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Deprag AST11-1 User Manual

Deprag AST11-1
122 pages
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014091en
Operating instruction booklet
- Translation of the original instruction -
Sequence controller
AST11-1
AST11-1-S
AST11-2
AST11-2-S
390041 A
390041 B
390042 A
390042 B
NOTICE ALL DOCUMENTATIONS !
Before beginning work this operating instruction booklet and the enclosed
safety instructions (no. 016000, pink-colored booklet) have to be read through
carefully. Always follow the instructions during operation. Give this operating in-
struction booklet and the appropriate safety instructions to the operator.

Table of Contents

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Deprag AST11-1 Specifications

General IconGeneral
BrandDeprag
ModelAST11-1
CategoryController
LanguageEnglish

Summary

1 DEFINITION OF SIGNAL WORDS AND SYMBOLS

2 SAFETY INSTRUCTIONS

3 INTENDED USE

4 SCOPE OF DELIVERY

5 SHORT DESCRIPTION

6 HARDWARE DESCRIPTION

6.1 Views of the AST11

Describes the front panel, rear view, and connection panel of the AST11.

6.2 Interface Description

Details fuses, voltage supply, Ethernet, screwdriver, I/O, serial, and feeder ports.

7 COMMISSIONING

7.1 Dimension Sheet

Provides dimensional drawings and specifications for the AST11 unit.

7.2 Assembly Instructions

Step-by-step guide for assembling and connecting the AST11.

7.3 Example for screwdriving systems

Illustrates a typical screwdriving system setup with the AST11.

7.4 Minimum bending Radius of Screwdriver Cable

Specifies the minimum bending radius for the screwdriver cable to prevent damage.

7.5 Information on programming the Sequence Controller

Discusses the pre-configuration and initial programming of the AST11.

7.6 Functioning of the Sequence Controller AST11

Explains the operational modes, including stand-alone and higher-level controller use.

8 INSTRUCTIONS FOR THE SEQUENCE CONTROLLER

8.1 General

Introduces programming methods and operational modes for the sequence controller.

8.2 Operating Elements

Details the physical components like display, LEDs, and keypad.

8.2.1 Functional Display (LEDs)

Explains the meaning of the LED indicators for power, ready, and status.

8.2.2 Keypad Layout

Describes the functions of the keypad buttons, including function, numerical, and menu keys.

8.2.3 Menu Structure

Illustrates the hierarchical menu structure of the sequence controller's interface.

8.2.4 Menu Functions

Explains menu functions, password protection, and how menus interrupt operation.

8.2.5 Description of the Menus

Provides descriptions for various menu categories like System Info, Process Data, and Setup.

9 F-FUNCTION

9.1 General

Introduces the F-Function's capabilities for supervision of assembly and screw joints.

9.2 Functionality

Explains how the F-Function operates, including shut-off conditions and error handling.

9.2.1 General

Describes the general operation, error signaling, and part change indication of the F-Function.

9.2.2 Operation with supervision of number of screw-joints per part

Details mode activated by inputting screw joints; controls time frame and counts O.K. joints.

9.2.3 Operation without the supervision of number of screw-joints per part

Describes mode where screw-joint supervision is inactive, but error handling still applies.

10 SETTINGS

10.1 Description of the adjustable parameters

Lists and describes parameters that can be adjusted in the system settings.

10.1.1 Parameters of the System Settings

Details adjustable parameters like IP address, language, torque unit, and speed reduction.

10.1.2 Special parameters for fieldbus systems (optional)

Covers specific settings for Profibus, Profinet, Ethernet IP, and EtherCAT fieldbus systems.

10.2 Default Values

Explains how to reset settings to factory defaults and lists default values.

10.2.1 System Settings

Lists default values for display contrast, language, torque unit, and other system parameters.

10.2.2 Special parameters for fieldbus systems (optional)

Provides default values for Profibus, Profinet, and Ethernet IP fieldbus configurations.

11 SCREWDRIVING STRATEGIES AND COMMANDS

11.1 Screwdriving Strategies

Describes various methods for fastening and loosening screws, including torque and angle control.

11.1.1 Fasten / Loosen to Torque

Details tightening/loosening process with stop control via torque, with optional angle monitoring.

11.1.2 Extended Fasten to Torque

Explains a tightening process with shut-off at preset torque, including optional angle monitoring.

11.1.3 Fasten / Loosen to Angle

Describes fastening/loosening based on angle of rotation, using angular displacement for control.

11.1.4 Fasten / Loosen to external Stop-Signal

Covers fastening/loosening process controlled by an external stop signal.

11.1.5 Friction value package (optional)

Introduces optional package for measuring and using friction values in screwing.

11.1.5.1 Friction value measurement

Details the process of measuring friction value during screw tightening.

11.1.5.2 Fasten to differential torque

Describes adding torque based on an occurring torque from a previous stage.

11.1.5.3 Fasten dependent on friction value

Connects friction measurement with screwing to differential moment.

11.2 Commands

Lists commands for displaying values, saving data, and controlling the screwing process.

11.2.1 Display values

Shows previous screwing level values on the touch display.

