buttons Depressed simultaneously

Switches unit between Run state and Bypass (program) State.

 [] and [] Cursor key (Vertical arrows).

Used to scroll through available data preset items. (D-NO)
Used to change display data values. (DATA)
Used as YES/NO acknowledge for Tool type and Torque unit changes and for confirmation of
the Parameter copy function. (Fig 7-3-6)

 [] and [] Cursor key (Horizontal arrows).

Used to scroll through available (16) parameter numbers. [WORK]
Selection of [WORK] # is for actual Fastening Operational Selection, that the Tool will per-
form while in Run State.
Arrows are used to select the appropriate Parameter for preset verification and changing
while in the Bypass State.
(Alternative WORK input while in Run State available though use of PLC inputs.)

(See Section 7.2.5, item 5 for more information on set-up selection using the Terminal I/O
(TB1) method for Work Selection)

Page 7-4
FUSION Operations Manual Chapter 7: System Operations (Rev.3a)

7.2 Run State Modes.

The FUSION system has two operational states that are controlled by depressing the
“MODE” and “SET” Buttons, on the front of the Controller, simultaneously, or by the PLC By-
pass input. The operational modes available in the Run State are identified below. Under
this condition, (after Power-up) the “MODE” and “SET” Buttons have not been pressed simul-
taneously, and the BYPASS external signal is not active. During the Run State, the display
mainly shows the results of fastening, abnormalities, preset values, etc.

7.2.1 Display indication modes.

Three modes can be selected while in the Run State by pressing the MODE push-button. By
using the [] and [] keys to change the D-NO selected, the DATA display contents may be
varied up or down. The displays will remain blank, and mode selection will be disabled while
the nutrunner is active. (BUSY) If an Abnormal condition occurs, the display will automati-
cally change to the Abnormal (Abn) display mode, displaying the abnormal code and sub-
code.

While the Controller Unit is in cycle it will display

the cycle status. The display will indicate where
the cycle is in its fastening sequence. The fol-
lowing abbreviations will be displayed in the data
display;
In : Initial Speed 1E : 1st Step End,2nd next
Fr : Freerun Speed 2d : 2nd Step End
SL : Slowdown Speed 2E : 2nd Step End,3rd next
Tq : Torque Speed 3d : 3rd Step
Lo: Varispeed High Speed
UA: Varispeed Final Speed
r1: Reverse

The Fastening results display mode is active

when the D-No displays one digit in the right hand
location, and one, two or three dashes in the left
hand location. The results details can be scrolled
by using the [] and [] keys to change the D-No.
This mode does not function while the Nutrunner
is Busy. Refer to 7.2.3

The Parameter display mode is active when the

D-No displays digits in both the right and left hand
locations. The parameter data can be scrolled
by using the [] and [] keys to change D-No.
Refer to 7.2.4

The Real time display mode is active when one

digit is active in the right hand display only.
When the power is turned on, the default display
mode is the REAL TIME display mode. The dis-
play contents can be scrolled by using the [] and
[] keys to change D-NO. Refer to 7.2.2
FIG. 7-2-1 Run State Display Modes

The Controller unit is in Status display mode when no digits are displayed. The STATUS display
indicates if an abnormal condition occurs or if an emergency stop has halted the system.

Page 7-5
Chapter 7: System Operations

7.2.2 Real-time display indication mode. D-NO：One digit

While the mode is in Real time display mode, [COUNT/D-NO] displays 0 ~8. You can
choose the desired type of data by pressing the [] and [] keys to change the [COUNT/D-
NO] (data number). The indicator will display the following data in the "DATA" area for the
selected D-No. The display will remain showing the parameter number.

The Controller will be in Real time display mode immediately after powering up the unit.
Once a fastening cycle has been performed the Controller will switch to Fastening results
display mode. Real time display mode can be selected at any time, while in the RUN
state by pressing the MODE push-button. Button operation during the real-time mode is in-
dicated in Fig. 7-2-2.

D-No DATA
0 Torque value.
1 Torque voltage.
2 Peak Torque (maximum hold).
3 Rotated Angle.
Thermal Overload Value 0-
4
100
5 Current Sensor Value
Start Trigger Level
6
127-255
Reverse Button Level 127-
7
255
8 FEC specific data
Torque value: The real-time torque value from the
torque transducer is displayed.

Torque voltage: The real-time torque signal voltage

from the torque transducer is displayed.

Peak torque: The peak torque, measured since the

last time the display mode was switched to Real
Time Display Mode. (This is reset when the display
mode is changed from the Real Time Display
Mode.)
Lock Spindle Mode : When [SET] is depressed
during this display, the motor is locked for up to one
minute allowing the spindle to be checked with a
torque wrench while displaying the reaction torque
on the data display. Press RESET to unlock the Mo-
tor before one minute has expired. WARNING: Do
not repeat this procedure repetitively or the mo-
tor will overheat.

Angle (rotation): The real-time angle of rotation of

the tool output shaft (in the fastening direction CW),
measured since the last time the display mode was
switched to Real Time Display Mode.
(-1999 to 9999)

Thermal Overload Level: Between 0 -100

(100=overload)
FIG. 7-2-2 Real time display selection

Page 7-6
FUSION Operations Manual Chapter 7: System Operations (Rev.3a)

D-NO: Left digit

7.2.3 Fastening Results Display Mode.
In Fastening results display mode (when [COUNT/D-NO] shows _0 ~ ), data can be ob-
tained by pressing the [] and [] keys to scroll the [COUNT/D-NO] until the desired DATA
item is displayed. The following information will be displayed in the [DATA] display section
for the displayed [D-NO]:

D-No DATA
_0 PEAK TORQUE.
_1 FINAL ANGLE
_2 1ST TORQUE RATE
_3 2ND TORQUE RATE.
_4 1ST STEP TIME.
_5 FINAL STEP TIME.
_6 CYCLE TIME
_7 FASTENING MODE.
_8 3RD TORQUE RATE
_9 NOT USED
0 FASTENING MODE.
=1 FASTENING STEPS
=2 NOT USED
=3 SELF CHECK (ON: enabled, OFF: disabled)
=4 REVERSE FLAG (ON:Reversed, OFF: Not Reversed
CAUSE OF FASTENING STOP:
0: RESET / NO DATA / AFTER REVERSE.
1: ABNORMAL SIGNAL.
=5 2: BYPASS SIGNAL.
3: STOP SIGNAL.
4: REJECT.
5: ACCEPT.
=6 TORQUE JUDGE tq H/L (FINAL) H/L (PEAK)
=7 ANGLE JUDGE AN H/L
RATE JUDGE r H/L (1ST) H/L (2ND)
=8
H/L (3RD)
=9 TIME JUDGE ti H/L (1ST) H/L (FINAL)
0 1ST INCREMENT TORQUE.
1 2ND INCREMENT TORQUE.
2 1ST FINAL TORQUE
3 1ST PEAK TORQUE.
4 FINAL TORQUE.
5 ANGLE AT PEAK TORQUE
6 PEAK CURRENT

FIG. 7-2-3 Fastening results display selection

Page 7-7
Chapter 7: System Operations

D-NO: Two digits

7.2.4 Parameter Display Mode
The FUSION system can store up to 16 different sets of parameters that can be selected for fastening
operations via the [] and [] keys (Horizontal arrows) or by PLC input signals WORK SELECT 0 ~
3 (see section 4.7.2.) In addition to parameter 1 ~ 16 there is a PARAMETER 0 that contains con-
figuration data common to all parameters.

Parameter display mode displays the preset values programmed in the CONTROLLER unit for fas-
tening operation. When parameter display mode is enabled, the [COUNT/D-NO] display will show 2
digits (00-73) representing the preset data number. The [DATA] display will show the corresponding
preset data value and the parameter display will indicate the parameter number (from 0 ~ 16). Use
the [] and [] keys to change the preset data number [D-NO]. If the [COUNT/D-NO] display is
showing the number 74 of the parameter number 1, pressing the [] key will change the [COUNT/D-
NO] display to the number 00 of the parameter number 2.

You can verify the fastening parameters by pressing the [] and [] keys at any time. However, it is
not possible to alter these settings in the Run state.

Note: Representation only, not actual data

Parameter No.00
System Parameter

00: Torque Unit

01: NR Version
02: Amplifier Version
03: Function Version
04: External Gear Ratio
～

20: Tool No. Parameter No.16

Parameter No.15
Parameter No.14

Parameter No.03
Parameter No.02
Parameter No.01

00: Fastening Mode

10: Calibration torque
11: Peak Low Torque
12: Peak High Torque
13: Standard Torque
～

96: Sequence Stage 6

97: Sequence Stage 7
98: Sequence Stage 8

FIG. 7-2-4a Parameter number selection

Page 7-8
FUSION Operations Manual Chapter 7: System Operations (Rev.3a)

7.2.5 Parameter Data List & Explanation

ITEM DATA SETTING WORK D- No DATA
VALUE No.
0 00 TORQUE UNIT #. 0: Nm
0 01 ROM VERSION (Not adjustable) 1: Kg.m
System
0 02 AMPLIFIER VERSION (Not adjustable) 2: Kgcm
0 03 FASTENING FUNCTION VERSION (1.03 for FEC) See Pg 7-12 3: Ft lb
0 04 External gear ratio 0.3 ~ 3.00
0 05 Gear Head Type
0 08 See Pg 7-13
Fastening Curve Storage (After ver. 5.17)
0 10 TOOL # (not adjustable) 4: in lb
0 11 TOOL CAL TORQUE.
Tool Data 0 12 CAL. VOLTAGE
0 13 ZERO TORQUE VOLTAGE
0 14 PULSES PER DEGREE
0 15 MOTOR TYPE
(This section is
0 16 TRANSMISSION RATIO
factory set and
cannot be 0 17 ROTATE CW=0 / CCW=1
changed) 0 18 CCW TQ. CAL. VOLTAGE
0 19 TOOL SERIAL # (1ST 4 DIGITS)
0 1A TOOL SERIAL # (2ND 4 DIGITS)
0 1b Tool Cycle count Upper 4 digit
0 1c Tool Cycle count Lower 4 digit
Tool type 0 20 TOOL # See List on next pages
0 21 Start switch trigger level 10 Change to 100 to disable
0 22 Start switch High Speed level 40 Change to 100 to disable
0 23 CW/CCW switch trigger level 20 Change to 100 to disable
0 24 Switch setup (Factory setup) 67
switch
Tool Info 0 25 Switch setup (Factory setup) 30
0 26 Switch setup (Factory setup) 1
0 27 Switch setup (Factory setup) 200
0 28 Switch setup (Factory setup) 5
0 29 Switch setup (Factory setup) 80
0 30 Year – ‘yyyy” example ‘2007’ See 7.5 for detail
Real Time Clock 0 31 Month & Date ‘mmdd example ‘0131’ = Jan. 31
(After ver. 2.20) 0 32 Hour & Minute ‘hhmm’ example ‘1759 = 17:59
0 33 Seconds ‘00ss’ example ‘0020’ = 20 seconds
RS232 Format 0 40 - 49 RS232 data alternate communication format See 4.8.4 for set-up
1~32 00 FASTENING MODE (METHOD + STEPS) See List on next pages
1~32 05 OPTION 1
1~32 06 OPTION 2- Torque Curve Store [0:enable, 1:disable]
1~32 10 FULL SCALE TORQUE (CAL TORQUE) +/- 20%
1~32 11 PEAK TORQUE LOW LIMIT
1~32 12 PEAK TORQUE HIGH LIMIT Max. Full Scale x 1.1
1~32 13 STANDARD (STD) TORQUE
1~32 14 SPEED CHANGE TORQUE
1~32 15 1ST TORQUE
Torque
1~32 16 SNUG TORQUE
1~32 17 THRESHOLD (THR) TORQUE
1~32 18 CROSSOVER (CROS) TORQUE
1~32 19 TORQUE INHIBIT LIMIT Max. Full Scale x 1.1
1~32 1A Not Used
1~32 1B BREAKAWAY TORQUE LIMIT Max. Full Scale x 1.1
1~32 1C FINAL TORQUE LOW LIMIT
1~32 1D FINAL TORQUE HIGH LIMIT Max. Full Scale x 1.1
1~32 1E 2ND RATE START TORQUE Max. Full Scale x 1.1
1~32 20 ANGLE LOW LIMIT
1~32 21 ANGLE HIGH LIMIT Max. 9999 deg
1~32 22 STANDARD (STD) ANGLE Max. 9999 deg
Angle 23
1~32 1ST ANGLE Max. 9999 deg
1~32 24 CROSSOVER ANGLE Max. 9999 deg
1~32 25 ANGLE CORRECTION 0-99 deg.
1~32 26 DIFF ANGLE (-)
1~32 27 DIFF ANGLE (+)
1~32 30 1ST TORQUE RATE LOW LIMIT For all Rate settings
1~32 31 1ST TORQUE RATE HIGH LIMIT Max. “5000”
Rate
1~32 32 2ND TORQUE RATE LOW LIMIT Setting “0000” in any of
1~32 33 2ND TORQUE RATE HIGH LIMIT The LOW rate settings
1~32 34 3RD TORQUE RATE HIGH LIMIT disables low rate judgment
1~32 35 3RD TORQUE RATE HIGH LIMIT
(Continued on next page)

