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AFC3000E-FB-EN-2

MFC-EN
ETHernet-I/P
Fieldbus
expansion Unit

Ethernet-I/P Fieldbus Expansion Unit

Revision History
Revision Date

Manual No.

Contents of Revision

08/20/2014

AFC3000-FB-EN-1

First Release

02/18/2016

AFC3000-FB-EN-2

Added Message Write Data info (pg. 35-38)

Manual Numbering Convention


AFC3000E-FB-EN-1
DSP1500= =Servo
Servo
Press
DSP1500
Press
AFC3000
=
Nutrunner
AFC1500 = Nutrunner
FUSION==DC
DCHand
HandTool
Tool
FUSION

Version Number
(Major Revision Level)
CC = CC-Link
DN = DeviceNet
PB = Profibus
PN = ProfiNet
EN = Ethernet-I/P

E = English Version
S = Spanish Version
*Japanese Version furnished by DDK
uses DDK numbering convention.

HW = Hardware Operation Manual


SW = Software Manual
FB = Fieldbus Manual

Any questions regarding the contents of this document or any related matter should be
directed to FEC Automation Systems at (586) 580-2622, faxed to (586) 580-2620 or emailed to
support@fec-usa.com.
The information set forth in the following document is the property of
FEC Automation Systems.
This document shall not be released to or copied for any person and/or organization without
the expressed prior consent of FEC Automation Systems.
Unauthorized reproduction or distribution of this manual is strictly prohibited.
Please contact FEC Automation Systems if you require additional copies.

PAGE 2

Ethernet-I/P Fieldbus Expansion Unit

Forward
This manual is intended as a supplement to the AFC3000 Hardware Operation Manual and should be
used in conjunction with information provided in that manual. FEC recommends reading that manual
before the contents of this manual (which only applies to systems requiring the optional Ethernet I/P
interface).

Ethernet-I/P
The AFC3000 Ethernet-I/P System conforms to the open field network Ethernet-I/P. Control of tools and
transactions of message information are executed by Ethernet-I/P explicit message communication.
Due to conformance with the open field network Ethernet-I/P System, connections with Ethernet-I/P devices
(master/slave) of other manufacturers are enabled.
Also, remote I/O communication and message communication can be executed at the same time.

System Structure (Ethernet-I/P)


PLC (Ethernet-I/P Master Station)

Remote I/O Communication


Message Communication

Ethernet-I/P MASTER
(1st Spdl.)
Slave
Station

2nd

3rd

32nd

Spdl

Spdl

Spdl

Ethernet-I/P Slave Stations of


Other Manufacturers

SLAVE

AFC3000 Ethernet-I/P System

PAGE 3

Ethernet-I/P Fieldbus Expansion Unit

Description of the Hardware (Ethernet-I/P)

Module
Status
LED

Link/
Activity
LED

Ethernet-I/P
Connector

Network
Status
LED

PAGE 4

Ethernet-I/P Fieldbus Expansion Unit

EDS File
An EDS file is an information file related to the communication specifications of Ethernet-I/P compatible
device and a separate, individual file exists for each device. The EDS file is necessary for using the
Ethernet-I/P configuration software to connect the MFC-EN and the PLC.
The EDS file is included in the installation CD for the AFC3000 User Console or may be downloaded from
the FEC website. Please refer to the instruction manual for the Ethernet-I/P configuration software
concerning the appropriate method for using the EDS file.

Module Pin Configuration


No.

Signal

Description

1
2
3
4
5
6
7
8

TD+
TDRD+
RD-

Send data +
Send data Receive data +
Not used.
Not used.
Receive data Not used.
Not used.

1
8

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

Be sure to connect the cable with all power turned OFF.


Caution

PAGE 5

Ethernet-I/P Fieldbus Expansion Unit

List of LED Indications


The module LEDs indicate the states of the nodes of the AFC3000 Ethernet-I/P System and the network
state.
B : Module
Status LED

A : Network
Status LED

C : Link
Activity LED

LED

Color
Off

State
Off
Lit up

Network
Status
LED

Green

Flash
Lit up

Red
Flash
Off

Module
Status
LED

Off
Lit up

Green
Flash
Red

Lit up
Flash

Off

Link
Activity
LED

Off
Lit up

Green
Flash

Details

Offline

Offline or power is not supplied.

Online
Communication
not established

Communicating normally.
Although online, connection is not established.

Connection
timeout
Power OFF

A critical error has occurred. / Redundant IP


address.
A connection timeout has occurred once or
more.
Power is not supplied.

Online
Communication
not established
Error

Normal state
Due to incomplete configuration or connection
failure, the device must be re-recognized.
A critical error has occurred.

Error
Link not
established
Not
communicating

A recoverable error has occurred.


ETHERNET link is not established and
communication is not performed.
ETHERNET link is established but
communication is not performed.
ETHERNET link is established and
communication is in progress.

Error

Communicating

PAGE 6

Ethernet-I/P Fieldbus Expansion Unit

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


I/O Input/Output

Maximum
Setting
Standard
Setting

Message Input/Output

MASTER Spindle

PLC MASTER

MASTER Spindle

PLC MASTER

PLC

Spindle

32bytes (256 points)

12bytes (96 points)

2048 word (4096 bytes)

16 word (32bytes)

32bytes (256 points)

8bytes (64 points)

2048 word (4096 bytes)

16 word (32bytes)

PLC

Spindle

AFC3000 Ethernet-I/P System Signal Specifications (PLC MASTER Spindle)


Number of MASTER Spindle Input Points 4 words 8 bytes (256 points)
Input signals are factory set and cannot be changed.
Word No.

No.01

No.02

BIT

0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

Signal

Word No.