11.2.2 Save values

Saves previous screwing level values into an end value data set.

11.2.3 Statistic

Affects the calculation of statistics for the previous screw level.

11.2.4 Print

Outputs results of the preceding step to the serial printer.

11.2.5 Waiting time

Inserts a waiting time into the program.

11.2.6 Hold position

Holds the screwdriver tension position.

11.2.7 Wait for input

Waits for an input signal to proceed to the next step.

11.2.8 Set output

Sets an output, available for output number 8.

11.2.9 Reset output

Resets an output, available for output number 8.

12 DOCUMENTATION

12.1 Final values

Explains how screwing results are stored in CSV data and can be loaded.

12.2 Curve Representation

Describes how screwdriving curves are created, viewed, and saved.

12.3 Statistic

Details how statistics are kept for the last 100 values per program and their calculation.

12.4 Print output

Explains how data can be printed in ASCII format using format strings and commands.

13 MAINTENANCE AND SERVICING

13.1 Updating the software

Covers updating the main control, touch display, and power element software via web interface.

13.1.1 Main control and touch display

Details the process of updating the software for the main unit and display.

13.1.2 Power element

Describes the procedure for updating the software of the power element.

13.2 Replace the filter mat of the sequence controller

Provides instructions and safety precautions for replacing the filter mat.

13.3 Spare parts

Lists available spare parts, including the filter mat with its part number.

14 ERROR DISPLAY AND TROUBLESHOOTING

14.1 System error

Guides on how to handle system errors, advising to contact DEPRAG for defects.

14.1.1 MINIMAT–EC-Servo Screwdriver

Lists system errors related to the MINIMAT-EC-Servo Screwdriver and their troubleshooting steps.

14.1.2 Power unit

Lists system errors concerning the power unit and provides troubleshooting guidance.

14.1.3 Main controller

Lists system errors related to the main controller and suggests troubleshooting actions.

14.1.4 Communication

Details communication errors and their potential troubleshooting steps.

14.2 Error in the screwing sequence

Lists common errors that occur during the screwing sequence and their solutions.

15 TROUBLE SHOOTING

Table 32: Troubleshooting

Provides a table summarizing common problems with AST11 and their resolutions.

16 REQUIRED ACCESSORIES

16.1 Power Cable

Lists available power cables for the AST11 with their part numbers.

17 OPTIONAL EQUIPMENT

17.1 Motor Cable for MICROMAT®-E

Lists motor cables for the MICROMAT-E screwdriver with different lengths and connections.

17.2 Extension for MICROMAT-E Motor Cable

Provides extension cables for the MICROMAT-E motor cable.

17.3 Plug

Lists the RJ45 plug with IP54 rating.

17.4 Fieldbus modules

Details available fieldbus modules for Profibus, Profinet, EtherCAT, and EtherNet/IP.

17.4.1 Profibus

Lists Profibus interface and connection cable part numbers.

17.4.2 Profinet

Lists Profinet interface and connection cable part numbers.

17.4.3 EtherCAT

Lists EtherCAT interface and connection cable part numbers.

17.4.4 EtherNet/IP

Lists EtherNet/IP interface and connection cable part numbers.

17.5 Toolbox

Describes the toolbox for expanding application possibilities and its components.

17.6 Standfuß

Lists the base for using the AST11 as a tabletop unit.

17.7 Barcode scanners

Specifies requirements and compatibility for barcode scanners.

17.8 Printer connector

Lists printer connector and cable part numbers.

17.9 Hardware-Module

Details the EMERGENCY-STOP-Module for AST11-1 and AST11-2.

17.10 Optional software packages

Lists optional software packages, including friction value software and GRAPH10.

17.10.1 Friction value software package

Describes software package for friction value measurement, differential torque, and friction-dependent screwing.

17.10.2 GRAPH10 – Superimposed graph display

Details the GRAPH10 program for superimposed graph display and its usage cost.

17.10.3 DataLogger

Describes the DataLogger program for recording and archiving data from sequence controllers.

17.10.4 TC30-PC Statistics

Details the TC30-PC Statistics software for evaluating screwdriving data.

17.10.5 DEPRAG ASTxx Serial Remote

Describes ASTxx Serial Remote program for saving screwdriving graphs and data.

18 Technical Data

Table 33: Technical Data

Provides comprehensive technical specifications for AST11-1 and AST11-2 models.

19 Glossary

Clearance for start

Defines the condition for screwdriver start based on 24V at the clearance to start input.

Command

Defines a general program step for creating screwdriving sequences.

EC screwdriver

Defines an EC screwdriver with a brushless electronic drive.

Main controller

Defines main controller for processing screwdriving programs.

Screwdriver logic

Electronic storing screwdriver data recognized automatically by the controller.

Screwdriving sequence

Sequence of the screwdriving process, consisting of strategies and commands.

20 EG-CONFORMITY DECLARATION

EC-Declaration of Conformity in accordance with the EC Machinery Directive 2006/42/EC

Manufacturer's declaration of conformity with EU directives and standards.

21 Service Locations and Authorized Partners

Contacts in Germany / worldwide

Information on DEPRAG contacts in Germany and worldwide, found on the web site.

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