Page 7-9
Chapter 7: System Operations

Time 1~32 40 INITIAL TIME Max. 999.9 sec

1~32 41 1ST STEP TIME LIMIT Max. 999.9 sec
1~32 42 FINAL TIME LIMIT Max. 300.0 sec
1~32 43 FIRST TIME LOW LIMIT Max. 999.9 sec
1~32 44 FINAL TIME LOW LIMIT Max. 300.0 sec
1~32 45 RAMP UP TIME 0.0 – 9.9 sec
(Consult FEC be- 1~32 46 RAMP DOWN TIME 0.0 – 9.9 sec
fore changing 1~32 47 REVERSE RAMP UP TIME 0.0 – 9.9 sec
these items) 1~32 48 TORQUE RECOVERY PULSES 0.0 – 50 pulses
1~32 50 INITIAL SPEED
1~32 51 FREE RUN SPEED
1~32 52 SLOW DOWN SPEED
Speed 1~32 53 TORQUE SPEED
1~32 54 REVERSE 1 SPEED
1~32 55 RECOVERY PULSE SPEED
1~32 56 Not Used
1~32 60 FREE RUN REVOLUTIONS Max. 99.9
1~32 61 TORQUE INHIBIT REVOLUTIONS Max. 99.9
1~32 62 Not Used
Revolutions 1~32 63 REVERSE 2 REVOLUTIONS
1~32 64 REVERSE 3 REVOLUTIONS
1~32 68 Not used
1~32 69 Not used
1~32 70 FULL SCALE CURRENT VALUE 100%
1~32 71 HIGH CURRENT LIMIT 100%
Current 1~32 72 LOW CURRENT LIMIT 0%
1~32 73 FASTENING CURRENT LIMIT 100%
1~32 74 Accept / Batch Count 0-99
1~32 80 CW Stop Limit Angle 30 (Set to 180 to disable)
1~32 81 CW Swing Pause Angle 1
1~32 82 CW Servo Lock Time 5
1~32 83 CW Motor Restart Time 80
Pistol Tool
1~32 86 CCW Stop Limit Angle 30 (Set to 180 to disable)
1~32 87 CCW Swing Pause Angle 1
1~32 88 Angle Head Torque Variation 5
1~32 89 CCW Motor Restart Time 30
1~32 90 Sequence Operational Mode
1~32 91 Sequence Stage 1
1~32 92 Sequence Stage 2
1~32 93 Sequence Stage 3
Sequence 1~32 94 Sequence Stage 4
1~32 95 Sequence Stage 5
1~32 96 Sequence Stage 6
1~32 97 Sequence Stage 7
1~32 98 Sequence Stage 8

Page 7-10
FUSION Operations Manual Chapter 7: System Operations (Rev.3a)

1) Display operation for Parameter selection

Parameter 1-32

Last Data at Parameter 32 (Parm. 16 shown)

FIG. 7-2-5 Parameter display D-No selection

Page 7-11
Chapter 7: System Operations

System “D-No” Explanation

2) Torque Unit [WORK]-00, [D-No]-00
00: Nm 01: Kgm 02:Kgcm 03:Ft. Lb. 04:In.Lb.

3) ROM Version [WORK]-00, [D-No]-01

Displays Controller ROM Version (Not adjustable)

4) Amplifier Version [WORK]-00, [D-No]-02

Displays Servo Version (Not adjustable)

5) Fastening Function Version [WORK]-00, [D-No]-03.

The Fastening Function Version is entered into [WORK]-00, [D-No]-03.
Enter the Set no. which corresponds to the Function Version desired from the table below.
Alternate Fastening Function mode selection
An alternate function mode exists which allows setting of additional functions for the fusion controller.
The function version that is set in the controller will be displayed when viewing (Work 00, D-No-03).
The last two digits of the function version correspond to the two digits to the right of “18” in the table
below.
(Ex.- Display “1.03” corresponds to set-up of 1803)

To make a change (when the function version is being displayed D-No 03):
1. Depress [SET] and [MODE] buttons at the same time (PROGRAM mode)
2. Depress [MODE] button (Display should show Work 00 D-No – 03)
3. Depress [SET] button
4. The cursor will blink on the leftmost digit
5. Use the [] and [] buttons to enter “18xx” whereas the xx is the desired setting. (18 must always be
entered as the leftmost digits)
6. Depress the [SET] button to enter the change into memory
7. “CHNG – NO” will appear in the display, use the [] and [] buttons to change NO to YES in the display
8. Depress [SET] to confirm and enter the change to memory
9. Depress [SET] and [MODE] buttons at the same time (return to RUN mode)
10. System MUST be re-booted in order to change the function mode.

Shown below are the available options for setting of this Data No.;
Set No. AFC S/W Comm. Speed Tool Type
Work Select Method
1800 – Comm. Speed 38400bps : Rev Sw – Slide/twist type : Work Select from Terminal TB1
1801 – Comm. Speed 38400bps : Rev Sw – Slide/twist type : Work Select from Front Panel
1802 – Comm. Speed 38400bps : Rev Switch - PB type : Work Select from Terminal TB1
1803 * – Comm. Speed 38400bps : Rev Switch - PB type : Work Select from Front Panel
1810 – Comm. Speed 9600bps : Rev Sw – Slide/twist type : Work Select from Terminal TB1
1811 – Comm. Speed 9600bps : Rev Sw – Slide/twist type : Work Select from Front Panel
1812 – Comm. Speed 9600bps : Rev Switch - PB type : Work Select from Terminal TB1
1813 – Comm. Speed 9600bps : Rev Switch - PB type : Work Select from Front Panel
*Denotes Default setting
Note: Adding (4) to any Set No. above, sets the Fastening function in “DDK Mode”- Changing the RS232 data output protocol
as listed in [4.8.5 Rear Panel RS232 Alternate Communication Protocol].

The effect of the Work Select Method;

*Select from Terminal TB1: (Note: This MUST be configured when using a Fieldbus interface)
o Work Select must take place from the TB1 Terminal located on the controller backpanel
o Batch OK reset input MUST be applied for clearing cycle count
**Select from Front Panel :
o Work Select can take place from the Controller front “WORK” button
o Batch OK reset input can be applied for clearing cycle count or cleared automatically at
the next START (upon Accept)
NOTE: If Fieldbus is installed, changing setup to “Work Select from Front Panel” will disable
the Fieldbus board and the Work Select can only be selected from Front Panel.

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FUSION Operations Manual Chapter 7: System Operations (Rev.3a)

6) External gear ratio [WORK]-00, [D-No]-04

Used to enter gear ratio for EXTERNAL gearing (0.3 – 3.000)

Default : 1.000 (1:1 gear ratio)

Note: If external gearing is used, be sure to set the proper gear ratio if different than 1:1 or ANGLE
count could be wrong.

7) Torque Curve Storage setup [WORK]-0 [D-No]-08

Standard setting: 0000 Version V5.17 or later
SET UP RANGE: 0000～3999
Setup torque curve storage as below;
３９９９
Number of ACCEPT 0-Maximum savable number
Set 999 if ALL are required.

Number of Torque Curve data ０：１００° １：２００° ２：４００° ３：６００°

Maximum savable number １０５ ７０ ４２ ３０

Example: When 1: 200° is chosen, and the judgment of 35 of the 70 savable fastening’s were
REJECT, then only 35 Accepted torque curves will be saved.
When setting 999 as the number(savable ACCEPT), 70 Accepted torque curves will be saved.
The stored data is updated by the latest data when it reaches the upper limit.
※ Data is cleared when power is turned off and/or changing the setup.

“Curve SAVE can be set up per each parameter number.

[WORK 1-32] [D-No. 06] (Data No. 6 Enable/Disable Save)

Page 7-13
 Chapter 7: System Operations

8) Tool Type Data number entry [WORK]-0 [D-No]-20.

The tool number is entered into [WORK]-0 [D-No]-20 and must be set correctly to match the
attached tool or an abnormal will result. (Tool Type Error) Enter the Tool Number which
corresponds to the tool being connected to the CONTROLLER Unit.

Note: When using the AFC software to program the controller, this tool number is automati-
cally set to the tool chosen in the software set-up.
Max.
Tool Max. RPM Min. RPM Max. Rate Weight
Tool Type Torque Unit
No. [Nm]
[rpm] [rpm] [Nm/deg] [kg]

4 HFT-015M50-A 15.00 1090 1 5.000 1.6 HFC-EC-16

6 HFT-015M80-S 15.00 1895 1 5.000 1.4 HFC-EC-16
5 HFT-025M80-A 25.00 1218 1 5.000 1.7 HFC-EC-16
12 HFT-040M80-A 40.00 735 1 5.000 1.7 HFC-EC-16
13 HFT-015M50-A1 15.00 1215 1 5.000 1.6 HFC-EC-16
15 HFT-025M80-A1 25.00 1070 1 5.000 1.7 HFC-EC-16
16 HFT-040M80-A1 40.00 648 1 5.000 1.9 HFC-EC-16
7 HFT-060M80-A 60.0 446 1 5.000 1.95 HFC-EC-16
19 HFT-080M80-A 80.0 330 1 50.00 3.7 HFC-EC-16
8 HFT-130M80-A 130.0 203 1 50.00 3.8 HFC-EC-16
14 HFT-015M80-S1 15.00 1600 1 5.000 1.4 HFC-EC-16
18 HFT-040M80-S 40.00 694 1 5.000 1.4 HFC-EC-16
11 HFT-040M80-T 40.00 694 1 5.000 3.1 HFC-EC-16
27 HFT-015M50-P1 15.00 1190 1 5.000 1.1 HFC-EC-16C
30 HFT-035M80-P1 35.00 778 1 5.000 1.37 HFC-EC-16C
21 HFT-010M50-S1 10.00 1800 1 5.000 1.3 HFC-EC-16
22 HFT-025M80-S1 25.00 1000 1 5.000 1.43 HFC-EC-16
29 HFT-055M80-S 55.00 508 1 5.000 3.0 HFC-EC-16
26 HFT-080M80-S 80.00 303 1 5.000 3.0 HFC-EC-16
20 HFT-015M50-P 15.00 1000 1 5.000 1.35 HFC-EC-16
3 HFT-060M80-T 60.00 420 1 5.000 HFC-EC-16
25 HFT-060M81-P 60.00 582 1 5.000 HFC-EC-16
17 HFT-015M80-A 15.00 1215 1 5.000 HFC-EC-16
10 HFT-040M80-L 40.00 805 1 5.000 HFC-EC-16
31 HFT-030M80-P1D 30.00 980 1 5.000 1.54 HFC-EC-16

Note: The list above contains the tool numbers for Standard tools. Tools in GREEN are
special and no longer used.

Page 7-14
FUSION Operations Manual Chapter 7: System Operations (Rev.3a)

9) Fastening Mode and Fastening Steps [WORK]-1~32, [D-No]-00.

The fastening mode is entered into [WORK]-1~16, [D-No]-00. Enter the Set Value number
which corresponds to the fastening method desired. The figure below describes the code
for the four numbers and how they relate to the type of fastening method and steps preferred.
Zero’s will display as blank (off) digits if there is no number (1,2 or 3) preceding them. (Ex-
ample: 0020 will display as _ _ 20 or 0121 will display as _121) When entering a new fas-
tening method, all four digits should be entered and SET.

[Fastening Method]
0 = Torque Control
1 = Angle Control

[Fastening Steps]
0 or BLANK = 1 Step w/ continuous snug Tq. angle count start*
1 = 1 Step Fastening
2 = 2 Step Fastening – Stops at 1st Tq.
3 = 3 Step Fastening – Stops at 1st and CROS Tq.