STOP
RESET
REVERSE
START
SEQ SELECT BIT 0
SEQ SELECT BIT 1
SEQ SELECT BIT 2
SEQ SELECT BIT 3
SEQ SELECT BIT 4
CYCLE COUNT UP
CYCLE COUNT CLEAR
SEQ SELECT No. ENABLE
INPORT 1
INPORT 2
INPORT 3
INPORT 4
SEQ SELECT No.1
SEQ SELECT No.2
SEQ SELECT No.3
SEQ SELECT No.4
SEQ SELECT No.5
SEQ SELECT No.6
SEQ SELECT No.7
SEQ SELECT No.8
SEQ SELECT No.9
SEQ SELECT No.10
SEQ SELECT No.11
SEQ SELECT No.12
SEQ SELECT No.13
SEQ SELECT No.14
SEQ SELECT No.15
SEQ SELECT No.16

PAGE 7

No.03

No.04

BIT

0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

Signal

SEQ SELECT No.17


SEQ SELECT No.18
SEQ SELECT No.19
SEQ SELECT No.20
SEQ SELECT No.21
SEQ SELECT No.22
SEQ SELECT No.23
SEQ SELECT No.24
SEQ SELECT No.25
SEQ SELECT No.26
SEQ SELECT No.27
SEQ SELECT No.28
SEQ SELECT No.29
SEQ SELECT No.30
SEQ SELECT No.31
SEQ SELECT No.32
BYPASS SPDL No.1
BYPASS SPDL No.2
BYPASS SPDL No.3
BYPASS SPDL No.4
BYPASS SPDL No.5
BYPASS SPDL No.6
BYPASS SPDL No.7
BYPASS SPDL No.8
BYPASS SPDL No.9
BYPASS SPDL No.10
ID DATA CLEAR
ID SELECT ENABLE

Ethernet-I/P Fieldbus Expansion Unit

Word No.

BIT

No.05

0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

Signal

Word No.

BYPASS SPDL No.11


BYPASS SPDL No.12
BYPASS SPDL No.13
BYPASS SPDL No.14
BYPASS SPDL No.15
BYPASS SPDL No.16
BYPASS SPDL No.17
BYPASS SPDL No.18
BYPASS SPDL No.19
BYPASS SPDL No.20
BYPASS SPDL No.21
BYPASS SPDL No.22
BYPASS SPDL No.23
BYPASS SPDL No.24
BYPASS SPDL No.25
BYPASS SPDL No.26

No.06

BIT

0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

Signal

BYPASS SPDL No.27


BYPASS SPDL No.28
BYPASS SPDL No.29
BYPASS SPDL No.30
BYPASS SPDL No.31
BYPASS SPDL No.32

* The word No. at the PLC side differs according to the setting of the node address, etc., so please be sure
to confirm before using. Please refer to the AFC3000 Operation Manual, Section 5-3-2 and 5-3-3 for
description of the respective signals.

Caution

Cautio
n

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


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

Be careful of the following points when using the BYPASS No. # (1 to 32) signals.
If a certain Unit is to be put in the BYPASS mode, set the corresponding signal
among the BYPASS No. # (1 to 32) signals to ON with the START signal of the Unit
being in the OFF state and the BUSY signal of the MASTER Spindle for PC
communication and I/O (PLC) control being in the OFF state.
When fastening is executed with any of the spindle BYPASS No. # (1 to 32) signals
in the ON state, the fastening judgment of that Unit will be ignored as if it does not
exist.
Also, when any of the BYPASS No. # (1 to 32) signals is set to ON with the BUSY
of the MASTER Spindle being in the ON state, the sequence judgment may result
in REJECT.

PAGE 8

Ethernet-I/P Fieldbus Expansion Unit

AFC3000 Ethernet-I/P System Signal Specifications (MASTER Spindle PLC)


Number of MASTER Spindle Output Points 32 bytes (256 bits)
The table below is an example of the Output mapping using Ethernet I/P. Output bits (256) are
allowed to be user-programmed using the AFC3000 User Console Software.
The allocation of the signals can be set on any bit/pin through the PLC Output Layout setting function
of the AFC3000 Software.
Please refer to 5-3-4 PLC Output Layout of the <<AFC3000 Operation Manual>> for list of available
output signals (Master and individual spindle signals)
EXAMPLE ONLY: Actual signal placement may vary upon user configuration
Word No.

Output word
No. 1
Output
Signal
Setting
Example

Output word
No. 2
Output
Signal
Setting
Example

BIT

0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

Signal

Word No.

TOTAL REJECT
TOTAL ACCEPT
TOTAL ABNORMAL
TOTAL READY
TOTAL BUSY
END
SEQ SELECT BIT 0
SEQ SELECT BIT 1
SEQ SELECT BIT 2
SEQ SELECT BIT 3
SEQ SELECT BIT 4
SPINDLE IN BYPASS
DATA AVAILABLE
CURRENT WARNING
CAL WARNING

Output word
No. 3
Output
Signal
Setting
Example

ZERO LEVEL WARNING

SEQ No.1 SELECTED


SEQ No.2 SELECTED
SEQ No.3 SELECTED
SEQ No.4 SELECTED
SEQ No.5 SELECTED
SEQ No.6 SELECTED
SEQ No.7 SELECTED
SEQ No.8 SELECTED
SEQ No.9 SELECTED
SEQ No.10 SELECTED
SEQ No.11 SELECTED
SEQ No.12 SELECTED
SEQ No.13 SELECTED
SEQ No.14 SELECTED
SEQ No.15 SELECTED
SEQ No.16 SELECTED

Output word

PAGE 9

No. 4
Output
Signal
Setting
Example

BIT

0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

Signal

SEQ No.17 SELECTED


SEQ No.18 SELECTED
SEQ No.19 SELECTED
SEQ No.20 SELECTED
SEQ No.21 SELECTED
SEQ No.22 SELECTED
SEQ No.23 SELECTED
SEQ No.24 SELECTED
SEQ No.25 SELECTED
SEQ No.26 SELECTED
SEQ No.27 SELECTED
SEQ No.28 SELECTED
SEQ No.29 SELECTED
SEQ No.30 SELECTED
SEQ No.31 SELECTED
SEQ No.32 SELECTED
REJECT No.1
ACCEPT No.1
ABNORMAL No.1
BYPASS No.1
REJECT No.2
ACCEPT No.2
ABNORMAL No.2
BYPASS No.2
REJECT No.3
ACCEPT No.3
ABNORMAL No.3
BYPASS No3
REJECT No.4
ACCEPT No.4
ABNORMAL No.4
BYPASS No.4

Ethernet-I/P Fieldbus Expansion Unit

Word No.

