Page 1 Stationary tool for installing Operating Instructions strap clamps OETIKER FAST 3000 Translation of the original Operating Instructions Item no. 08903979 Issued 03.2019 Oetiker Schweiz AG, Horgen, Switzerland...
Page 2: Table Of Contents
General safety instructions ........................2-14 Covers ..............................2-16 Special safety instructions ........................2-16 Safe methods of working ........................2-17 Using the FAST 3000 via an external control system ................2-17 Conversions, modifications ........................2-17 Qualified personnel ..........................2-18 2.10 Maintenance work ..........................2-20 2.11 Overload protection of the crimping cut-off head ................2-21 2.12 Noise level ............................
Page 3 Cable connections to the crimping force monitoring .................6-60 Switching on the FAST 3000 .......................6-61 Correctly positioning the FAST 3000 ....................6-63 6.5.2 Positioning of the FAST 3000 installation tool with the alignment aid ........6-67 6.5.3 Dimensions for correctly positioning the FAST 3000 .............6-69 Normal operation (production) ......................6-71 Laboratory mode (password-protected) .....................
Page 4 OETIKER FAST 3000 Contents 6.8.5 Crimping force monitoring verification ...................6-85 6.8.6 Adjusting the crimping force monitoring ................6-87 6.8.7 Loading new settings/measurement programs to the CFM units .........6-93 GUI ................................7-95 Touch Panel ............................7-95 Computer ............................7-95 GUI Layout ............................7-96 Menu structure ............................
Page 5 Replacing the control cabinet or tool mechanism ................9-150 Tools and consumable materials for maintenance ................9-151 Controlling the FAST 3000 via an external PLC .................. 10-158 10.1 Control via a field bus (Ethernet/IP or Profinet) ................10-158 10.1.1 Settings for the Ethernet/IP communication protocol ............10-158 10.1.2 Settings for the Profinet HW configuration ................
Page 6 OETIKER FAST 3000 Contents 13.3.7 PrErr_15: Closing force outside tolerance ................13-177 13.3.8 War_2: Button contact error ....................13-177 13.3.9 ToErr_5: Drive error active ....................13-178 13.3.10 ToErr_6: Emergency stop circuit open / ToErr_14: Emergency Stop ........13-178 13.3.11 PrErr_3: Crimping error CFM1 envelope curve 1 ..............13-179 13.3.12 PrErr_4: Crimping error CFM1 envelope curve 2 ..............13-179...
Page 7 OETIKER FAST 3000 Contents 13.3.40 War_10 No power supply – external enable, press Start ..........13-188 13.3.41 War_11 Remove strap ......................13-189 Appendix ..............................14-190 Help and Support ............................ 15-191 Issued 03.19 08903979...
Page 8: Information About This Manual
OETIKER FAST 3000 Information about this manual Information about this manual Symbols and means of representation used Safety notices are used in this manual to warn of the risk of personal injury or property damage. Always read and observe these safety notices.
Page 9: Scope
They contain important instructions for safe working procedures. For the version FAST 3000 with Light curtain the corresponding leaflet “Manual FAST 3000 Light Curtain” has to be considered. 1.2.1 FAST 3000 •...
Page 10: Rating Plates
OETIKER FAST 3000 Information about this manual 1.2.2 Rating plates Fig. 2 Rating plates Abbreviations Newton seconds millimeters milliseconds kilogram Crimping Force Monitoring Issued 03.19 08903979 1-10...
Page 11: Stickers On The Fast 3000
OETIKER FAST 3000 Information about this manual Stickers on the FAST 3000 CAUTION Comply with all safety stickers and always exercise great care when using the FAST 3000. Stickers (1, 2, 3) on the FAST 3000 Fig. 3 Wear safety glasses!
Page 12: Associated Documents
OETIKER FAST 3000 Information about this manual Fig. 4 Stickers (1, 2) on the crimping cut-off head and alignment aid General warning signs: Never use a FAST 3000 without force sensors. Warning sign: Magnetic field Permanent magnet Associated documents •...
Page 13: Basic Safety Instructions
• If the FAST 3000 is integrated into an assembly cell it can be used without the optional two-hand control desk and without the optional touch panel. In such cases the integrator is responsible for the safe integration of the FAST 3000 into the assembly cell.
Page 14: General Safety Instructions
Basic safety instructions Implemented safety concept for safe operation The FAST 3000 is intended for operation by a single operator. It is prohibited for a third person to start the clamping cycle. To exclude the risk that parts of limbs my be crushed between the WingGuard clamp and the goods being ®...