[Fastening Direction]
0 or BLANK = CW (clockwise) Fastening
1 = CCW (counterclockwise) Fastening

[Reverse Operation]
0 or BLANK = Not Used
1 = Slow Reverse Start (1.5 sec. @ 20 RPM)
2 = Varispeed
3 = Both 1 & 2

*Normal Snug angle count vs. Continuous Snug Tq. Angle Count

Angle count with normal SNUG mode (XX11)

Angle value is not counted up when torque is below SNUG TORQUE.
[In case Standard Angle is 90 °]
50° 40 °

SNUGTQ

Angle count using continuous SNUG TQ angle count Method (XX01)

Once SNUG TORQUE is reached, angle value is counted up regardless of the torque v
alue.
[In case Standard Angle is 90 °]
90 °

SNUG TQ

Page 7-15
Chapter 7: System Operations

[Fastening][Torque][Angle][Rate][Time][Speed][Revolutions][Current] [Pistol] Parameter

Parameter No.01 ~32

Data No.05 Fastening Option 1

0100: Enables judgment of difference of high and low angle.
0000:QL OK SIGNAL LEVEL ON (FASTENING END ~ NEXT START)
2000:QL OK SIGNAL PULSE ON (FASTENING END ~ for 300ms)
1000: REDUCE FASTENING REACTION “WORK SELECT” INPUT WILL RESET “TOTAL
OK” AFTER BATCH COUNT IS REACHED
COUNT=5

START

OK

TOTAL OK

COUNT/D-No C1 C2 C3 C4 C5 C1
WORK ACCEPT ON

ACCEPT ON ACCEPT OFF

* When combining multiple functions, add the data numbers in hex.
Ex.) 0400 + 0002 + 0004 = 0406

Data No.06 Fastening Option 2

0000: No Torque Curve Storage

＊ ＊ ＊ ＊

0:enable 1:disable

Page 7-16
FUSION Operations Manual Chapter 7: System Operations (Rev.3a)

Data No.10 Calibration torque

The calibration value is set according to the tool type (capacity). However, depending on the applica-
tion characteristics or the prevailing torque generated external to the tool output shaft, the value of the
applied torque and the torque display by the Fusion unit may mismatch. In this case, it is possible
to adjust the FULL SCALE TORQUE (CAL) value, so the displayed torque matches the installation
torque registered by an external torque transducer (Master).

The CAL value can be adjusted up to %of the FULL SCALE TORQUE value.

Example:
Consider the HFT-080M80-A tool. Nominal CAL value = 8.0 Kg.m.
Range of adjustment: from 6.2 Kg.m to 9.4 Kg.m.

Use the following formula on a collection of at least 10 fastenings when a calibration correc-
tion is necessary:

New CAL value = Master transducer mean/ FEC transducer mean x Existing CAL val-
ue

Note: The torque unit (Kgm, Nm, Ft.Lbs, etc.) must be the same for all terms. Do not
mix torque units in calculation or errors will result.

If the new CAL value is out of the adjustable range, the [Err] message will be displayed.

Example.
Tool Full Scale value (EXISTING CAL) is 78.4 Nm.
STD torque is 49.0 Nm.
Master transducer mean for 10 piece run is measuring only 47.5 Nm.
FEC transducer mean for 10 piece run is measuring 49.0 Nm.

The new CAL value is obtained as follows:

(47.5/49.0 x 78.4) = 76.0

The FULL SCALE TORQUE (CAL) value must be corrected to 76.0 Nm and en-
tered at [PARM} 1~16 [D-NO] 10.

Data No.11 Peak Torque Low Limit [Nm, Kgm...]

Data No.12 Peak Torque High Limit Nm, Kgm...]
Setting range: 0 ~ [10: Calibration torque] × 1.1
Setting points for the High and Low limits of the Peak Fastening Torque. If the High or Low limits are
exceeded the operation is rejected.

Data No.13 Standard Torque [Nm, Kgm...]

Setting range: 0 ~ [10: Calibration torque] × 1.0
Set point of the Fastening Standard (Target) Torque. This function is only available when Torque
method is selected for [00: Fastening Mode].

Page 7-17
Chapter 7: System Operations

Data No.14 Speed Change Torque [Nm, Kgm...]

Setting range: 0 ~ [10: Calibration torque] × 1.0
Set the torque value that switches slow down speed to torque speed.
SPEED
60 Freerun Revolutions
Fastening
40 Initial Time

51 Freerun
Speed

52 Slowdown Speed
63 Reverse Revolutions

50 Initial Speed
53 Torque Speed
15 1st torque
23 1st angle

14 Speed Change Torque

54 Reverse Speed

Even if Freerun Revolutions are not achieved, the speed will change to
Slow Down Speed when Speed Change Torque is detected.

Data No.15 1ST Torque [Nm, Kgm...] Setting range: 0 ~ [10: Calibration torque] × 1.0
Data No.23 1ST Angle [deg] Setting range: 0 ~ 9999
1ST stop / synchronization point for multiple step fastening operations.
End point for 1st torque rate calculation. [17: Threshold Torque is beginning]
Shift point for changing to Torque Speed [53: Torque Speed]
End of 1st Time and beginning of Final Time

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FUSION Operations Manual Chapter 7: System Operations (Rev.3a)

Data No.16 SNUG Torque [Nm, Kgm...]

Setting range: 0 ~ [10: Calibration torque] × 1.0
Snug Torque is only available as a control start point when [00: Fastening Mode] is set
for Angle Control method.

Angle (of rotation) Judgment is conducted from Snug Torque to Fastening end when this
torque value is achieved, for all fastening methods. The Angle when this torque value is
achieved is considered the 0° start point for judgment.

(Example.) When [16: SNUG Torque] is 10Nm, [22: Standard Angle] is 90°.
Torque

Judgment torque

16 SNUG
10Nm

Angle
90°

22 Standard Angle

All values related to Angles are referenced from [16:SNUG Torque]

Data No.17 Threshold Torque [Nm, Kgm...]

Setting range: 0 ~ [10: Calibration torque] × 1.0
Start point for 1st Torque Rate monitoring

Torque

15 1ST
31 Rate 1 High Limit
30 Rate 1 Low Limit

17 Threshold

Angle

If 1st Torque Rate monitoring is not required, [17:Threshold Torque] should be set
the same or higher than [10: Calibration Torque]

Page 7-19
Chapter 7: System Operations

Data No.18 CROS Torque [Nm, Kgm...]

Setting range: 0 ~ [10: Calibration torque] × 1.0
2nd stop / synchronization point for multiple step fastening operations.
End point for 2nd torque rate calculation. [1E: 2nd Rate Start Torque is beginning]
Start point for 3rd Torque Rate calculation. [Fastening End is the stop point]

Torque

13 Standard
35 Rate 3 High Limit
34 Rate 3 Low Limit

18 CROS

Angle

If 3rdt Torque Rate monitoring is not required, [18:CROS Torque] should be set the
same or higher than [10: Calibration Torque]

Data No.24 CROS Angle [deg] (NOT USED as standard function)

Setting range: 0 ~ 9999
2nd stop / synchronization point for multiple step fastening operations.
End point for 2nd torque rate calculation. [1E: 2nd Rate Start Torque or 26: 2nd Rate Start Angle
is the beginning]
Start point for 3rd Torque Rate calculation. [Fastening End is the stop point]

Torque

35 Rate 3 High Limit

34 Rate 3 Low Limit

Angle
24 CROS 22 Standard

Data No.19 Torque Inhibit Limit [Nm, Kgm...]

Setting range: 0 ~ [10: Calibration torque] × 1.1
Limit for ignoring the Torque value sensed during fastening start due to inertia. When the ini-
tial Torque exceeds the Torque Inhibit Limit during [61: Torque Inhibit Revolutions] an
ABNORMAL will be generated and fastening will end.

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FUSION Operations Manual Chapter 7: System Operations (Rev.3a)

Data No.1B Breakaway Torque Limit [Nm, Kgm...]

Setting range: 0 ~ [10: Calibration torque] × 1.1
When this torque is exceeded during Reverse 2 or 3 operations, an Abnormal will be
generated that will stop the operation.

Data No.1C Final Low Torque [Nm, Kgm...]

Data No.1D Final High Torque [Nm, Kgm...]
Setting range: 0 ~ [10: Calibration torque] × 1.1
For [Angle Method], sets the High and Low limits for Torque at the point that the final Fastening Angle
is achieved.
For [Torque Method], during Torque Recovery, sets the High and Low limits for Torque at the
point that the final Fastening is completed.

Data No.1E 2ND Rate Start Torque [Nm, Kgm...]

Setting range: 0 ~ [10: Cal torque] × 1.0
Start point for 2nd Torque rate monitoring [Crossover is the end]

Torque

18 CROS
33 Rate 2 High Limit
32 Rate 2 Low Limit

1E 2ND

Angle
If 2nd Torque Rate monitoring is not required, [1E:2nd Rate Start Torque] should be
set the same or higher than [10: Calibration Torque]

Data No.26 2ND Rate Start Angle [deg] (NOT USED as standard function)
Setting range: 0 ~ 9999 degrees
Start point for 2nd Torque rate monitoring [CROS Torque/Angle is the end]

Torque

33 Rate 2 High Limit

32 Rate 2 Low Limit

Angle
26 2ND 24 CROS

Page 7-21
Chapter 7: System Operations

Data No.20 Low Angle [deg]

Data No.21 High Angle [deg]
Setting range: 0~9999
Sets the High and Low limits for Fastening Judgment Angle as measured from [16:SNUG
Torque] to Fastening End. If the High limit is reached the fastening operation will stop even if
the operation is not complete.

Data No.22 Standard Angle [deg]

Setting range: 0~9999
Sets the target Angle value for fastening as measured from [16:SNUG Torque].
This is only available when [00: Fastening Mode] is Angle Mode.

Data No.25 Correction Angle [deg]

Setting range: 0~99
Compensation value for when the Final Angle value of the equipment does not match the value
read from an external master device.
Normally, this value shall be set as 0.

Data No.30 1st Rate Low Limit [Nm/deg]

Data No.31 1st Rate High Limit [Nm/deg]
Setting range: 0~Tool type’s maximum torque rate
Sets the high and low limits for the Torque rate measured between the two points
[17:Threshold Torque] and [15:1ST Torque] or [23:1st Angle].
Judgment is conducted at the point when [15:1ST Torque] or [23:1st Angle] is achieved or when
Fastening ends, whichever occurs first.

Data No.32 2nd Rate Low Limit [Nm/deg]

Data No.33 2nd Rate High Limit [Nm/deg]
Setting range: 0~Tool type’s maximum torque rate
Sets the high and low limits for the Torque rate measured between the two points
[1E:2nd Rate Start Torque] or [26:2nd Rate Start Angle] and [18:CROS Torque] or
[24:CROS Angle].
Judgment is conducted at the point when the [18:CROS Torque] or [24:CROS Angle] is
reached or when Fastening ends, whichever occurs first.

Data No.34 3rd Rate Low Limit [Nm/deg]

Data No.35 3rd Rate High Limit [Nm/deg]
Setting range: 0~Tool type’s maximum torque rate
Sets the high and low limits for the Torque rate measured between the two points
[18:CROS Torque] or [24:CROS Angle] and Fastening End.

Data No.40 Initial Time [sec]

Setting range: 0 ~ 999.9
During initial time, the start of the fastening operation will be conducted at [50: Initial Speed]
When [40 Initial Time] is set as 0, the operation will start in [51: Freerun Speed]

Data No.41 1ST Time High Limit [sec]

Setting range: 0~999.9
Set the high time limit between the start of fastening and [15: 1ST Torque] or [23: 1ST Angle].
When this time elapses before reaching the target, the process is rejected.

Data No.42 Final Time High Limit [sec]

Setting range: 0~999.9
Set the high time limit between [15:1ST Torque] or [23: 1ST Angle] and Fastening end
When this time elapses before reaching the target, the process is rejected.

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FUSION Operations Manual Chapter 7: System Operations (Rev.3a)

Data No.43 1ST Time Low Limit [sec]

Setting range: 0~999.9
Set the low time limit between the start of fastening and [15: 1ST Torque] or [23: 1ST Angle].
When the target is reached before this time has expired the process is rejected.

Data No.44 Final Time Low Limit [sec]

Setting range: 0~999.9
Set the high time limit between [15:1ST Torque] or [23: 1ST Angle] and Fastening end
When the target is reached before this time has expired the process is rejected.

Data No.45 Ramp up Time [sec]

Setting range: 0~9.9
This is the time constant from when the fastening operation starts until when the speci-
fied speed is achieved.

Data No.46 Ramp Down Time [sec]

Setting range: 0~9.9
This is the time constant from when the fastening operation stops until when the speed becomes ze-
ro.