BIT

Signal

Word No.

BIT

Signal

0 REJECT No.5
0 RUN REV HI REJ No.5
1 ACCEPT No.5
1 RUN REV LO REJ No.5
2 ABNORMAL No.5
2 LO CUR LIMIT WARNING No.5
3 READY No.5
3 HI CUR LIMIT WARNING No.5
Output word
4 BUSY No.5
4 CURRENT WARNING No.5
Output word
No. 5
5 BYPASS No.5
5 CAL VOLTAGE WARNING No.5
No. 7
6 TORQUE HOLD No.5
6 ZERO VOLT WARNING No.5
Output
7 PAR SEL (BIT0) No.5
7 JUDGE COMBO (BIT1) No.5
Output
Signal
8 PAR SEL (BIT1) No.5
8 JUDGE COMBO (BIT2) No.5
Signal
Setting
9 PAR SEL (BIT2) No.5
9 JUDGE COMBO (BIT3) No.5
Setting
Example
10 PAR SEL (BIT3) No.5
10
JUDGE COMBO (BIT4) No.5
Example
11 PAR SEL (BIT4) No.5
11 JUDGE COMBO (BIT5) No.5
12 TORQUE HI REJ No.5
12 JUDGE COMBO (BIT6) No.5
13 TORQUE LO REJ No.5
13 JUDGE COMBO (BIT7) No.5
14 FTQ HI REJ No.5
14 JUDGE COMBO (BIT8) No.5
15 FTQ LO REJ No.5
15
0 SNUG TQ HI REJ No.5
0
1 TQ INHIBIT HI REJ No.5
1
2 F ANGLE HI REJ No.5
2
3 F ANGLE LO REJ No.5
3
Output word
4 DIFF + ANG REJ No.5
4
No. 8
Output word
5 DIFF ANG REJ No.5
5
Thru
No. 6
6 RATE 1 HI REJ No.5
6
No. 16
7
RATE
1
LO
REJ
No.5
7
Output
8
RATE
2
HI
REJ
No.5
8
Signal
Output
9 RATE 2 LO REJ No.5
9
Setting
Signal
10 RATE 3 HI REJ No.5
10
Example
Setting
11 RATE 3 LO REJ No.5
11
Example
12 1ST TIME HI REJ No.5
12
13 1ST TIME LO REJ No.5
13
14 2ND TIME HI REJ No.5
14
ND
15 2 TIME LO REJ No.5
15
The example above (output word 5-7) shows an example of all available signals for each spindle.
While normally not all signals are used, any of the signals (for each spindle) can be preset
(programmed using the AFC3000 software) to any output bit.
* The word No. at the PLC input side differs according to the setting of the node address, etc., so please be
sure to confirm before using. Please refer to the AFC3000 Operation Manual, Section 5-3-2 and 5-3-3 for
description of the respective signals.

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


Caution

PAGE 10

Ethernet-I/P Fieldbus Expansion Unit

Fieldbus Setting (Ethernet-I/P)


The fieldbus settings are set in the Fieldbus Setting menu of the AFC3000 User Console. The following
setting window is displayed when Multi Fieldbus Setting is selected at the menu bar.
In the Bus Type Select/communication window, selection of the fieldbus type, uploading, downloading,
and verification of fieldbus settings with respect to the Unit, and browsing and saving of fieldbus settings
with respect to the PC can be performed.

Caution

The standard set values are set as the factory settings in the
Unit. Do not change the settings unless there is a special
reason.
Be sure to perform backup before changing the fieldbus
settings of the Unit.

Bus Type Select: The type of bus is selected from the list. Also, when Upload is executed, the bus
type is judged automatically and reflected in the selection part.
Configuration File
Browse: A fieldbus configuration file (*.nrfcf) is read from the PC.
Save: A fieldbus configuration file (*.nrfcf) is saved in the PC.
Upload:

The fieldbus settings are read from the MASTER Spindle for PC communication
and I/O (PLC) control.

Download:

The fieldbus settings are written into the MASTER Spindle for PC communication
and I/O (PLC) control. (Re-activate the control power after writing.)

Verify:

The fieldbus settings of the MASTER Spindle for PC communication and I/O
(PLC) control and the fieldbus settings in the User Console are compared.

PAGE 11

Ethernet-I/P Fieldbus Expansion Unit


In the Ethernet-I/P screen (of the AFC3000 Software), setting of the Ethernet-I/P interface is performed. The
network settings, the I/O size, and the message size can be changed.

Default (the settings are set to the factory settings when this is selected)
Network Settings
IP address
Subnet Mask
Default Gateway

192.168.11.50
255.255.255.0
192.168.11.1

I/O Setting Data Length [PLC to MASTER Spindle]: 8 bytes [64 bits]
I/O Setting Data Length [MASTER Spindle to PLC]: 32 bytes [256 bits]
Message Data Length [PLC to MASTER Spindle]: 32 bytes [256 bits]
Message Data Length [MASTER Spindle to PLC]: 4096 bytes [32768 bits]
* The number of message block bytes is fixed at 250 bytes.

