Bosch Rexroth Tightening System 350

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5 Control signals

This chapter contains detailed information on the control signals in the Rexroth

Tightening System 350. The information provided in this document refers to software

versions V2.100 and higher of the BS350 operating system.

• Definitions (page 122)

• Description of all PLC signals (page 126)

• KE communication unit (page 156)

• KE timing diagrams (page 163)

• Tightening controller (page 172)

• SE timing diagrams (page 178)

Main Page

Table of Contents5
About this Documentation9
Overview of this Documentation10
Validity of the Documentation10
Additional Documentation11
Representation of Information11
Safety Instructions11
Symbols and Representations12
Designations13
Abbreviations16
Safety Instructions17
About this Chapter18
Using and Communicating the Safety Instructions18
Instructions for Use19
Operating Instructions20
Cleaning Instructions20
Maintenance and Repair Instructions21
Disposal Instructions21
Intended Use21
Introduction21
Application Areas22
Improper Use22
Personnel Qualifications23
General Safety Instructions24
Product- and Technology-Dependent Safety Instructions for Rexroth Tightening System 35025
Protection against Accidental Contact with25
Electrical Parts25
Protective Extra-Low Voltage for Protection against Electric Shock27
Protection against Dangerous Movements27
Protection against Magnetic and Electromagnetic Fields During Operation and Assembly30
Protection against Accidental Contact with Hot Parts3030
Protection During Handling and Assembly31
Protection When Handling Batteries31
Protection against Pressurized Lines32
The Tightening System 35034
Definitions34
System Design34
Compact System34
Modular System37
Description of the Tightening System 35039
CS351 Compact System39
Modular System43
Tightening Spindles46
Ergospin Hand-Held Nutrunner47
Cables54
Software54
Integration in an Entire System55
Compact System55
Modular System56
Communication between the Tightening System and the BS350 Operating System57
External Communication58
Process Quality Manager (PQM)58
Construction Guidelines59
Design of a Bolted Connection60
Clamp Force and Distortion of Connected Parts, Operating Forces60
Determination of the Required Torque to Create a Bolted Connection61
Torque Ranges64
Tightening Case (Soft - Hard)64
Tightening Processes65
Tightening System Design65
Tightening Spindle65
Ergospin Hand-Held Nutrunner69
Connection Cables70
Control and Power Electronics74
Connected Load78
Calculation of Power Loss82
Reduce Cycle Time84
Electrical Connections between the Tightening System and the Production Environment88
Display88
Integration of the Tightening System in an Installation89
Ambient Conditions89
Design of Mains Connection98
Grounding99
Performance Level (PL) Within the Rexroth Tightening System 350103
Identification of the Compact System/Card Rack Field and the Modules106
Assembly Notes106
Rework Station108
Use of Additional Components (Accessories)109
Compatibility with Foreign Substances112
Planning Guidelines112
Planning Assistance112
3-D/CAD Data112
Circuit Diagrams113
Control Signals121
Definitions122
Tightening Channel122
Tightening Controller122
Tightening Cell (FC)122
Application Block (FO)123
PLC Signals123
Description of All PLC Signals126
Input Signals126
Output Signals140
KE Communication Unit156
PLC Signals of KE Communication Unit156
Sequence162
KE Timing Diagrams163
Switching on the KE163
Normal Sequence of a Tightening Application (OK Tightening) with Use of Resrsall163
Normal Sequence of a Tightening Application (OK Tightening)164
Normal Sequence of an Already Selected Tightening Application164
Attempted Start of an Invalid (E.g. Not Programmed or Incorrectly Programmed) Tightening Application165
(Application 2)165
Controlling the Ergospin Leds by an External Controller165
Results Reset (FO X Resrs) after the End of a Tightening Application166
Results Reset (FO X Resrs) During Completion of a Tightening Application166
Cancelation of a Tightening Application by Removing the Start Signal167
KE System Error167
Cancelation of a Tightening Application by FC en168
Start a 2Nd Tightening Application, Accessing at168
Running Tightening Application168
Simultaneously Starting Two Tightening Applications with Partially the same Tightening Channels169
Simultaneously Starting a Tightening Application Via Cw and Ccw Leads to a System Error169
Acknowledging of a Class 3 System Error Via KE Resf170
Attempted Acknowledgement of a Class 1 System170
Error Via KE Resf170
Bypassing a Spindle with Ch X.y Byps or Via the Operating Program171
Behavior of FC Rdy and FO X Rdy in Bypass Mode171
NOK Lock of a Tightening Application and Acknowledgement with FO X Nokac171
Tightening Controller172
PLC Signals from the Tightening Controller172
Sequence175
SE Timing Diagrams178
Switching on the Tightening Controller178
Normal Tightening Process with Program Change179
And Without Results Reset179
Cancelation of a Tightening Process by Removing the Start Signal179
Recognition of "Play at Start Switch180
Controlling the Ergospin by an External Controller180
Cancelation of a Tightening Process by System Error181
System Error at Start of a Tightening181
Cancelation of a Tightening Process by Removing the en Enable Signal182
Acknowledgement of a Class 3 System Error Via the PLC Interface182
PLC Behavior with a Class 1 System Error182
Setting the Trigger Output183
NOK Lock and Acknowledgement183
Incyccw184
Result Reset (Resrs) after Tightening Process End184
Result Reset (Resrs) before Tightening Process185
End185
Ergospin185
Reaching the Monitoring Limit of Ergospin after186
A Tightening186
Automatic Data Backup186
Clockwise Tightening (Cw) and Subsequent Loosening Program (Ccw), Changing the Direction of Rotation (Ccwsel) on the Ergospin188