Data No.47 Reverse Ramp up Time [sec]

Setting range: 0~9.9
This is the time to increase rotation speed when conducting reverse operations.

Page 7-23
Chapter 7: System Operations

Data No.48 Torque Recovery Pulses

Setting range: 0~50 pulses
In Torque Method Fastening, after the fastening operation has reached the target torque, the torque
will be held at Standard Torque for this duration of pulses depending on the setup below.
Unless this function is required to compensate for relaxation in the fastener, set the torque recovery
value at 0.0 and do not perform the torque recovery process.

1 to 39
If set between 1-39, once STANDARD TORQUE is reached, the number set be-
tween 1-39 pulses will be performed

[STANDARD TORQUE]

Recovery Pulse 1 to 39 TIMES

40 to 50
If set 40 – 50, pulsing will start after reaching 1st Torque until Standard Torque is
achieved. The number of extra pulses once Standard Torque is reach is deter-
mined by the 1st digit of the 2 digit number.

(EXAMPLE)
When setting 43 , once first torque is reached, pulsing begins. 3 additional
pulses are performed once Standard Torque is reached. (The “3” in 43)

[STANDARD TORQUE]

[1ST TORQUE]

Recovery Pulse 3 TIMES

NOTE: Setting “50” will perform the maximum recovery pulses of 10 in this
mode. TORQUE SPEED should be set 60 -150rpm. Setting of 100-150rpm is
optimal. The function may become unusable over 150rpm.

Please set D-No.83 and D-No.89 to “30” when using the recovery pulse function.
Set D-No. 81 to”1”, D-No. 82 to “0” and D-No. 84 to “3”.
Caution This function may reduce fastening accuracy.

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FUSION Operations Manual Chapter 7: System Operations (Rev.3a)

Data No.50 Initial Speed [rpm]

Setting range: Tool’s minimum rpm ~ Tool’s maximum rpm
Sets the speed at which the tool will begin operations. Slower speeds are used to aid in fastener
engagement.

Data No.51 Freerun Speed [rpm]

Setting range: 1 ~ Tool’s maximum rpm
Sets the high speed rundown value used to drive a fastener to seating. Shifts to [52: Slow Down
Speed] when [14:Speed Change Torque] is sensed.

Data No.52 Slow Down Speed [rpm]

Setting range: 1 ~ Tool’s maximum rpm
Sets the speed used to draw the fastener down to [15: 1st Torque] or [23:1st Angle].
When [15: 1st Torque] or [23:1st Angle] is sensed the operation will switch to [53: Torque Speed]

Data No.53 Torque Speed [rpm]

Setting range: 1 ~ Tool’s maximum rpm
Sets the speed during final fastening operations.
*Slower torque speed results in better fastening accuracy.

Data No.54 Reverse Speed 1 [rpm]

Setting range: 1 ~ Tool’s maximum rpm
Reverse 1 operates when the manual reverse input is selected (TB1 Terminal) or when
the tool reverse switch is activated and the start trigger depressed.

Data No.55 Recovery Pulse Speed [rpm]

Setting range: Tool’s minimum rpm ~ Tool’s maximum rpm
Sets the speed during Recovery pulse operation.

Data No.60 Freerun Revolutions [rev]

Setting range: 0 ~ 99.9
Sets the number of revolutions the system will run from the beginning of the fastening operation until
[51:Freerun Speed] is no longer needed.
Override shifts to [52: Slow Down Speed] when [14:Speed Change Torque] is sensed.

Data No.61 Torque Inhibit Revolutions [rev]

Setting range: 0 ~ 99.9
For operation that require large starting torque.
Duration for ignoring the Torque value sensed at Fastening start due to inertia. When the initial
Torque exceeds the [19: Torque Inhibit Limit] during [61: Torque Inhibit Revolutions] an ABNORMAL
will be generated and fastening will end.

Data No.63 2nd Reverse Revolutions [rev]

Setting range: 0 ~ 99.9
Just the value which between 1 and 2 Step, is set is reversed.

Data No.64 3rd Reverse Revolutions [rev]

Setting range: 0 ~ 99.9
Just the value which between 2 and 3 Step, is set is reversed

Page 7-25
Chapter 7: System Operations

Data No.70 Full Scale Current [%]

Data No.71 High Current Limit [%]
Data No.72 Low Current Limit [%]
Data No.73 Fastening Current Limit [%]
Setting range: 0 ~ 120%
Used as a redundant check of the fastening process. Please contact FEC Inc. for assistance.
No.70=100%
No.71=100%
No.72=0%
No.73=100% (Will limit the amount of current allowed during fastening. Be careful when settin
g too low or tool could stall during operation)

Data No.74 Accept Batch Count

Setting Range: 0 – 99
Used to set the number of accepts for WORK ACCEPT. Setting “0” disables function.

Data No.80 CW Stop Angle (Pistol Pulse Function) [Deg]

Setting Range: 0 – 200
Used to set the swing stop angle in the CW direction. This is the angle the pistol will swing up to be-
fore shutting off. Setting “180” disables function.

Data No.81 CW Swing Pause Angle (Pistol Pulse Function) [Deg]

Setting Range: 0 – 200
Used to set the swing Pause angle in the CW direction.

Data No.82 CW Swing Stop Servo Lock Time (Pistol Pulse Function) [msec]
Setting Range: 0 – 500
Used to set the swing stop servo lock time in the CW direction.

Data No.83 CW/CCW Motor Resume Time (Pistol Pulse Function) [msec]
Setting Range: 0 – 500
Used to set the motor resume time in the CW direction.

Data No.86 CCW Stop Angle (Pistol Pulse Function) [Deg]

Setting Range: 0 – 200
Used to set the swing stop angle in the CW direction. This is the angle the pistol will swing up to be-
fore shutting off. Setting “180” disables function.

Data No.87 CCW Swing Pause Angle (Pistol Pulse Function) [Deg]
Setting Range: 0 – 200
Used to set the swing Pause angle in the CW direction.

Data No.88 Angle Head Torque Variation [%]

Setting Range: 0 – 500% (0~4: disables function) (Default disabled)
Sets limit for torque variation caused by an angle head in an angle tool. (system internally monitors
torque variation) An ABN 2_2 occurs when this is set and variations goes over this set amount.

Data No.89 CCW Motor Resume Time (Pistol Pulse Function) [msec]
Setting Range: 0 – 500
Used to set the motor resume time in the CW direction.

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FUSION Operations Manual Chapter 7: System Operations (Rev.3a)

Data No.90 Sequence Operational mode

Data number 90 must be set in order to enable the Batch or Sequence function. Other Functions are
set also with Data 90.
Accept Relay Output Timing (xxx1)
(xxx0) QL-OK Pulse 300ms
Data No. 90 (xxx1): QL-OK Pulse 800ms
Stop Input (xxx2)
0 0 0 0 (xxx0): Normally Open Stop Input
(xxx2): Normally Closed Stop Input
Total Accept Relay Output (xxx4)
(xxx0): Solid Output Signal
(xxx4): Pulse Output Signal
(Add numbers to determine setting number – ex. QL-OK Pulse 800ms
(xxx1) + Pulse Output Signal (xxx4) = 0005)

Batch Function Enable (xx1x)

(xx0x): Batch Function Disable
(xx1x): Batch Function Enable
Auto Reverse – Between 1st & 2nd Step (fastening=2 step) (xx2x)
(xx0x): Auto Reverse OFF
(xx2x): Auto Reverse ON
Auto Reverse – Between 2nd & 3rd Step (fastening=3 step) (xx4x)
(xx0x): Auto Reverse OFF
(xx4x): Auto Reverse ON
(Note: Batch function must be Enabled for Auto Reverse to work)
(Add numbers to determine setting number – See example above)

Sequence Function Enable (x1xx)

(x0xx): Sequence Function Disable
(x1xx): Sequence Function Enable
Auto Reject Upon non-Completion (x2xx) (F/W Ver. 5.10 or later)
(x0xx): No Output until Sequence is completed
(x2xx): REJECT Output if Sequence stops before completion

(Add numbers to determine setting number – Ex. Sequence Function Enabled (x1xx)
+ Reject Output if Sequence stops before completion (x2xx) = 0300.

Note: you can only ENABLE either the Batch or the Sequence function at one time

START signal must be maintained during sequence – if START is lost during sequence, fas-
tening stops – Fastening will start from beginning upon next start

Page 7-27
Chapter 7: System Operations

Data No.91 Sequence Stage 1 [Parameter / Count or Dwell]

Data No.92 Sequence Stage 2 [Parameter / Count or Dwell]
Data No.93 Sequence Stage 3 [Parameter / Count or Dwell]
Data No.94 Sequence Stage 4 [Parameter / Count or Dwell]
Data No.95 Sequence Stage 5 [Parameter / Count or Dwell]
Data No.96 Sequence Stage 6 [Parameter / Count or Dwell]
Data No.97 Sequence Stage 7 [Parameter / Count or Dwell]
Data No.98 Sequence Stage 8 [Parameter / Count or Dwell]

Setting range: Parameter 0 ~ 32 / Count or Dwell 0 ~ 99

BATCH / SEQUENCE PROGRAM EXAMPLES

Batch Function
There are 4 data digits used for each step which specifies the parameter number and number
of “accepts” required in order to go to the next step. The fastening must be within the parame-
ter limits (Accepts) to be counted. (WORK ACCEPT signal turns on after each step is com-
plete – Both the Green ACCEPT LED on the controller and tool flash upon the step completion)
0 2 0 4
Number of accepts to complete step
Parameter Number to be used for step

Batch Data Number Data Operation

Step
90 0010 Activate Batch Program
1 91 0103 Fasten 3 times using Parameter 1
2 92 0204 Fasten 4 times using Parameter 2
3 93 0701 Fasten 1 time using Parameter 7
4 94 0000 End (“0000” Ends Batch)
5 95 0000
6 96 0000
7 97 0000
8 98 0000

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FUSION Operations Manual Chapter 7: System Operations (Rev.3a)

Sequence Function
There are 4 data digits used for each step which specifies the parameter number and dwell
time after the step is complete.
0 1 0 5
Dwell Time to be used after step
Parameter Number to be used in step

Sequence Data Number Data Operation

Step
90 0300 Activate Sequence Program (with Reject if not complete)
1 91 0105 Run Parameter 1 and dwell 0.5 second after
2 92 0203 Run Parameter 2 and dwell 0.3 second after
3 93 0300 Run Parameter 3
4 94 0000 End (“0000” Ends Sequence)
5 95 0000
6 96 0000
7 97 0000
8 98 0000
Parameter Number Operation
1 Fasten to 10 Nm
2 Turn CCW for 360 degrees by angle method.
3 Fasten to 15 Nm

Parameter 1 Parameter 2 Parameter 3

Note: PARAMETER (WORK) NUMBER must be selected from PLC prior to having the START
signal input
The START signal can be input from terminal (A2) or the start trigger on the tool.
The system operates as dead man, so the START signal must be held on during operation.
The system aborts the sequence operation upon any reject during the sequence steps.
The Accept signal is only output at end of a successful sequence operation.
The fastening result and the torque curve are only available at the end of sequence.
The fastening result of each step will be stored into stored data memory.

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Chapter 7: System Operations

7.2.6 STATUS display

Two types of controller STATUS can be displayed, either STOP or ABNORMAL.

1) When the STOP signal is activated:

The [DATA] display will indicate when the STOP signal has halted the FUSION as shown in
the figure.

2) When an ABNORMAL condition occurs, the display will show a flashing "A" character fol-
lowed by a number that represents the Abnormal number code. The [COUNT/D-NO] displays
a dash and a number that represents the SERVICE CODE NUMBER or SUB Code.
The figure below shows a display reporting the Abnormal code 9 and the Sub code number 0.
(Refer to chapter 9)

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FUSION Operations Manual Chapter 7: System Operations (Rev.3a)

7.3 Download / Setup Mode Operation (Bypass Mode Only)

The FUSION system has two operational states that are controlled by depressing the
“MODE” and “SET” Buttons, on the front of the Controller, simultaneously, or by the PLC By-
pass input. The operational modes available in the Bypass State are identified below.
Under this condition, the “MODE” and “SET” Buttons have been pressed simultaneously, or
the BYPASS external signal is active. During the Bypass State, the controller displays and
allows setting of all available parameter presets.