I/O setting
Data Length [PLC to MASTER Spindle]
Setting range: 2 bytes [16 bits] to 12 bytes [96 bits]
Data Length [MASTER Spindle to PLC]
Setting range: 2 bytes [16 bits] to 32 bytes [256 bits]
The Number of Message Bytes Settings
Data Length [PLC to MASTER Spindle]
Setting range: 0 byte [0 bit] to 32 bytes [256 bits]
Data Length [MASTER Spindle to PLC]
Setting range: 0 byte [0 bit] to 4096 bytes [32768 bits]
Note: Power must be cycled if any of this configuration is changed and downloaded to the Master
controller

PAGE 12

Ethernet-I/P Fieldbus Expansion Unit

Fieldbus Message Setting (MASTER Spindle PLC)


The message information output from the MASTER Spindle for PC communication and I/O (PLC) control
is set in the AFC3000 User Console software. The maximum size of the message output that can be
handled is 4096 bytes.
The output order of the message data is: Multi Format Data Spindle format data of Spdl. No. 1
Spindle format data of Spdl. No. 2 Spindle format data of Spdl. No. 32.
The message output format is selectable (in the AFC3000 Software) to output either BCD format or
ASCII format, both examples are listed below.
Please contact the PLC manufacturer regarding the setting at the PLC side.
Multi Format Output Items (BCD Format)
Output
Items

Number
of Bytes

Fastening
Data

LSB (1word)

Multi Format
PLC Input Data

20

13

28

12
A

34
B

56
C

00
D

NUL

NUL

MSB (16word)

Date

Time
ID *1
SEQ No.
(1 to 32)

4
32

20135
28
12:34:56
ABCDEF

00

02

00
00
00
00

01
02
04
08

REJECT
ACCEPT
ABNORMAL
STOP
RESET
STOP
BYPASS
START OFF
IN CYCLE

00

10

00
00
00

20
40
80

SEQ
Judgment
*2

SEQ
4
123456
00 12 34 56 - Cycle
Count
*1: The ID is fixed at 32 bytes (16 words) and is output in ASCII format. NULL letters are set as unset
values.
*2: Please refer to AFC3000 Operation Manual, Sequence Judgment regarding the details of SEQ
Judgment.
Do not use the following characters when inputting the ID data.
: backslash (yen mark), /: slash,
Caution

:: colon, *: asterisk, ?: question mark,


: double quotation, < >: inequality signs, |: pipe sign

PAGE 13

Ethernet-I/P Fieldbus Expansion Unit

Multi Format Output Items (ASCII Format)


Output
Items

Number
of Bytes

12:34:56

32

ABCDEF

Time

ID*1
SEQ No.

REJECT

ACCEPT

ABNORMAL

STOP

RESET STOP

BYPASS

START OFF

IN CYCLE
8

123456

NUL

NUL

NUL

NUL

NUL

SEQ
Cycle
Count

2013528

10

SEQ
Judgment
*2, *3

PLC Input Data Letter String


2

Date

(1 to 32)

Multi Format

Fastening
Data

*1: The number of output bytes of the ID is fixed at 32 bytes (16 words). NULL letters are set as unset
values.
*2: Please refer to AFC3000 Operation Manual, Sequence Judgment regarding the details of SEQ
Judgment.
*3: (20H) is the ASCII code for (space).
Do not use the following characters when inputting the ID data.
: backslash (yen mark), /: slash,
Caution

:: colon, *: asterisk, ?: question mark,


: double quotation, < >: inequality signs, |: pipe sign

PAGE 14

Ethernet-I/P Fieldbus Expansion Unit


Spindle Format Output Items (BCD Format)
Output Items
Spindle No. (1 to 32)
PAR No. (1 to 32)

Spindle format

Number of
Bytes

Fastening
Data

00

01

00

02

Spindle Judgment*1
Spindle Cycle Count (8
digits)
TOOL Cycle Count (8 digits)

Peak Torque*2

LSB (1word)

MSB (2 word)
-

123456

00

12

34

56

12345678

12

34

56

78

12.34

00

12

34

02

Final Torque*2

12.34

00

12

34

02

Snug Torque*2

5.67

00

05

67

02

1st Peak Torque*2

12.34

00

12

34

02

2nd Peak Torque*2

12.34

00

12

34

02

Final Angle*2

123.4

00

12

34

01

Differential Angle*2

-12.3

00

01

23

11

Rate 1*2

1.234

00

12

34

03

Rate 1 Increment Torque*2

12.34

00

12

34

02

Rate 1 Increment Angle*2

123.4

00

12

34

01

Rate 2*2

-0.123

00

01

23

13

Rate 2 Increment Torque*2

12.34

00

12

34

02

Rate 2 Increment Angle*2

123.4

00

12

34

01

Rate 3*2

0.123

00

01

23

03

Rate 3 Increment Torque*2

12.34

00

12

34

02

Rate 3 Increment Angle*2

123.4

00

12

34

01

1st Time*2

123.456

12

34

56

03

2nd Time*2

123.456

12

34

56

03

Cycle Time*2

654.321

65

43

21

03

Peak Current*2

12.3

00

01

23

01

Angle at Peak Torque*2

123.4

00

12

34

01

Rundown Revolutions*2

12.34

00

12

34

02

ZERO Voltage*2

-0.123

00

12

34

13

CAL Voltage*2
Spindle Cycle Count (4
digits)*3
TOOL Cycle Count (4
digits)*3
Load rate

3.512

00

35

12

03

123456

01

23

12345678

23

45

20

00

20

*1: In regard to the Spindle Judgment, Judgment Data 1 is output as , Judgment Data 2 is output
as , Error Data is output as , and 1st Reject Item is output as . The values output as , ,
and are respectively set by bit allocation from Fieldbus Message Setting of the AFC3000 User
Console.
Note: shaded area described on next page