Page 15 Shipping method • Full address Details can be found in the OETIKER tools catalog. Improvements to the machine In our endeavor to continuously improve the quality of our products, we reserve the right to make improvements without changing the Operating Instructions. Details of dimensions, weights, materials, performance ratings and names may therefore be subject to necessary changes.
Page 16: Covers
Basic safety instructions Covers CAUTION Use the FAST 3000 only when all covers are correctly fitted. Fig. 5 Protective covers on the FAST 3000 Make sure that identification marks and warning instructions on the machine are always present and legible.
Page 17: Safe Methods Of Working
• During operation of the machine and when performing maintenance, wear safety glasses. • The FAST 3000 is intended for operation by only a single operator. The closing cycle may not be initiated by a second person. • Keep sufficient free space around the product. Users must not be hampered by third persons.
Page 18: Qualified Personnel
OETIKER FAST 3000 Basic safety instructions Qualified personnel WARNING Hazards due to operation by unauthorized or unqualified personnel. This device may be used only by authorized and qualified personnel. Use other than in accordance with the Operating Instructions is prohibited. The levels of authorization for use are as follows:...
Page 19 OETIKER FAST 3000 Basic safety instructions “Maintenance mechanic”: • has the knowledge described for the “Operator” • is familiar with the mechanical techniques required for working on the machines and tools (fastening, cleaning, lubricating) • knows the applicable procedures described in this document •...
Page 20: Maintenance Work
OETIKER FAST 3000 Basic safety instructions The “Electrician” is authorized to perform the following activities: • The activities performed by the “Maintenance mechanic” • Repair of the tool if it is in a defective condition • Removal of the covers and opening the control cabinet for access to the components •...
Page 21: Overload Protection Of The Crimping Cut-Off Head
OETIKER FAST 3000 Basic safety instructions 2.11 Overload protection of the crimping cut‑off head CAUTION Do not remove the overload protection of the crimping cut‑off head. Using the tool without overload protection and CFM force load cells can lead to mechanical damage.
Page 22: Scope Of Supply Of The Fast 3000 Tool
OETIKER FAST 3000 Scope of supply of the FAST 3000 tool Scope of supply of the FAST 3000 tool Overview of the main components of the FAST 3000 Design of the FAST 3000 tool Fig. 7 Issued 03.19 08903979 3-22...
Page 23: Available Main Configurations
OETIKER FAST 3000 Scope of supply of the FAST 3000 tool Connecting cable Control cabinet Two-hand dongle, thin Two-hand dongle (emergency stop two-hand control desk, used if the two-hand control desk is not connected) Touch panel / optional Foot pedal / optional...
Page 24 OETIKER FAST 3000 Scope of supply of the FAST 3000 tool Configuration Scope of supply OETIKER FAST 3000 + CFM ‑ PROFINET Part number 13500210 Oetiker FAST 3000 with CFM and PROFINET The tool is supplied with a tool carrier Issued 03.19...
Page 25: Optional Extras
Two-hand control desk for autonomous operation of the FAST 3000. Touch panel, complete Part number 13500278 Touch panel for controlling the FAST 3000 if no laptop or supervisory controller is used. Foot pedal Part number 13500105 Foot pedal to allow hands-free use of the FAST 3000 during tests or in the laboratory.
Page 26 Part number 13500232 Adapter jaws for verification of the closing force. The CAL 01 must be ordered separately. Jaws kit for CFM verification on the FAST 3000 Part number 13500237 For CFM verification The CAL 01 must be ordered separately.
Page 27: Brief Description Of The Fast 3000
Pressing the clamping button secures the strap end. • After the start of the closing cycle the strap end is drawn in by the FAST 3000 until a certain closing force is achieved. Precise control of the force is ensured by the force load cell and the high-performance electro-mechanical drive.
Page 28: Design Of The Tool Mechanism
OETIKER FAST 3000 Brief description of the FAST 3000 Design of the tool mechanism Fig. 8 Tool mechanism of the FAST 3000 Crimping cut-off head The crimping cut-off head crimps the WingGuard clamp and cuts off ® the projecting strap end.
Page 29 OETIKER FAST 3000 Brief description of the FAST 3000 Spirit level Using the spirit level it can be checked that the tool is correctly positioned vertically (see Section 6.5 ). Sleeve for the sensor signal cable Sleeve that contains the sensor signal cables for crimping monitoring.
Page 30: Design Of The Fast 3000 Crimping Cut-Off Head
OETIKER FAST 3000 Brief description of the FAST 3000 Design of the FAST 3000 crimping cut‑off head CAUTION Risk of damage to the crimping jaws and the cut-off die. Make sure that only the intended OETIKER PG270 WingGuard strap clamps are used. Otherwise the ®...