7.3.1 Download Mode selection

Immediately after the bypass condition has been entered, the unit is in the initial Download /
Setup mode with the unit number displayed on the Count /D-No Display. The AFC User
Console software allows the CONTROLLER Unit setup via a computer’s RS232 Port. To
program the CONTROLLER unit with the display programmer, press the [MODE] key to
change to the primary setup mode. (If the CONTROLLER unit is performing some data
communication to an external computer, the download mode will be maintained until the op-
eration is completed.)

(Refer to the AFC Console Manual for information about the Download Mode).

Pressing both the [MODE] & [SET] keys at the same time
puts the controller into BYPASS mode.

FIG. 7-3-1 CONTROLLER Unit in Download mode.

Page 7-31
Chapter 7: System Operations

7.3.2 Setup Mode selection

Depressing the Mode button will initiate the Setup mode. Immediately after the setup mode
is established, a blinking number will appear in the [COUNT/D-NO.] display. The cursor
(blinking mode) will move between the 2 digit positions each time the [MODE] button is
pressed. The blinking character can be increased or decreased using the [] and [] but-
tons. The [COUNT/D-NO] characters will display the data corresponding to the Parameter
data list (7.2.5). The [DATA] characters will display the actual value of the [COUNT/D-NO]
as it is currently set. You may edit the currently indicated data using the Data Edit mode.
Press the [SET] button to enter into the Data Edit mode on the indicated [COUNT/D-NO.] that
you want to change. (See 7.3.4 and 7.3.5 for detail)

FIG. 7-3-2 Setup mode D-No selection

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FUSION Operations Manual Chapter 7: System Operations (Rev.3a)

7.3.3 Parameter # selection

All 16 Parameter sets can be setup using the programmer. Data corresponding to the se-
lected parameter number will be displayed in the [DATA] display. The diagram below de-
scribes the selection. Selection of the FUSION system 16 different sets of parameters for
programming purposes is accomplished by depressing the [] and [] Cursor key (Hori-
zontal arrows) while in primary setup mode. In addition to parameter 1 ~ 16 there is a
PARAMETER 0 that contains configuration data common to all parameters.

FIG. 7-3-3 Parameter display D-No selection

Page 7-33
Chapter 7: System Operations

7.3.4 Data # selection

The value for digit 1 and 2 of the [COUNT/D-NO] display may only be changed when the
(blinking) cursor is in the respected position. The [COUNT/D-NO] value is changed with the
[] and [] keys. Data corresponding to the data number [COUNT/D-NO] display will appear
in the [DATA] display (Refer to section 7.2.5). If the cursor is in the 1st digit position, by
pressing the [] or [] keys, the DATA number will be scrolled by tens. If the cursor is in the
2nd digit position, the DATA number scrolling will be one by one. As noted in the Parameter
Data List chart, the preset values are not arranged in a perfect sequence and some numbers
may be skipped. When scrolling the DATA numbers, it will scroll to the next existing value in
the same or the following parameter number.

FIG. 7-3-4 Data No. changing

Page 7-34
FUSION Operations Manual Chapter 7: System Operations (Rev.3a)

7.3.5 Data Edit mode operation.

Depressing the [MODE] button will bring up the pri-

mary setup mode. The blinking cursor will be posi-
tioned in the right most digit in the [COUNT/D-NO]
field and depressing it again will bring it to the left digit
of the field. Use the [] and [] buttons to select the
desired [COUNT/D-NO] number which is to be edited.

After you have selected the Parameter number and

the Data number you would like to edit, press the
[SET] button to enter the Data Edit mode. The blink-
ing digit will now appear at the left digit of the DATA
field. You can move one digit to the right each time
you press the [MODE] button. By pressing the but-
ton four times, you leave the Data Edit mode and re-
turn to the Setup mode (without saving any changes).
Use the [] and [] buttons to increase or decrease
the digit that is blinking.

After changes have been made, pressing the [SET]

button will save the changes and exit to the Setup
mode.

If the entered values are out of range / limits, "Err" will

appear, and the new data will be ignored. In this
case, return to the parameter number selection (using
the [MODE] key) and enter data that is acceptable.

FIG. 7-3-3 Setup mode operation

When the Torque Unit number (PARM 0 D-NO 00) or the Tool Type (PARM 0 D-NO 20) is
changed, the [DATA] display will show "CHNG," and the D-NO display will show "NO." Use
the vertical arrow buttons to choose YES or NO; YES means that the data will be entered if
the confirmation SET button is pressed. The [SET] and [MODE] buttons will have no effect
when "NO" appears. If no button is pushed within five seconds, the new data will be ig-
nored, and the system will exit the Data Edit mode.

Note:
When the Torque Unit (PARM 0, and D-NO 00) or the Tool Type (PARM 0, and D-No 20)
is changed, all torque settings (D-No 00-1E) and speed settings (D-No 50-56) will be
cleared.

Page 7-35
Chapter 7: System Operations

7.3.6 Parameter copy.

To speed parameter data entry, it may be beneficial to copy from one parameter set to an-
other parameter set. This is especially the case if only minor changes are required. Use
the procedure below for the parameter copy function using the display;

 When the system is in Setup mode,

select Data number 01 of Parameter 00.
(This data corresponds to the ROM ver-
sion and is non adjustable data.)

 Press the Set button and the cursor

will jump to the left digit position of the 4
digit data display. (There will be a deci-
mal point between the second and third
digit) The first two digits specify which
parameter number is to be copied FROM
and the two digits after the decimal point
specify which parameter number is being
copied TO.

 Edit the numbers to change the dis-

play to get the desired source and target
parameter numbers. (The example to the
left shows parameter 1 being copied to
parameter 2)

 Press the SET button to proceed

with the copy.

 Press either arrow button to confirm

the change (YES) or to cancel it (NO).
(The display will return to the Setup
Mode if no action is taken within 4 sec-
onds)

 If YES is displayed, press the SET

button again to copy the parameter.

FIG. 7.3.6 Parameter copy procedure

Page 7-36
FUSION Operations Manual Chapter 7: System Operations (Rev.3a)

7.4 Calibration Adjustment.

The calibration value is set according to the tool type (capacity). However, depending on the
application characteristics or on the prevailing torque generated external to the tool output
shaft, the value of the applied torque and the torque display by the CONTROLLER unit may
mismatch. In this case it is possible to adjust the FULL SCALE TORQUE (CAL) value, so
the displayed torque matches the installation torque registered by an external torque trans-
ducer (Master).

The CAL value can be adjusted up to %of the FULL SCALE TORQUE value.

Example:
Consider the HFT-025M80-A tool.
Nominal CAL value = 3.5 Kg.m.
Range of adjustment: from 2.8 Kg.m to 4.2 Kg.m.

The FULL SCALE TORQUE value is read from Parameter 1 ~16 D-No 10.

Use the following formula on a collection of at least 10 fastenings when a calibration correc-
tion is necessary:

New CAL value = Master transducer mean/ FEC transducer mean x Existing CAL value

Note: The torque unit (Kgm, Nm, FtLb, etc.) must be the same for all terms. Do not mix
torque units in calculation or errors will result.

If the new CAL value is out of the adjustable range, the [Err] message will be displayed.

Example:
Tool Full Scale value (EXISTING CAL) is 35.00 Nm.
STD torque is 25.0 Nm.
Master transducer mean for 10 piece run is measuring only 24.00 Nm.
FEC transducer mean for 10 piece run is measuring 26.0 Nm.

The new CAL value is obtained as follows:

(24.00/26.00 x 35.00) = 32.305

The FULL SCALE TORQUE (CAL) value must be corrected to 32.30 Nm and en-
tered at [WORK} 1~16 [COUNT/D-NO] 10.

NOTE: WORK 1~16 can have different Calibration values entered. This
provides for an improved accuracy rating over an extended torque range.

Notice: An alternative method of checking calibration using a static torque device (wrench or
bench checker) can be done using the Locked Spindle Mode method. The motor can be
electrically locked while the operator manually applies torque with the tool (using the tool as a
torque wrench) and then comparing the readings from the FEC Controller data display vs. the
torque displayed from the master. See 7-2-2 for a description of how to put the spindle into
the Locked Spindle Mode.

Page 7-37
Chapter 7: System Operations

7.5 Optional Real Time Clock Module

The Fusion system stores 10000 cycles of fastening results in its flash memory. In order to
add a Date/Time stamp to this data, an optional Real Time Clock module can be added to the
controller. This module is added into the back of the controller inside of the access panel at
the upper right side.
When this clock module is added, the date & time will be attached to the stored data every
cycle. This function is available in Firmware version 2.20 or later

The AFC software will be required for restoring stored data from controller.

Clock module model : ANG-RTC

Backup power source : Electric double layer capacitor

Backup memory duration : Approx. 10000 hours

Backup power charge time Approx. 1hour

If the controller power is turned off for more than 2 months, the clock backup power will be
lost & the time settings will be lost.
The Clock can be set using the front display & keypad the same method as changing param-
eter data. See the table below for parameter numbers.

Work # Data # Item Example

00 30 Year ‘yyyy’ ‘2005’ Year 2005
00 31 Month & Date ‘mmdd’ ‘0131’ January 31st
00 32 Hour & Minute ‘hhmm’ ‘1759’ 17:59
00 33 Seconds ‘00ss’ ‘0020’ 20 second

Seconds will be set as ‘00’ when Hour & Time (Data # 32) is changed.

Note: Clock may be off approx. 10 seconds / month. Adjust as required.

AFC Software version 5.16 or after added function to program Date/Time from
software.

Page 7-38
FUSION Operations Manual Chapter 7: System Operations (Rev.3a)

7.6 Tubenut Head Set-up

Tubenut heads are used for applications that require a socket to be inserted around a tube to
fasten an accompanying tubenut. They require a special function to re-align the “U” shaped
socket back to it’s “open” position in order to remove the nutrunner from the tube after fas-
tening. When using an optional Tubenut head, special programming options MUST be set-
up to enable the Tubenut socket automatic return function along with various other considera-
tions.

Tubenut head applications inherently present safety concerns especially in the area of the
open “U” shaped socket. The opening of the “U” shaped socket presents a PINCH POINT
while rotating.

WARNING: KEEP ALL BODY PARTS AWAY FROM THE TUBENUT HEAD
SOCKET OPENING DURING OPERATION OR PERSONAL INJURY MAY
RESULT!

PLEASE CONSULT YOUR PLANT SAFETY PERSONNEL BEFORE

USING THIS HEAD!

All safety precautions MUST be followed to ensure safe operation and

operator safety!

Page 7-39
Chapter 7: System Operations

7.6.1 Recommended Parameter Set-up for Tubenut Head

The following parameters are recommended for setting up the Tubenut head function.

1. Fastening Function Version [WORK]-00, [D-No]-03

Change to version for Tubenut head tool (1.00, 1.01, 1.10, 1.11)
(See page 7-12 for function version change procedure)

2. External Gear Ratio [WORK]-00, [D-No]-04

Default is “1.000”. If the gear ratio is other than 1:1, then the gear ratio
must be adjusted here or angle readings will not be correct when fastening.
(ex. If gear ratio is 1:1.132, then “1.132” should be entered here)

3. Gear Head Selection [WORK]-00, [D-No]-05 (Firmware Ver. 2.33 or higher)

Select the version of Tubenut head you are using. (CW or CCW) This is de-
termined by the direction the NUTRUNNER must rotate in order to rotate the
tubenut head in the FASTENING direction and is dependant on the gearing
in the tubenut head. (Without the tubenut head attached to the nutrunner,
slowly rotate the tubenut socket in the CW direction and take notice of which
direction the square drive is turning on the other end of the head. If it ro-
tates in the SAME direction, use the CW setting. If it rotates in the
OPPOSITE direction, use the CCW setting)

“00” : Normal (Default) (Disables Tubenut Function)

“01” : CW Tubenut Head (Enables CW Tubenut Function)
“03” : CCW Tubenut Head (Enables CCW Tubenut Function)

WARNING: Setup proper CW / CCW rotation PRIOR to running the tool with the
Tubenut head attached or Tubenut Head damage may occur! (The Tubenut
head stop detail which re-aligns the “open” slot in the socket gear may be bro-
ken if too much force is applied)

4. Full Scale Torque [WORK]-01(thru-32), [D-No]-10

This value will need to be adjusted to make up for torque loss through the
tubenut gearing. (This should be determined by using the calibration ad-
justment method – Section 7-4) This value changes with tool size and ca-
pacity.