Disconnecting the Tightening Tool and Using the "Spdck" PLC Signal189
Connecting the Tightening Tool and Using the "Spdck" PLC Signal190
Open Position Referencing191
Tightening Process with Opening the Flat Output Drive in Tightening Direction192
Linking of Two Programs (Automatic Program Start)193193
Data Services195
Overview of the Tightening Results Communication196
Interface Standards198
Protocols for Results Output199
Identification Codes200
Quality Code206
Special Cases for Tightening Results207
Tightening Results from Several Steps of a Tightening Process209
Chronological Sequence of the Tightening Results Data210
Formats of the Results Output211
Ethernet Communication214
Fundamentals of the Ethernet Tightening Data Output215
Results Output Via FTP220
Formats of the Results Output225
Opening and Closing the FTP Connections for Results Output240
Results Data Transfer with Ethernet241
Initial Operation of the Ethernet Connection246
Mass Storage Diagnosis252
Error Messages in Connection with Ethernet/Ftp258
Communication259
Fundamentals of the 3964R and RK512 Tightening Data Output260
ID Code Transfer to the Tightening System Via the 3964R Protocol266
Results Output with the 3964R and RK512 Protocols269
Setting Results Output Parameters271
Chronological Sequence for Tightening Results285
Data Provision285
Error Messages in Connection with the 3964R and RK512 Protocols287
PLC Communication288
Fundamentals of Tightening Results Output Via Field Buses289
Results Output Via Field Bus292
Transferring the ID Codes to the Tightening System Via Field Bus292
Formats of the Results Output294
Results Data Transfer with Field Busses306
Effects Stop Field Bus and Communication Stop Field Bus to I/O Signals309
Error Messages in Connection with Field Buses309
Send Range Extension (Multitelegram)310
Printer-Communication316
Results Output on Printer317
Formats of the Results Output320
Chronological Sequence of the Tightening Result Data Output Process322
Error Messages in Connection with the Results Output Via a Printer324
Toolsnet Communication324
Overview324
Installing the Toolsnet Gateway325
Configuring the Toolsnet Gateway326
Mode of Operation of the Toolsnet Gateway327
Settings in the BS350328
Assignment of XML Protocol to Toolsnet Protocol329
Error Analysis and Treatment329
Rexroth Open Protocol330
Settings in the BS350 Operating System330
Open Protocol335
Diagnosis and Troubleshooting335
Message Structure335
Rexroth OP-Ford337
Rexroth OP-BMW338
Messages339
HTTP Protocol434
Settings in the BS350 Operating System435
Parameter of Results Output436
Example: Calculation of the Data Volume for Results Files443
VW-XML 2.X Protocol445
Settings in the BS350 Operating System446
Configuration of the OK/NOK Counter for VW-XML448
PLC-Signals449
Tightening Status Code (SSC) and Tightening Status Messages451
Messages452
Process Data453
Rexroth IPM Protocol454
Message Structure456
Settings in the BS350 Operating System457
Protocol466
Status of Rexroth IPM Protocol467
Field Bus Customer Protocols468
PROFINET Connection According to BMW RPA Standard (RPA Interface)468
PLUS Protocol Connection472
Technology472
Principles of Operation472
Implementing the Sequences476
Configuring the PLUS Protocol Connection in the BS350 Operating System477
Settings for Integra 6 Standard PLC Interface480
QDA Protocol500
Detail Information501
Settings in the BS350 Operating System503
Total Calculation of Average Torque Value507
Diagnosis and Troubleshooting509
Error Codes510
PFCS 2-Port511
Settings in the BS350 Operating System511
Ports515
Integra-XML Protocol515
Settings in the BS350 Operating System516
Basic Commissioning519
Overview520
General Instructions520
Recommended Filter Intervals (Gradient Parameters)522
Overview of Commissioning Steps524
Assembling the Tightening Cell526
Assembling the Tightening Spindle526
Assembling the Ergospin Hand-Held Nutrunner526
Assembling the CS351 Compact System526
Assembling the Modular System526
Interface Modules (IM)527
Setting up the Connections528
Motor-Breaker534
Switching on the Tightening Cell534
Connecting the PC for Programming536
Connecting the PC536
Installing the Operating System BS350 on the PC537
Starting the BS350538
Setting up the Programming Interface539
Logging in to the Tightening System (Password Entry)541
Sending and Saving542
Sending Files542
Saving Data543
Data Backup with the Backup Function545
Automatic Data Backup with Backup/Restore Function545
Operating the Compact System549
General Information on the Configuration549
Online Configuration550
Offline Configuration576
Defining a Tightening Program577
Configuration SE/CS PLC Assignment Table580
Setting the Time on the Tightening Controller581
Synchronizing Date and Time with an External Clock581
Sequence Test582
Operating the Modular System585
General Information on the Configuration585
Online Configuration of the KE586
KE Configuration Offline603
Configuring the Tightening Channels604
Defining the Tightening Program606
Defining a Tightening Application606
SE PLC Assignment Table608
KE PLC Assignment Table609
Setting the KE Time610
Sequence Test610
Saved ("Automatic") Channel Configuration611
Compact System612
Modular System613
Configuring the Tightening Channel617
Configuring the Optional Additional Module Barcode Scanner622
Nutrunner Test624
Special Operating Features of the Hand-Held Nutrunner Ergospin/CC-Ergospin626
Special Features of Ergospin with Open Flat Output Drive with Mechanical Safety Catch626
Special Features of Ergospin with Open Flat Output Drive Without Safety Catch626
Special Features of Ergospin with Angle Compensation630
Special Features for CC-Ergospin and634
System634
Special Characteristics of Nexo Cordless Wi-Fi Nutrunner Operation636
Service and Sales639
Service639
Sales640
Internet640

Bosch Rexroth Tightening System 350 - Control signals

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