PAGE 15

Ethernet-I/P Fieldbus Expansion Unit

*2: With each of the output items besides Spindle No., Parameter No., Spindle Judgment, Spindle
Cycle Count (8 digits 4 digits), Tool Cycle Count (8 digits 4 digits), and Load rate, the results
are output in the order of: indication up to a maximum of 6 digits (without the decimal point) in 2
words (4 bytes), sign, and number of digits to the right of the decimal point.
12 34
56 0 2

Sign

Number of Digits to the right of the Decimal Point


Details

Indication

Details

Indication

0
1

+ value

No digits right of decimal point

- value

1 digit right of the decimal point

2 digits right of the decimal point

3 digits right of the decimal point

4 digits right of the decimal point

5 digits right of the decimal point

*3: With each of Spindle Cycle Count (4 digits) and Tool Cycle Count (4 digits), numerical values of
the millions, hundred thousands, ten thousands, and thousands places are output as 4-digit BCD
data.
Also, as the cycle count next to 9,999,999 times (99 99BCD), 10,000,000 times is output as (00
00BCD).

PAGE 16

Ethernet-I/P Fieldbus Expansion Unit


Spindle Format Output Items (ASCII Format)
Output Items

Spindle Judgment*2

2
2
4

1
2

123456

Spindle format
1 word

] ]

1
1

] ]

2
2
5
2
2

.
.
.
.
.

3
3
6
3
3

4
4
7
4
4

1
2

Rate 1 Increment Torque

10
6

1.234
12.34

Rate 1 Increment Angle

123.4

10
6

-0.123
12.34

Rate 2 Increment Torque


Rate 2 Increment Angle

123.4

Rate 3 Increment Torque

10
6

0.123
12.34

Rate 3 Increment Angle

123.4

Cycle Time*3

10
10
8

123.456
123.456
654.321

Peak Current*3

10

12.3

Angle at Peak Torque

123.4

Rundown Revolutions*3

12.34

ZERO Voltage

-0.123

CAL Voltage

3.512

Spindle Cycle Count (4


digits)*4
TOOL Cycle Count (4
digits)*4

123456

Occurrence

Judgment

Occurrence

Judgment

Occurrence

.
.

2
3

0
2

.
.

1
3

2
4

0
2

.
.

1
3

2
4

1
1
6

2
2
5

3
3
4

.
.
.

4
4
3

5
5
2

6
6
1

3
4

Judgment

Judgment

Occurrence

Judgment

Occurrence

Occurrence

Occurrence

]
3

Judgment

Judgment

Occurrence

Judgment

Occurrence

Warning

]
2

]
1

4
*1: (20H) is the space code (space).

Load rate

1234567
8
20

Occurrence

Judgment

Judgment

2nd Time*3

Occurrence

1st Time*3

Judgment

Rate 3*3

-12.3

Differential Angle*3

123.4

Final Angle*3

Rate 2*3

5 word

2nd Peak Torque

1
1

Rate 1*3

4 word

8
8
8
6
6

1st Peak Torque

3 word

1
2

1234567
8
12.34
12.34
5.67
12.34
12.34

2 word

Spindle Cycle Count (8


digits)
TOOL Cycle Count (8
digits)
Peak Torque*3
Final Torque*3
Snug Torque*3

Fastening
Data

] ]

Spindle No. (1 to 32)*1


PAR No. (1 to 32)

Number
of Bytes

*2: In regard to the Spindle Judgment, Judgment Data 1 is output as , Judgment Data 2 is output as
, Error Data is output as , and 1st Reject Item is output as . The values output as , ,
and are respectively set by bit allocation from Fieldbus Message Setting of the AFC3000 User
Console.

PAGE 17

Ethernet-I/P Fieldbus Expansion Unit

*3: With each of the output items for which there are set values of high and low limits, the results are
output in the order of: sign, result indication (including the decimal point), judgment code, and 1st
Reject (failure) item. Also with items besides the differential angle and rates 1 to 3, is not output,
and for the peak current, is not output.

- 123.5L X

Sign

Judgment Code

Indication

Details

Indication

Space (20H)

+ value

Space (20H)

- (2DH)

- value

H (48H)
L (4CH)

Details
Within high and low limit, no warning (peak
current)
Outside high limit, high limit warning (peak
current)
Outside low limit, low limit warning (peak
current)

1st Reject Item


Indication

Details

X (58H)

1st Reject item

Space (20H)

Reject item besides the 1st Reject

*4: With each of Spindle Cycle Count (4 digits) and Tool Cycle Count (4 digits), numerical values of
the millions, hundred thousands, ten thousands, and thousands places are output as 4-digit BCD
data.
Also, as the cycle count next to 9,999,999 times (99 99), 10,000,000 times is output as (00 00).

PAGE 18

Ethernet-I/P Fieldbus Expansion Unit


Judgment Data 1 and 2 Items (in common with BCD and ASCII)
The Judgment data and the Abnormal data of the operation results are set by bit allocation. In regard
to the setting method, please refer to Fieldbus Message Setting in the <<AFC3000 User Console
Instruction Manual>>.
Item

Classification

Logic

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

REJECT

RESET STOP

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


This is output when fastening ends with the fastening results being within the
judgment ranges.
This is output when an error occurs in the system or during the fastening
operation.
This is output when the BYPASS signal is set to ON at the start of fastening
or during the fastening process.
This is output when the STOP signal is set to OFF at the start of fastening or
during the fastening process.
This is output when the RESET signal is set to ON at the start of fastening or
during the fastening process.