5. Torque Inhibit Limit [WORK]-01(thru-32), [D-No]-19

When using the Tubenut function, the Torque Inhibit Limit parameter sets the
MAX. amount of torque that can be sensed during the Torque Inhibit Revolu-
tion setting. This is used to set the max. torque to be sensed during the
start of rotation of the socket or until the socket “U” opening moves to a
closed position. This will protect from damage anything being inserted
into the path of the socket as it rotates in the OPEN space. If this torque
value is exceeded during the Torque Inhibit Revolution (Work – 01 (thru-16)
D-No-61), a REJECT will result. This cannot be set too low or nuisance
REJECTS will occur during normal motor start-up.
Recommended setting: .75 – 1.5Nm
NOTE: This setting will vary by tool size and Tubenut head configuration.

WARNING! – Do not set this ABOVE the recommended setting or per-

sonnel injury may result!

6. Torque Inhibit Revolutions [WORK]-01(thru-32), [D-No]-61

Set Torque Inhibit Revolution so that the torque can be checked during motor
start-up (Just enough revolution for the socket to close the “U” opening)
Recommended setting: .3rev

Page 7-40
 FUSION Operations Manual Chapter 7: System Operations (Rev.3a)

7. Initial Time [WORK]-01(thru-32), [D-No]-40

Set Initial Time so that revolution time/speed is slow during motor start-up
(the time that the socket is rotating in the socket “U” opening)
Recommended setting: .3sec

8. Initial Speed [WORK]-01(thru-32), [D-No]-50

Set Initial Speed for slow rotation while socket is rotating through the “U”
opening.
Recommended setting: 60rpm max.

9. Reverse Speed [WORK]-01(thru-32), [D-No]-54

Reverse speed is used to re-align the socket after a fastening.
Recommended setting: 60 – 100rpm max.

10. Ramp Up Time [WORK]-01(thru-32), [D-No]-45

Sets motor ramp-up time from slow to higher speeds
Recommended setting: 1.0 – 1.5sec.
(Can only be set in Supervisory security mode)

11. Ramp Down Time [WORK]-01(thru-16), [D-No]-46

Sets motor ramp-down time from high to slower speeds
Recommended setting: 1.0sec.
(Can only be set in Supervisory security mode)

12. Socket Return Torque [WORK]-01(thru-32), [D-No]-1A

(Uses Offset Torque Limit data – since it is not used in Fusion)
Note: [D-No] 1A cannot be seen Sets the torque at which the socket returns and stops at after a fastening.
using the AFC software, however Recommended setting: 6.0 - 10Nm
it will be transferred/copied with Must be set by using Automatic Parameter Setup Function in AFC software
the parameter data file.
or manually entered using the controller display keypad

7.6.2 Tubenut Head Operation

When using a Tubenut head, a special function is required to re-align the socket after normal
fastening operations and allow the socket to be placed onto the nut to be fastened. The
start trigger must be held “ON” for the complete fastening of the part. If the trigger is re-
leased during the fastening cycle, the fastening will stop. The fastening can be re-started by
simply squeezing the trigger again. Use the procedures below to re-align the Tubenut sock-
et.

First Time Power-Up / Socket Re-alignment

If the Tubenut socket is not aligned use the following procedure to re-align the open socket.
 Press the “Reverse” pushbutton (Tool RED / GREEN LED’S will flash)
 Press the start trigger
 Hold the start trigger until the socket is re-aligned and the tool shuts off (tool au-
tomatically shuts off)
NOTE: If the socket is turning in the wrong direction to re-align the head (Re-alignment must
turn CCW for proper operation), the Gear Head Selection is wrong ([WORK]-00, [D-No]-05).

(more on next page)

Page 7-41
Chapter 7: System Operations

Return to Home Position after Fastening

After fastening a part, the tubenut socket must be re-aligned in order to remove it from the
part. Use the procedure above to re-align the socket if removal is desired. Use this proce-
dure to re-align the socket and remove the head from the part after a complete fastening.
 Hold down start trigger until fastening is complete
 While still HOLDING the start trigger after fastening is complete, lift socket off of
the nut being fastened
 Release start trigger and the socket will re-align automatically.
 If the trigger is inadvertently released before the socket is re-aligned, follow the
procedure above to re-align the socket.

Page 7-42
FUSION Operations Manual Chapter 8: Maintenance and Inspection (Rev. 3)

Chapter 8: Maintenance and Inspection

Page 8-1
Chapter 8: Maintenance and Inspection

8.1 Inspection Items

A scheduled inspection is recommended to keep the FUSION System in the best condition. A
preventive maintenance routine should be set-up. Recommended inspection schedules are
given for each item.

WARNING:Follow Lockout/Tagout and other safety precautions when connecting or

disconnecting cabling, wiring, and equipment. Always verify the System is disabled
prior to touching any moveable components
.

8.1.1 Nutrunner (Tool)

Recommended Schedule: Quarterly

It is important to keep the nutrunner tools clean and properly adjusted to ensure correct fas-
tening and accurate system outputs. Inspect each tool, and ensure the following conditions
exist:

 All environmental conditions are within the specified ranges.

 The duty cycle is within specifications, and the motor is producing normal heat levels.

 The tool is producing normal levels of noise and vibration (no irregular noise)

 The tool is free from excessive contamination and foreign matter.

 The tool is securely mounted, with mounting bolts properly tightened.

 The Tool cable is securely connected to the tool.

8.1.2 Tool Cable

Recommended Schedule: Quarterly

This cable connects the tool to the Controller unit. Ensure the following conditions are met:

 The cables are free from unnecessary binding, force and tension and are free to move.

 The cables are in good condition, sufficiently insulated (no cuts) with no indication of broken
wires.

 The cables are free from excessive contamination and foreign matter.

 The cables are securely connected to the Controller unit and to the nutrunner (connectors are
tight).

 The cables are free from heat distortion, and are not warm or hot to the touch.

 The cables and cable connectors are securely and correctly fastened.

(See 4.11.1 for Cable Installation Guidelines)

Page 8-2
FUSION Operations Manual Chapter 8: Maintenance and Inspection (Rev. 3)

8.1.3 Controller Unit

Recommended Schedule: Quarterly

The Controller Unit requires careful use and handling. Inspect each Controller unit and en-
sure the following requirements are met:

 The environmental conditions are within specifications.

 There is no moisture, oil, or foreign matter on the unit.

 The unit is securely mounted, with appropriate clearance on all sides.

 All screws (for the cover of the unit and for mounting) are correctly tightened.

 The input power remains within specifications at all times.

 The unit is not producing any abnormal (excessive) heat.

 Unit cables (on the back and the underside) are securely fastened and without damage.

8.1.4 Auxiliary Tool Heads (Crowsfoot, Tubenut, Hold & Drives, etc.)
Recommended Schedule: Monthly

External auxiliary heads require special attention due to the nature of their small design with-
standing high forces. These heads are typically designed for a maximum of 250,000 cycles
or less and should be inspected more frequently than a standard tool. (life cycle is depend-
ant upon the torque it is used at).
Typically, these heads should be inspected and greased every 10,000 cycles. During this in-
spection, the inspection time may be lengthened or shortened depending on the conditions
seen during the first few inspections. (this will very by application)

Inspect each tool, and ensure the following conditions exist:

 The head is producing normal levels of noise and vibration (no irregular noise)

 The head is free from excessive contamination and foreign matter.

 The head turns freely with no binding

 The head is securely mounted to the tool, with mounting bolts properly tightened

 All covers, screws and bolts are in place and securely tightened on head

 The head is sufficiently lubricated (approx. 1/5 oz. of grease each application) Do NOT over
grease!

Auxiliary Head Lubrication Information

Description Part Number
Grease Gun GG-K97
Lubriplate Grease (14oz) GR-132-A
Lubriplate Grease (6 lb can) GR-132-B

Page 8-3
Chapter 8: Maintenance and Inspection

8.2 Basic Operational Tests

WARNING:Follow Lockout/Tagout and other safety precautions when connecting or
disconnecting cabling, wiring, and equipment. When performing the
following inspections, verify that the system is disabled prior to touching any
moveable components.

8.2.1 Torque Transducer.

The system can perform a transducer check before each fastening cycle, comparing the val-
ues from the torque transducer (zero and calibration) to the data stored in the system
memory. The system is maintenance free, however it can be manually checked as follows:

 1. Be sure that the nutrunner is in the READY mode.(powered up) and not running.

 2. Check that the torque display shows 0 when the keyboard-display unit RESET key is being
pressed.

 3. At the same time as 2 (above), check that “ABN” is not displayed on the Data display.

 4. Check that the display is showing the full scale torque value when the Controller unit CAL
key is being pressed.

 5. At the same time as 4 (above), check that “ABN” is not displayed on the Data display.

 If any of these checks fail internal limits, an ABNORMAL will be generated and “ABN” will
display. See Chapter 9 for troubleshooting.

8.2.2 Resolver.
Take the following steps to manually inspect the resolver:

 1. Make sure that the system will not be started by an operator.

 2. Place the Controller keyboard-display unit into the real-time display mode (Chapter 7 -
Display has only one digit active in the D-NO display. This is the default mode when power is
applied). The [D-NO] display must be set to [3] using the Up/Down arrow keys in order to
see the angle of rotation on the DATA display.

 3. If the socket of the tool is turned in the clockwise direction, the angle indication should in-
crease.

 4. Verify that the angle rotated matches the indicated angle in the data display.

8.2.3 Motor.
If doubts about the condition of the motor exist, the windings can be manually checked with a
Ohm meter. To check the motor, measure the winding's resistance and the isolation re-
sistance.

 1. Power down the system.

 2. Disconnect the motor connector from the tool assembly.

 3. Measure the resistance between windings. (Refer to Fig 8-2-3)

Page 8-4
FUSION Operations Manual Chapter 8: Maintenance and Inspection (Rev. 3)

 4. Measure the isolation resistance between each pair and the frame.
Insulation resistance: Using a megohmmeter, 500 VDC, 50 Mohms or more, test the insula-
tion resistance between the motor windings and the motor case. The values should register in
excess of 50 Mohms for each winding.

FIG. 8-2-3 Motor Inspection

Motor Winding Resistance*

MOTOR SIZE Pins A - M Pins M - L Pins L - A
(M80)   
(M50)   
Tolerance + / - 10%

Resolver Winding Resistance

MOTOR SIZE Pins C - D Pins P - R Pins V - S
(M80)   
(M50)   
Resolver windings should not be “Open” or zero ohms.

Insulation Resistance
MOTOR SIZE Pins J - K Pins K - L Pins L - J
(M80) More than 50 mega ohms at 500 VDC
(M50)

Page 8-5
Chapter 8: Maintenance and Inspection

8.2.4Transmission Disassembly and Inspection

 The planetary gear transmissions used in the FUSION System's tool assemblies are de-
signed to withstand the forces exerted upon them by high production requirements of modern
assembly plants.

 The total cycle count of the tool assembly is stored on the Tool Preamplifier and can be re-
trieved using the FUSION User Console Software. This count can be used for diagnostic and
maintenance purposes. (Only FEC can reset this counter)

 To prolong the life of the transmission assembly, the components must be inspected and
greased at regular intervals.
 FEC INC. recommends performing this procedure initially after equipment has been in use for
one year or 500,000 cycles, whichever is reached first.
 When the initial maintenance is performed, the condition of the transmission assembly should
be analyzed to determine future maintenance requirements. Systems operating under more
severe conditions (Full scale torque in high temperatures) may require maintenance every
250,000 cycles, while other systems may only require maintenance every one million cycles.

1. REMOVE TRANSMISSION FROM TOOL ASSEMBLY. Separate the transmission from the motor
by disassembling tool assembly drive end. (See Tool Assembly Manual)

Note: Care must be taken when disassembling the tool assembly. Small parts and wiring can easily
be lost or damaged.
2. DISASSEMBLE TRANSMISSION. Refer to the appropriate transmission assembly drawing while
disassembling the transmission for cleaning.
3. CLEAN TRANSMISSION PARTS. Clean all parts with an appropriate solvent, such as mineral
spirits, to remove all excess grease and contamination. Parts should be carefully wiped dry with a
lint-free cloth to remove any residue. Allow the parts to dry thoroughly in an area free from contami-
nation.
4. INSPECT TRANSMISSION PARTS. Examine all gears, pins, bearings, etc. for signs of exces-
sive wear. Replace any part that failed or appears it may fail.
5. LUBRICATE TRANSMISSION PARTS. Reassemble the transmission in a contaminant-free ar-
ea. Re-pack all bearings and grease all gears. Do not pack the transmission housing with excessive
grease; over-greasing could damage the tool and cause it to stall. Recommended grease: Sunoco
Sunaplex 992 EP or equivalent.
6. REASSEMBLE TRANSMISSION. Refer to the appropriate transmission assembly drawing while
reassembling the transmission. If needed, rotate the gears to aid in the assembly process. If the
transmission does not rotate freely after re-assembly, then disassemble the transmission again to iso-
late and correct the cause.
7. RE-ASSEMBLE TOOL. If needed, rotate the output shaft to align the transmission planetary
gears with the motor output shaft. If the transmission does not rotate freely after reassembling the
tool, then disassemble the tool again to isolate and correct the cause.