Page 31 OETIKER FAST 3000 Brief description of the FAST 3000 Head housing cover Particulars of the crimping cut-off head: CFM force load cell and its brackets Fig. 10 Force sensor bracket Crimping force sensor Issued 03.19 08903979 4-31...
Page 32: Two-Hand Control Desk
Acknowledgement button (“Acknowledge”; to display and acknowledge closures that are not OK, and error messages) Green indicator light (“Ready”; indicates that the FAST 3000 is ready for operation) Buzzer (active in laboratory mode, indicates the closing cycle is about to start) Issued 03.19...
Page 33: Description Of The Process Monitoring Of The Fast 3000
The purpose of the FAST 3000 is to close OETIKER WingGuard strap clamps. ® NOTE For the recommended values for the process parameters please refer to the technical data sheet of the OETIKER PG270 WingGuard strap clamp. ® Fig. 12 Closure data table Issued 03.19...
Page 34: Functional Description Of Control Of The Closing Force
3. Phase 3 In phase 3, the FAST 3000 force control mode is active. • As soon as the closing force has remained within the closing force tolerance for a period specified by the closing force holding time, the crimping of WingGuard clamp tail starts.
Page 35: Closing Force
Some applications require a specific applied force and a specific period of time, so that the components are ideally connected. With the FAST 3000, the user can adjust this period of time. In general, soft materials require a longer holding time than harder ones.
Page 36: Sample Curves With Different Closing Force Parameters
OETIKER FAST 3000 Description of the process monitoring of the FAST 3000 5.1.8 Sample curves with different closing force parameters The preset closing force parameters function on all applications, including very hard ones. It is therefore recommended the settings are not changed unnecessarily.
Page 37 OETIKER FAST 3000 Description of the process monitoring of the FAST 3000 Diagram/Setting Comment • Switch point reduction set to a higher value • The FAST 3000 switches earlier to phase 2. • The drive begins to reduce speed at 1250 N (600 N before reaching the closing force) •...
Page 38: Plausibility Test Of The Closing Force Sensor
5.1.9 Plausibility test of the closing force sensor During each closing cycle, the FAST 3000 performs a plausibility test of the closing force sensor. In the unloaded state, a test is carried out as to whether the measured force is approx. 0 N. In addition, the system tests in a lightly loaded state whether the measured force is within the expected range.
Page 39: Mechanical Design
OETIKER FAST 3000 Description of the process monitoring of the FAST 3000 5.2.2 Mechanical design The following figure shows the action of the forces applied to the crimping jaw. Viewed from the crimping jaw side. Fig. 15 Application of force to on the crimping jaws...
Page 40 OETIKER FAST 3000 Description of the process monitoring of the FAST 3000 The force is transmitted via the crimping jaw pivot pins to the force transmission lever of the crimping head transmit. NOTE Due to the principle of leverage the force is divided between the transmission lever and the spacer plate.
Page 41: Cfm: Typical Ok Force Curve
EO 2: Second envelope curve: If the actual force curve infringes the upper or lower envelope curve limit, the crimping operation will be evaluated as not OK. EO 4: Uni-Box: Transmits the force values on entry and exit to the FAST 3000 PLC. See next section. Second peak: The crimping jaw reaches its end position Relaxation effects.
Page 42: Cfm: Wear Detection
These force values are transmitted to the FAST 3000 PLC, which calculates the difference between the entry force and exit force. If the difference is less than a specific value, an error message is generated (Zero N is the standard setting, adjustable range –100 to +100 N).
Page 43: Cfm: Sample Curves Of Crimping Operations
OETIKER FAST 3000 Description of the process monitoring of the FAST 3000 5.2.5 CFM: Sample curves of crimping operations CFM curve Image of the closed clamp Left Wings unusually thin and not closed to a sufficient height. Right Description During wing closure the clamp housing was not parallel to the crimping cut-off head.
Page 44 OETIKER FAST 3000 Description of the process monitoring of the FAST 3000 CFM curve Image of the closed clamp Left Right Description During wing closure the clamp housing was not parallel to the crimping cut-off head. The following criteria have led to the not OK evaluation: First envelope curve (EO 1) right (Troubleshooting see chapter 13.3.15 )
Page 45 Crimping jaw struck the edge of the strap instead of reaching underneath the strap. The closure process is aborted in order to protect the crimping jaws of the FAST 3000 against damage. Cancellation triggered by maximum force of the left crimping jaw.