START OFF

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

ACCEPT
ABNORMAL
Spindle
Judgment

Details

BYPASS
STOP

Peak torque low limit Reject/peak torque high limit Reject


Torque Reject

Final torque low limit Reject/final torque high limit Reject


Snug torque high limit Reject
Start torque inhibit high limit Reject
Final angle low limit Reject/final angle high limit Reject

Angle Reject
Fastening
Reject Items

Differential - angle Reject/Differential + angle Reject


Rate 1 low limit Reject/Rate 1 high limit Reject

Rate Reject

Rate 2 low limit Reject/Rate 2 high limit Reject


Rate 3 low limit Reject/Rate 3 high limit Reject
1st time low limit Reject/1st time high limit Reject

Time Reject
Rundown
Revolutions
Current Value
Warnings
Information
Signal

Information
1 to 8

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


Rundown revolution high limit Reject/rundown revolution low limit Reject
Low current value limit warning/high current value limit warning
This is output when a REJECT condition of any of information signal settings
INFO 1 to 8 is detected. The information signal is set at the AFC3000 User
Console.

Abnormal Data Items (in common with BCD and ASCII)


Abnormal State No.

Abnormal State 1
Abnormal State 3
Abnormal State 4
Abnormal State 5
Abnormal State 6
Abnormal State 8
Abnormal State 9
Abnormal State 10

Details

Torque transducer error


Preamplifier error
System memory error
Servo apply error
Servo type error
Servo amplifier error
Setting data error
Multi signal error

PAGE 19

Ethernet-I/P Fieldbus Expansion Unit


1st Reject (Failure) Item (in common with BCD and ASCII)
The contents of the 1st Reject (failure) item are output in BCD format. The output values are fixed
according to item and are output as shown below.
Item

Output Format (BCD Format)

No REJECT

00

Peak torque high limit REJECT

01

Peak torque low limit REJECT

02

Final torque high limit REJECT

03

Final torque low limit REJECT

04

Final angle high limit REJECT

05

Final angle low limit REJECT

06

Differential + angle REJECT

07

Differential - angle REJECT

08

Rate 1 high limit REJECT

09

Rate 1 low limit REJECT

10

Rate 2 high limit REJECT

11

Rate 2 low limit REJECT

12

Rate 3 high limit REJECT

13

Rate 3 low limit REJECT

14

1st time high limit REJECT

15

1st time low limit REJECT

16

2nd time high limit REJECT

17

2nd time low limit REJECT

18

Rundown revolution high limit


REJECT
Rundown revolution low limit
REJECT
Snug torque high limit REJECT
Start torque inhibit high limit
REJECT

19
20
21
22

PAGE 20

Ethernet-I/P Fieldbus Expansion Unit


Output Items: Example of Spindle Judgment Output Data (in common with BCD and ASCII)
The judgment data of Spindle judgment are set by bit allocation of 2 bytes. The conditions of the
output data can be changed by combination of the logic OR/AND.
Judgment data setting
Judgment Data 2 (BIT)
Judgment Data 1 (BIT)
Item
7
6
5
4
3
2
1
0
7
6
5
4
3
2
1
0
Logic

OR

OR

OR

OR

OR

OR

OR

OR

OR

OR

OR

OR

OR

OR

OR

OR

ACCEPT

REJECT

ABNORMAL

BYPASS

STOP
RESET
STOP
Peak Torque
High Limit
REJECT
Peak Torque
Low Limit
REJECT
Final Torque
High Limit
REJECT
Final Torque
Low Limit
REJECT
Final Angle
High Limit
REJECT
Final Angle
Low Limit
REJECT

~
Error Data Setting
The error data of Spindle judgment is set by bit allocation of 1 byte. The data corresponds to the
abnormal state No. when an error occurs.
Error Data (BIT)
Item
7
6
5
4
3
2
1
0

Abnormal state 1

Abnormal state 3

Abnormal state 4

Abnormal state 5

Abnormal state 6

Abnormal state 8

Abnormal state 9
Abnormal state 10

PAGE 21

Ethernet-I/P Fieldbus Expansion Unit


Example 1: Spindle judgment is ACCEPT
1word
2word
Output
Judgment
Judgment
Occurring
Item
Error Data
Data 1
Data 2
Fastening Reject
Spindle
01
00
00
00
Judgment
Example 2: Spindle judgment is REJECT: Final Torque Low Limit Reject
1word
Output
Item

2word

Judgment
Data 1

Judgment
Data 2

Error Data

Occurring
Fastening Reject

02

08

00

04

Spindle
Judgment

Example 3: Spindle judgment is ABN3-3


1word
Output
Item

2word

Judgment
Data 1

Judgment
Data 2

Error Data

Occurring
Fastening Reject

04

00

02

00

Spindle
Judgment

Example 4: Spindle judgment is START OFF: Peak Torque Low Limit Reject
1word
Output
Item

2word

Judgment
Data 1

Judgment
Data 2

Abnormal
Data

1st Reject Item

40

02

00

02

Spindle
Judgment

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

Number of
Bytes

Spindle cycle count (4 digits)

2bytes

Data Format
BCD Format

Tool cycle count (4 digits)

2bytes
For each of the cycle counts, numerical values of the millions, hundred thousands, ten thousands, and
thousands places are output as 4-digit BCD data. Also, as the cycle count next to 9,999,999 times (99
99BCD), 10,000,000 times is output as (00 00BCD). In the case of a 32-Spindle system, the total length
of the message data is 64 words (128 bytes).
Fieldbus Message Output Example (when not set) (Note:PLC output ref. for Allen Bradley)
Format
Spindle
No.
1
2

Output Item

Result Output

Spindle cycle count


Tool cycle count
Spindle cycle count
Tool cycle count

1234
12345
123456
1234567

PLC Output
C00
C01
C02
C03

00 01
00 12
01 23
12 34

32

Spindle cycle count


Tool cycle count

12345678
20000678

C062
C063

23 45
00 00

PAGE 22

Ethernet-I/P Fieldbus Expansion Unit


Message Information Output Example (Multi Format) (Note:PLC output ref. for Allen Bradley)
Multi Format
Output Item
Sequence
Cycle Count

Result Output
216
2013-06-21

Time

10:23:36

Sequence Judgment

REJECT

C06

00 01

Sequence No.