Page 8-6
FUSION Operations Manual Chapter 8: Maintenance and Inspection (Rev. 3)

8.3 Replacements
WARNING: DO NOT CONNECT OR DISCONNECT CABLES OR OTHER SYSTEM
COMPONENTS WITH POWER APPLIED. FOLLOW LOCKOUT/TAGOUT AND
OTHER APPLICABLE SAFETY PRECAUTIONS WHEN CONNECTING OR
DISCONNECTING CABLING, WIRING, AND EQUIPMENT.

NOTE:When replacing the FUSION System Controller unit, ensure that the new unit is con-
figured with the same Hardware and the same Firmware version as the unit being replaced.
(Controller Unit displays the Firmware Version number when “WORK” 00 D-NO 01 is select-
ed. Version will show in the Data Display. ie. 1.02)

8.3.1 Controller Unit Replacement (No Partial Replacement)

All tools operate from one model of Controller (HFC-EC-16). When one Controller unit is be-
ing replaced with another, it is important to verify that the new unit is set-up identical to the
unit being removed.

1. Verify the controller power is off. Ensure all cables connected to the controller are clearly marked
(for ease of reconnection).
2. Disconnect all cables from the rear (& front if applicable) of the unit. If wires are connected to the
I/O terminal on the controller and to avoid removing all the I/O wires, you may simply disassemble the
terminal block from the controller using the top and bottom screws holding the terminal block to the
controller, and reassemble the terminal block to the new controller.
3. Turn the controller on the cover hinges 90 degrees and Lift up on the controller unit to remove.
4. Verify the new controller unit dip switches are set the same as the unit being replaced. Refer to
Section 4.10.
5. Verify the SAN Units have the same configuration (hardware and software).
6. Install the new controller in reverse order of removal.
7. Apply power and confirm operation. (After approximately 5 seconds, the controller will finalize the
Power On Self Test (POST)).

The new Controller will require reentry of the preset data. Refer to Chapters 6
and 7.

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Chapter 8: Maintenance and Inspection

8.3.2 Replace Nutrunner (tool).

Do not attempt to replace a component of the tool - the tool must be replaced as a complete
assembly. The tool type identification can be found on the identification tag affixed to the tool
and on the System [TOOL TYPE] preset value.

WARNING: DO NOT CONNECT OR DISCONNECT CABLES OR OTHER SYSTEM

COMPONENTS WITH POWER APPLIED.
1. Verify all System power is off.
2. Twist connector on the tool in the (CCW) direction and pull connector from tool.
3. Replace tool and plug in connector aligning the key in the connector to the keyway in the tool.
4. Twist connector in the (CW) direction to the fully locked position.
5. Power – up controller and confirm no ABN (abnormal) is displayed in the LED display. (Controller
automatically checks that replacement tool is the same type)

8.3.3 Replace homerun cable

1. Verify all System power is off.

2. Disconnect the damaged cable(s) from the nutrunner tool and the Controller unit, and replace with
the spare cable(s). (Align keyways on both ends and fully twist connectors into the locked position)

Note: Wave Washer (Part# WAV-25036) can be used to tighten the tool side twist lock connector if
desired. The washer must be split and inserted by threading the washer underneath the twist lock
rollers.

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FUSION Operations Manual Chapter 9: Troubleshooting (Rev. 3)

Chapter 9: Troubleshooting

Page 9-1
Chapter 9: Troubleshooting

9.1 Abnormal Conditions.

When an abnormal condition is detected by the system, the affected spindle stops, and lights
“Abn” in the [DATA] display. For ease of troubleshooting the nature of the abnormal, the sys-
tem provides an abnormal code in the [PARM] display and an abnormal sub-code in the
[COUNT/D-NO] display.
Note: ABNORMALS are not to be confused with fastening REJECTS. Abnormal’s signify a
failure of a system process or self check during the fastening cycle.

 Abnormal code display.

When an Abnormal condition occurs, the display mode will automatically change to the
STATUS mode. (If the display is not in the STATUS mode, depress the MODE button until a
blinking “A” appears in the [WORK] display area) A code number appears at the right side of
the blinking character. This code refers to some specific type of failure detailed in the tables
shown in the following sections.

 Abnormal Sub-code display.

The number shown at the most right position in the [COUNT/D-NO] display area is a sub-
code that can be used in conjunction with the Abnormal failure code to further narrow down
the cause of the fault. See the following sections.

Example of Abnormal Code 9 Sub-Code 0

Abnormal Code Table

ABNORMAL
CODE DESCRIPTION
1 Torque Transducer Error.
2 Over Torque Error.
3 Tool EEPROM error.
4 System Memory Error.
5 Servo Amplifier Reply Error.
6 Servo Type Mismatch Error.
7 NOT USED
8 Servo Amplifier Error.
9 Parameter Error.

Abnormal sub-codes and specific actions for troubleshooting are detailed in the following
section.

WARNING:DO NOT CONNECT OR DISCONNECT CABLES OR OTHER SYSTEM

COMPONENTS WITH POWER APPLIED.

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 FUSION Operations Manual Chapter 9: Troubleshooting (Rev. 3)

9.2 Torque Transducer Abnormals

Calibration Error
When the CAL switch is pressed on the Fusion front panel, "E" is shown if the FULL-SCALE
preset value is missing or a wrong tool is connected.

RECOVERY:
1. Program correct Full Scale Preset value for the tool connected
2. Exchange tool cable, tool and/or controller with known working units. Reinitialize the
system after each exchange, and make note of any change in the location of the ab-
normal.
3. Replace the defective component.

9.2.1 Code 1-0 TORQUE TRANSDUCER / ZERO VOLTAGE ERROR

Zero level does not match master level read from tool EEPROM during power on initializa-
tion.
This abnormal is caused from;
1. When the tool transducer is sensing excessive torque due to pressure on the tool body.
2. If the controller or the transducer cable is located in an electric or magnetic noise field.
3. When the torque transducer, Tool cable or the controller malfunctions.

RECOVERY:
1. Check that the tool has no signs of an external force being applied to it. (No heavy impact
has occurred with the tool assembly)
2. Verify that the cable or controller is not located near any high voltage transient power
sources. Relocate as required and reinitialize.
3. Exchange tool cable, tool and/or controller with known working units. Reinitialize the sys-
tem after each exchange, and make note of any change in the location of the abnormal.
4. Replace the defective component.

9.2.2 Code 1-1 TORQUE TRANSDUCER / CAL VOLTAGE ERROR

Calibration voltage error during power on initialization.
This abnormal is caused from;
1. When the tool transducer is sensing excessive torque due to pressure on the tool body.
2. If the controller or the transducer cable is located in an electric or magnetic noise field.
3. When the torque transducer, Tool cable or the controller malfunctions.

RECOVERY:
1. Check that the tool has no signs of an external force being applied to it. (No heavy impact
has occurred with the tool assembly)
2. Verify that the cable or controller is not located near any high voltage transient power
sources. Relocate as required and reinitialize.
3. Exchange tool cable, tool and/or controller with known working units. Reinitialize the sys-
tem after each exchange, and make note of any change in the location of the abnormal.
4. Replace the defective component.

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Chapter 9: Troubleshooting

9.2.3 Code 1-2 TORQUE TRANSDUCER / ZERO CHECK ERROR

Zero level voltage loaded to memory from tool EEPROM during initialization does not match
the actual zero level during a self check with the self check function DISABLED.

This abnormal is caused from;.

1. When the tool transducer is sensing excessive torque due to pressure or vibration during
the fastening cycle start.
2. If the controller or the transducer cable is located in an electric or magnetic noise field.
3. When the torque transducer, Tool cable or the controller malfunctions.

RECOVERY:
1. Check that the tool has no external force applied to it.
2. Verify the tool mounting bolts are tight and nothing is cause excessive vibration to the tool.
3. Verify that the cable or controller is not located near any high voltage transient power
sources. Relocate as required and attempt again the fastening start input.
4. Exchange tool cable, tool and/or controller with known working units. Input the start signal
after each exchange, and make note of any change in the location of the abnormal.
5. Replace the defective component.

9.2.4 Code 1-3 TORQUE TRANSDUCER / CAL SELF CHECK ERROR

Calibration level voltage error after a fastening start was attempted.

This abnormal is caused from;

1. When the tool transducer is sensing excessive torque due to pressure or vibration during
the fastening cycle start.
2. If the controller or the transducer cable is located in an electric or magnetic noise field.
3. When the torque transducer, Tool cable or the controller malfunctions.

RECOVERY:
1. Check that the tool has no external force applied to it.
2. Verify the tool mounting bolts are tight and nothing is cause excessive vibration to the tool.
3. Verify that the cable or controller is not located near any high voltage transient power
sources. Relocate as required and attempt again a fastening start input.
4. Exchange tool cable, tool and/or controller with known working units. Input the start input
after each exchange, and make note of any change in the location of the abnormal.
5. Replace the defective component.

9.2.5 Code 1-4 TORQUE TRANSDUCER /STARTED ON ZERO ERROR CONDITION

The start signal was input while a Zero voltage abnormal condition existed.
RECOVERY:
1. Interlock the PLC circuit to disable the start signal during an existing abnormal condition.
2. Follow the ZERO VOLTAGE ERROR abnormal help procedure.

9.2.6 Code 1-5 TORQUE TRANSDUCER / STARTED ON CAL ERROR CONDITION

The start signal was input while a Cal voltage abnormal condition existed.
RECOVERY:
1. Interlock the PLC circuit to disable the start signal during an existing abnormal condition.
2. Follow the CAL VOLTAGE ERROR abnormal help procedure.

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 FUSION Operations Manual Chapter 9: Troubleshooting (Rev. 3)

9.2.7 Code 1-6 TORQUE TRANSDUCER / ZERO LEVEL SELF CHECK ERROR
Zero level voltage loaded to memory from tool EEPROM during initialization does not match
the actual zero level during a self check with the self check function enabled.

This abnormal is caused from;

1. When the tool transducer is sensing excessive torque due to pressure on the tool body.
2. If the controller or the transducer cable is located in an electric or magnetic noise field.
3. When the torque transducer, Tool cable or the controller malfunctions.

RECOVERY:
1. Check that the tool has no external force applied to it.
2. Verify that the cable or controller is not located near any high voltage transient power
sources. Relocate as required and reinitialize.
3. Exchange tool cable, tool and/or controller with known working units. Reinitialize the sys-
tem after each exchange, and make note of any change in the location of the abnormal.
4. Replace the defective component.

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Chapter 9: Troubleshooting

9.3 Torque Over Abnormals

9.3.1 Code 2-1 TORQUE OVER ABNORMAL / TORQUE INHIBIT HIGH LIMIT.
High torque was detected during the Torque Inhibit Function which was greater than the
Torque Inhibit high limit parameter.

The cause of this abnormal is;

1. Torque Inhibit High Limit parameter set too low for application.
2. Initial starting torque is too high for size of tool. (If limit is set at full scale torque)
3. Excessive binding of output shaft or driver during Torque Inhibit.

RECOVERY:
1. Raise Torque Inhibit Limit.
2. Check that the tool has no external force applied to it.
3. Verify that torque required is not more than tool capability.
4. Verify that nothing is binding on the output shaft of the tool while it begins it’s cycle.

9.3.2 Code 2-2 TORQUE OVER ABNORMAL / ANGLE HEAD TORQUE VARIATION.
High Torque irregularity over the set limit of (D-No. 88) was detected with the in the Angle
Head of the tool.

The cause of this abnormal is;

1. Possible degradation of the Angle Head gears.
2. Initial starting torque is too high for size of tool. (If limit is set at full scale torque)
3. Excessive binding of output shaft or driver during Torque Inhibit.

RECOVERY:
1. Adjust Angle Head Variation limit (D-No.88) between 0-100
2. Replace tool with known good tool, if OK, the Angle Head of the tool removed may be ex-
periencing wear of the internal gears.
3. Verify that torque required is not more than tool capability.
4. A highly fluctuating fastening joint may cause this limit to be reached – Adjust the limit in
this case. (a joint fluctuating between hard and soft multiple times while fastening)

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 FUSION Operations Manual Chapter 9: Troubleshooting (Rev. 3)

9.4 Tool EEPROM Errors

9.4.1 Code 3-0 PREAMPLIFIER / TOOL ID CHECKSUM ERROR
Communication data Checksum error between the Preamplifier and the CONTROLLER Unit.
Data is not reliable due to data error.

This abnormal is caused from;

1. If the controller or the transducer cable is located in an electric or magnetic noise field.
2. When the torque transducer, Tool cable or the controller malfunctions.

RECOVERY:
1. Verify that the cable or controller is not located near any high voltage transient power
sources. Relocate as required and reinitialize the system.
2. Exchange Tool cable, tool and/or controller with known working units. Reinitialize the sys-
tem after each exchange, and make note of any change in the location of the abnormal.
3. Replace the defective component.

9.4.2 Code 3-1 PREAMPLIFIER / TOOL TYPE ERROR

The connected tool type does not match the tool type programmed into the controller. This
error may occur in the multi- tool type application or when controllers are replaced and not
reprogrammed with the correct configuration.

RECOVERY:
1. Verify the tool type name from the tool identification tag
2. Compare the tool tag name with the setup value located on Data Display (see 7.2.5)
3. Program proper tool number into CONTROLLER Unit or change tool to proper tool.

9.4.3 Code 3-2 STARTED WITHOUT TOOL CONNECTED

The start signal was applied while a TOOL IS NOT CONNECTED abnormal condition exist-
ed.
RECOVERY:
1. Interlock the PLC circuit to disable the start signal during an existing abnormal condition.
2. Follow the TOOL IS NOT CONNECTED (Code 3-3) abnormal help procedure.

9.4.4 Code 3-3 PREAMPLIFIER / TOOL IS NOT CONNECTED

Communications error between the tool preamplifier and the controller.

This abnormal is caused from;

1. The tool cable is not connected
2. If the controller or the transducer cable is located in an electric or magnetic noise field.
3. When the torque transducer, Tool cable or the controller malfunctions.

RECOVERY:
1. Verify that the tool cable is properly connected
2. Verify that the cable or controller is not located near any high voltage transient power
sources. Relocate as required and reinitialize the system.
3. Exchange Tool cable, tool and/or controller with known working units. Reinitialize the sys-
tem after each exchange, and make note of any change in the location of the abnormal.
4. Replace the defective component.

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Chapter 9: Troubleshooting

9.5 System Memory Errors

9.5.1 Code 4-0 SYSTEM MEMORY ERROR / FLASH ROM WRITE ERROR
Communications error to internal CONTROLLER Flash ROM during WRITE attempt.

This abnormal is caused from;

1. Metal chips and/or debris has migrated inside CONTROLLER Unit through vent holes.
2. Flash ROM IC chip has malfunctioned

RECOVERY:
1. Remove CONTROLLER Unit and blow or shake out debris.
2. Replace and return unit to FEC for repair.

9.5.2 Code 4-1 SYSTEM MEMORY ERROR / FLASH ROM READ ERROR
Communications error to internal CONTROLLER Flash ROM during READ attempt.

This abnormal is caused from;

1. Metal chips and/or debris has migrated inside CONTROLLER Unit through vent holes.
2. Flash ROM IC chip has malfunctioned

RECOVERY:
1. Remove CONTROLLER Unit and blow or shake out debris.
2. Replace and return unit to FEC for repair.

9.5.3 Code 4-2 SYSTEM MEMORY ERROR / SERVO AMP FLASH ROM ERROR
Communications error to internal CONTROLLER Servo Amp flash ROM.

This abnormal is caused from;

1. Metal chips and/or debris has migrated inside CONTROLLER Unit through vent holes.
2. Flash ROM IC chip has malfunctioned

RECOVERY:
1. Remove CONTROLLER Unit and blow or shake out debris.
2. Replace and return unit to FEC for repair.

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 FUSION Operations Manual Chapter 9: Troubleshooting (Rev. 3)

9.6 Servo Amplifier Response / Resolver

9.6.1 Code 5-0 SERVO AMPLIFIER REPLY ERROR / NO REPLY FROM RESOLVER
The controller is attempting to turn the motor, but is not receiving any signals back from the
resolver to indicate that the tool is actually turning.

This abnormal is caused from;

1. The motor/resolver cable is damaged or not connected
2. When the resolver, motor, or the controller malfunctions.
3. If there is excessive binding in the fastener, transmission, or the spindle assembly keeping
the motor from turning.

RECOVERY:
1. Verify that the motor cable is connected and not damaged.
2. Connect all spare tool cables to the existing tool.
3. Exchange tool and/or controller with known working units. Reinitialize the system after
exchanges.
4. Inspect and correct any binding in the spindle assembly, transmission or fasteners.

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Chapter 9: Troubleshooting

9.7 Servo Type Error

9.7.1 Code 6-0 SERVO TYPE ERROR / SERVO TYPE MISMATCH
The CONTROLLER Unit model does not match the connected motor type.

1. Verify the servo type tag with the motor type tag.

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 FUSION Operations Manual Chapter 9: Troubleshooting (Rev. 3)

Servo Amplifier Error

9.9.1 Code 8-1 SERVO AMPLIFIER ERROR / SERVO IS OVER HEATED

The CONTROLLER servo circuit has overheated.

This abnormal is caused from;

1. The controller servo drive circuit has failed.
2. If the environment temperature is more than 122 degrees Fahrenheit (50 degree centi-
grade) without any air flow.
3. Source voltage is very close to the limit and the environment temperature is also close to
the limit.

RECOVERY:
1. Replace the controller
2. Provide additional cooling to the enclosure.
3. Verify and correct the source voltage as required.

9.9.2 Code 8-4 SERVO AMPLIFIER ERROR / OVER CURRENT

The CONTROLLER servo circuit experienced a current overload.

This abnormal is caused from;

1. The controller servo drive circuit has failed.
2. If the environment temperature is more than 122 degrees Fahrenheit (50 degree centi-
grade) without any air flow.
3. Source voltage is very close to the limit and the environment temperature is also close to
the limit.
4. Maximum torque is being run or exceeded by the tool every cycle.
5. Speed may be too low or too high during torque speed.

RECOVERY:
1. Replace the controller
2. Verify proper cooling for the enclosure.
3. Verify and correct the source voltage as required.
4. Verify proper torque or work piece.
5. Adjust torque speed setting.

9.9.3 Code 8-5 SERVO AMPLIFIER ERROR / INTERNAL POWER SUPPLY.

The CONTROLLER servo power supply circuit is not working properly or the input voltage is
above the maximum limit.

This abnormal is caused from;.

1. The controller internal power supply has failed
2. Source voltage is very close to the limit and the environment temperature is also close to
the limit.
3. If the environment temperature is more than 122 degrees Fahrenheit (50 degree centi-
grade) without any air flow.

RECOVERY:
1. Replace the controller
2. Provide additional cooling to the enclosure.
3. Verify and correct the source voltage as required.

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Chapter 9: Troubleshooting

9.9.4 Code 8-6 SERVO AMPLIFIER ERROR / INPUT VOLTAGE ABNORMAL

The CONTROLLER servo power supply circuit has detected improper input voltage either
above or below the specified limits

This abnormal is caused from;

1. The controller internal power supply has failed
2. Source voltage is out of the limit and/or the environment temperature is also close to the
limit.
3. One or more phases of input power is missing

RECOVERY:
1. Replace the controller
2. Provide additional cooling to the enclosure.
3. Verify and correct the source voltage as required.

9.9.5 Code 8-9 SERVO AMPLIFIER ERROR/ OVER SPEED.

The resolver signal received at the CONTROLLER indicates an over speed condition.

This abnormal is caused from;

1. The resolver cable or resolver has failed.

RECOVERY:
1. Check resolver using method in 8.2.2
2. Replace resolver cable to spare cable
3. Replace tool assembly.

9.9.6 Code 8-10 SERVO AMPLIFIER ERROR / OVER LOAD ( I SQUARE T)

The duty cycle of the fastening application is too severe for this size of tool, or for the param-
eters currently setup.

RECOVERY:
1. Reduce duty cycle - Increase tool “downtime or off time” and/or increase torque speed to
reduce the amount of time running at high torque/slow speed.
2. If the problem remains, a larger tool assembly may be required for this application. Please
contact FEC.

9.9.7 Code 8-11 SERVO AMPLIFIER ERROR / RESOLVER SIGNAL ERROR.

The resolver signal received is not correct.

RECOVERY:
1. Check the cable; look for loose connectors for visible damages to the cable.
2. Replace with known good tool.

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 FUSION Operations Manual Chapter 9: Troubleshooting (Rev. 3)

9.9.8 Code 8-14 SERVO AMPLIFIER ERROR / MOTOR CONTROL CIRCUIT ERROR.
An abnormality occurred in the Motor Control circuitry in the controller.

RECOVERY:
1. Check that the GROUND is connected on the controller supply power.
2. Internal tool or cable damage – Replace Cable, Replace Tool.
3. Cycle power to OFF (leave off for more than 10 seconds) and Turn on power

9.9.9 Code 8-15 SERVO AMPLIFIER ERROR / POWER ON ERROR.

The Controller power on was not completed successfully.

RECOVERY:
1. Turn off power, Wait 10 sec minimum and power back on.

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Chapter 9: Troubleshooting

9.10 Parameter Error

9.10.1 Code 9-0 PARAMETER ERROR / MISSING SPEED PRESET.
Some speed preset is not setup in the parameter number selected or the wrong parameter
number has been selected by the PLC.

RECOVERY:
1. Verify that the parameter number that is being selected by the PLC is configured in the
controller.
2. Check that the reverse speed preset is not <0> or out of the specified speed range of the
tool.

9.10.2 Code 9-1 PARAMETER ERROR / MISSING TIME or SPEED PRESET

Some Time or Speed preset is not setup in the parameter number selected or the wrong pa-
rameter number has been selected by the PLC.

RECOVERY:
1. Verify that the parameter number that is being selected by the PLC is configured in the
controller.
2. Check that the reverse speed preset is not <0> or out of the specified speed range of the
tool.

9.10.3 Code 9-2 PARAMETER ERROR / PARAMETER SELECT ERROR

The parameter selected was empty.
RECOVERY:
1. Verify that the parameter number that is being selected by the PLC is configured in the
controller.
2. Check that the fastening presets are not <0> or out of the specified range for the tool.

9.10.4 Code 9-3 PARAMETER ERROR / MISSING REVERSE SPEED

The Reverse speed preset is missing.
RECOVERY:
1. Verify that the parameter number that is being selected by the PLC is configured in the
controller.
2. Check that the reverse presets are not <0> or out of the specified range for the tool.

9.10.5 Code 9-4 PARAMETER ERROR / TORQUE SPEED NOT SET

The Torque speed preset is missing.
RECOVERY:
1. Verify that the parameter number that is being selected by the PLC is configured in the
controller.
2. Check that the Torque speed is not set as <0> or out of the specified range for the tool.

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 FUSION Operations Manual Chapter 9: Troubleshooting (Rev. 3)

9.10.6 Code 9-5 PARAMETER ERROR / TORQUE SETUP ERROR

One of the Torque presets is out of range

RECOVERY:
1. Verify that the Torque presets are in range for the tool size.
2. Check that the torque presets are not <0> or setup as specified in 6.1.1.

9.10.7 Code 9-6 PARAMETER ERROR / ANGLE SETUP ERROR

One of the Angle presets is out of range

RECOVERY:
1. Verify that the Angle presets are in range for the tool size.
2. Check that the Angle presets are not <0> or setup as specified in 6.1.2.

9.10.8 Code 9-7 PARAMETER ERROR / REVERSE TORQUE OVER.

The Reverse torque is more than 1.5 times the Full Scale Torque.

RECOVERY:
1. Verify that the preset value is correct.
2. If the value is correct, check the application. The size of the tool is not adequate for this
application or the fastener being reversed may be over-torqued.

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Chapter 9: Troubleshooting

9.11 FUSION CONTROLLER Unit Fastening Faults and Causes

9.11.1 Torque Accept Conditions

The Accept LED will light for the following reasons:

1. The previous fastening was completed within all preset limits (TORQUE, ANGLE, 1st RATE, 2nd
RATE, and TIME).

9.11.2 Torque Reject Conditions

The Reject LED will light for the following reasons:

1. The final fastening torque is not between the low and high Torque limits, low and high angle limits,
low and high rate 1, 2 and 3 or the time 1 or final time limits set in the parameter presets.

Page 9-16