C07

00 01

Final Message Information


Area
(when 250 bytes are set)

C124

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

PAGE 23

PLC Input (ASCII Format)


C00 to
C07
C08 to

_____216
2013-06-21

C17
C18 to

10:23:36

C25
C26 to

REJ_

C29
C30 to

_1

C31

Date

PLC Input (BCD Format)


C00
00 00
C01
02 16
C02
20 13
C03
06 21
C04
10 23
C05
36 00

C124

Ethernet-I/P Fieldbus Expansion Unit

Message Information Output Example (Spindle Format) (Note:PLC output ref. for Allen Bradley)
Spindle Format
Spdl.
No.

Output Item

Result
Output

Peak Torque [Nm]

12.34

Final Torque [Nm]

12.34

Final Angle [deg]

123.4

Rate 1 [Nm/deg]

1.234

Rate 2 [Nm/deg]

5.678

Rate 3 [Nm/deg]

9.012

1st Time [sec]

12.345

2nd Time [sec]

6.789

Peak Torque [Nm]

23.45

C32
C33

00 34
56 02

~
00 45

C49

67 02

~
Free area

C48

45.67

Peak Torque [Nm]

34.56

~
4

00 12
34 02
00 12
34 02
00 12
34 01
00 12
34 03
00 56
78 03
00 90
12 03
01 23
45 03
00 67
89 03
00 23
45 02

Peak Torque [Nm]

C00
C01
C02
C03
C04
C05
C06
C07
C08
C09
C10
C11
C12
C13
C14
C15
C16
C17

~
3

PLC Input (BCD Format)

C74

_12.34__
_12.34__

C15
C16 to

_123.4HX

C23
C24 to

__1.234___

C33
C34 to

__5.678___

C43
C44 to

__9.012___

C53
C54 to

_12.345___

C63
C64 to

__6.789___

C73

C74

C4095

C00 to
C07
C08 to

Final Message Information


Area
(when max 4096 bytes
setup)

PLC Input (ASCII Format)

C4095

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


Note: Each spindles data will reside in the same location regardless of whether the spindle is used in a
particular fastening cycle.
(Example: If a system has 3 connected spindles and spindle #1 is not used in a sequence (for a particular
model for example), then the data for spindle #2 & #3 will only be sent and will reside in their spindles data
location skipping the spindle #1 location)

PAGE 24

Ethernet-I/P Fieldbus Expansion Unit

PLC Setting Example


This procedure is written for using Rockwell Automation RXLogix5000 V15.02.00 and Allen Bradley
CompactLogix L32E. If the system is not the same as listed above, setup may be different. Please
contact to PLC manufacturer for detail as each PLC may be different
1.

Register MASTER Spindle Fieldbus unit to network


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

Select Generic Ethernet Module from module list and click the OK button.

PAGE 25

Ethernet-I/P Fieldbus Expansion Unit


Specify Name (FEC AFC3000), IP address, and Connection Parameters that matches the
parameters set to the Fieldbus setup using the AFC3000 User Console software.
Note: Input / Output size MUST match the settings programmed in the Ethernet I/P setting of the
AFC3000 Fieldbus setup or PLC (Ethernet I/P) error will occur.

AFC3000

Click on the Connection tab and set connection setup as below.

PAGE 26

Ethernet-I/P Fieldbus Expansion Unit


When the Master Spindle Fieldbus unit is added to the I/O configuration, the data table will be added
to the controller tags automatically.

AFC3000_2:I (shown as AFC1500 in above screenshot)


Input signals from AFC3000 controller. (FEC to PLC)
AFC1500_2:O (shown as AFC1500 in above screenshot)
Output signals to AFC3000 controller. (PLC to FEC)
AFC1500_2:C (shown as AFC1500 in above screenshot)
Message communication data from the AFC3000 controller. (AXIS to PLC for fastening result data.)
An additional program/command needs to be added for sending/retrieving the data.

PAGE 27

Ethernet-I/P Fieldbus Expansion Unit


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

Select the DATA TYPE format (BCD or ASCII).


Data from the Master (Multi) and Spindle (Axis) must be configured in the table below each tab. The
Multi format contains the Header data (such as Date, Time, Sequence #, Cycle Count, etc. aka data
that comes from the Master Unit) The Axis format contains the actual spindle fastening data (such as
Torque, Angle, Time, Rate, etc.) Right click on the table and select the item from the pop up window
that you wish to be transferred.

(Example of Multi format selection shown above)


Note: Selecting Null deletes the item from the list.
PAGE 28

Ethernet-I/P Fieldbus Expansion Unit


(Example of Axis format selection shown below this format will be for EACH spindle connected in the
system to the Master Unit)

When the system has more than 1 spindle, the data will be output in spindle sequential order as shown
below.
Data from total fastening status (Multi data)
Data from SPINDLE 1
Data from SPINDLE 2
Data from SPINDLE 3
|
Data from up to SPINDLE 32

After the fastening result data has been setup, download the changed configuration to the Master controller.

PAGE 29

Ethernet-I/P Fieldbus Expansion Unit


PLC program.
1. Read_Tag needs be added to the Controller Tags for message transfer
This data tag contains the configuration of the message transfer.
Each MSG command needs to have its own Read_ tag.

AFC3000
AFC3000
AFC3000

The MSG command is used for transferring the fastening result.

PAGE 30

Ethernet-I/P Fieldbus Expansion Unit


Property of the MSG command is shown below. (Right Click in MSG command)

A2

AFC3000:C.Data[0]

Message Type
Service Type
Service Code
Class
Instance
Attribute
Destination

CIP Generic
Get Attribute Single
E
A2
1 ~ 17
5
The controller tag C should be selected

Note: Each message command can only handle 250 bytes. If more than 250 bytes of data needs to
be transferred, another controller tag needs be added (Read_tag) for the buffer and another MSG
command needs be added. The second MSG command should have its instance as 2 with its
Destination address incremented to the next block of data (250, 500, 750, 1000, etc.) and so on up
to a maximum of 17 for up to 4096 bytes of message data).
Example: [AFC3000:C.Data(250)] for the second block of 250 bytes

PAGE 31

Ethernet-I/P Fieldbus Expansion Unit


At the communication tab screen, select Path. The AFC3000 controller will show up in the
browser as shown below.

AFC3000
AFC3000

AFC3000
AFC3000

ETHERNET-MODULE AFC3000
ETHERNET-MODULE AFC3000_2

PAGE 32

Ethernet-I/P Fieldbus Expansion Unit


An example of a message transfer PLC program is shown below.

AFC3000:C.Data[0]
250

AFC3000:C.Data[250]
250

This program transfers up to 250 bytes of fastening result data.


The first MSG command has 1 as Instance and is sending the data into AFC1500:C[0] memory
block. The second MSG command has 2 as Instance and sending the data into another data
memory block AFC1500:C[250] that would have been manually added when the second Read_tag
was added.
Note: All instructions above that show AFC1500 would be AFC3000 for the AFC3000 setup.

Note: The above information contained in this procedure are meant for REFERENCE ONLY when
configuring an FEC Ethernet I/P interface using FEC AFC3000 User Console Software, FEC
AFC3000 Nutrunner System, Rockwell Automation RSlogix 5000 software and Allen Bradley
CompactLogix L32E hardware. Actual application configuration may differ from this set-up depending
on the PLC chosen for the application.

PAGE 33

Ethernet-I/P Fieldbus Expansion Unit


Message Data Example written for an AFC1500 System showing the :C register data
(AFC1500 would be AFC3000 for AFC3000 system)

AFC1500 User Console


MONITOR Screen for
above Data

PAGE 34

Ethernet-I/P Fieldbus Expansion Unit

Fieldbus Message Setting (PART ID Data - PLC to FEC Master Spindle)


1. Contents of Sent Data: ASCII Data
Refer to 3. below regarding the actual sent results.
2. Max. message length: 16words/32 bytes
(As configured in AFC3000 Software)
3. Input Example
Select ASCII letters to send message information from the PLC to the MASTER Spindle for PC
communication and I/O (PLC) control. (Only ASCII Data can be recognized by FEC Master)
The message information sent from the PLC to the MASTER Spindle for PC communication and I/O
(PLC) control is reflected in the fieldbus communication, the AFC3000 User Console, the Unit
RS232C, and the expansion RS232C.
- The standard set value for the ID input data is 32 bytes (16 words). Be careful
because even when a value beyond this is set, only the 32 bytes from the start
are saved in the fastening result retention of the Unit.
- Do not use the following characters.
Caution
: backslash (yen mark), /: slash,
:: colon, *: asterisk, ?: question mark,
: double quotation, < >: inequality signs, |: pipe sign

PLC configuration

PAGE 35

Ethernet-I/P Fieldbus Expansion Unit

PLC CONFIGURATION DATA WRITE


A Write_Tag needs to be added to the Controller Tags for data to be sent from the PLC to the FEC Master
Spindle. (Such as part ID Data) This data when received by the FEC Master spindle will be Married with
the fastening result data so that the fastening data would now contain the part ID number providing a birth
history for the part being fastened.
The Write_Tag contains the configuration of the message transfer. A MSG command (Message command
in the PLC logic) must be used in conjunction with a Write_Tag to send data. In the case below,
VIN_Number_Write tag has been setup and configured (following pages)

PAGE 36

Ethernet-I/P Fieldbus Expansion Unit

Below are the properties which must be setup for the Message Configuration of the Write_Tag.
(Right Click in MSG command)

Message Type
Service Type
Service Code
Class
Instance
Attribute
Destination

CIP Generic
Get Attribute Single
10
A2
1
5
The controller tag VIN_Number or whatever Write Tag you setup should be selected

Note: The FEC Master spindle will only take a maximum of 32 Bytes for the Write_Tag (Part ID data)
configurable (between 0-32 bytes) in the AFC3000 software for the Fieldbus Message Setup. So an
instance of 1 is all that is required in the above setup for WRITING data using the Message Command.

PAGE 37

Ethernet-I/P Fieldbus Expansion Unit

PLC Logic Example: Sending Message data to FEC Master Spindle

The MSG message command initiates the message data to be sent or received. The Write tag sends the
data to the device connected, and the Read tag retrieves the data from the connected device.
In the example above, the Write MSG command takes place at or near the start of the machine cycle before
the FEC controller has been issued a START command. (The FEC Master Spindle, can receive the Write
Data any time before the end of the fastening cycle. Once received, the data is buffered and will be used
until new message data is received or the ID DATA CLEAR Input signal is enabled (See Input signals).
(The ID data received by the FEC Master Spindle will be married with the fastening data and will continue to
use the same message data it receives until new data is sent or the ID Data Clear signal is turned on. Care
must be taken so data is not recorded with the same ID data in that case)
The Read Tag in the example above is shown happening AFTER the FEC fastening is completed. Once
fastening is completed, the MSG Read command can be performed and the fastening result data will be
read into the PLC.

PAGE 38