Page 46 OETIKER FAST 3000 Description of the process monitoring of the FAST 3000 CFM curve Image of the closed clamp Left Chip formation under the wing. Right Description Slanting application; the right side is lower than the left side. Closure of the clamp on an oblique solid surface.
Page 47 OETIKER FAST 3000 Description of the process monitoring of the FAST 3000 CFM curve Image of the closed clamp Left No wing formation. Right Issued 03.19 08903979 5-47...
Page 48 OETIKER FAST 3000 Description of the process monitoring of the FAST 3000 Description • Slanting application; the right side is lower than the left side. Closure of the clamp on an oblique solid surface. • Foreign Object leads to a gap between cut off punch and WingGuard housing, therefore there is a collision ®...
Page 49 The FAST 3000 PLC checks if if the following condition is fulfilled: Exit Force – Entry Force < Threshold value. If yes, the FAST 3000 PLC outputs an error message and the closure operation is evaluated as not OK.
Page 50 OETIKER FAST 3000 Description of the process monitoring of the FAST 3000 CFM curve Image of the closed clamp Left Right wing not formed, left wing badly formed. Right Description Right crimping jaw completely broken off. In comparison to good jaws:...
Page 51 OETIKER FAST 3000 Description of the process monitoring of the FAST 3000 CFM curve Image of the closed clamp Left Right Description Right crimping jaw partially broken off: The following criteria have led to the not OK evaluation: Second envelope curve (EO 2) left (Troubleshooting see chapter 13.3.12 ) •...
Page 52 OETIKER FAST 3000 Description of the process monitoring of the FAST 3000 CFM curve Image of the closed clamp Left Right Description Both jaws partially broken off: In comparison to good jaws: The following criteria have led to the not OK evaluation: •...
Page 53 OETIKER FAST 3000 Description of the process monitoring of the FAST 3000 CFM curve Image of the closed clamp Left Right Description Right jaw partially broken off: The following criteria have led to the not OK evaluation: Second envelope curve (EO 2) right (Troubleshooting see chapter 13.3.16 ) Issued 03.19...
Page 54 OETIKER FAST 3000 Description of the process monitoring of the FAST 3000 CFM curve Image of the closed clamp Left Right Description Fastening screws of the head housing cover are not sufficiently tight. Lock is still OK! Refer to chapters 9.3.2 and 9.3.3 for information about the correct tightening torque.
Page 55 OETIKER FAST 3000 Description of the process monitoring of the FAST 3000 CFM curve Image of the closed clamp Left Right Description Closing force set to 800 N instead of the standard setting of 1850 N. CFM force level greater than at 1850 N, due to the in general lower stress level in the clamp band.
Page 56: Cut-Off Monitoring
OETIKER FAST 3000 Description of the process monitoring of the FAST 3000 CFM curve Image of the closed clamp Left Right Description Closing force set to 2500 N instead of the standard setting of 1850 N. CFM force level less than at 1850 N , due to the in general higher stress level in the clamp band.
Page 57: Working With The Fast 3000
Hazardous situation due to improper installation. Read and understand the safety advice, Section 2 . Make sure that the FAST 3000 has enough space around it to ensure the operator is not hampered or bumped into by other persons. Attach the FAST 3000 installation tool and its control cabinet to the attachment points provided.
Page 58 Lay the connecting cable so that the crimping cut-off head tilts downwards. The commissioning procedure of the FAST 3000 includes the following steps: Install the components of the FAST 3000 so that they cannot fall off, so they recognize ergonomic factors and so that clamps can be correctly closed.
Page 59: Connections To The Control Cabinet
EtherCat CFM Hardwire I/O power supply Foot pedal ProfiNet (active only on Oetiker FAST 3000 + CFM-Profinet) EtherNet (TCP / Ethernet IP) External emergency stop (if this port is not connected to an external emergency stop the thin two-hand dongle must be plugged in.) Two-hand control desk (if no two-hand control desk is connected the two-hand dongle must be plugged in.)
Page 60: Cable Connections To The Crimping Force Monitoring
Fig. 21 Control unit, connections Cables for connecting the crimping force-monitoring devices to the FAST 3000 control cabinet 24-V power supply for the crimping force monitoring devices Cable conduit and bracket for the force signal cables (use an M5 bolt for strain relief of the cables and attach the bracket to a secure surface).
Page 61: Switching On The Fast 3000
For further information on controlling the FAST 3000 without the two-hand control desk ( see Section 10 ). NOTE The FAST 3000 may not be initialized when a clamp or other part is inserted in the crimping cut-off head. Disregard of this rule can lead to breakage of the crimping jaws.
Page 62 To initialize the FAST 3000, press the blue flashing button (3) on the two-hand control desk. The FAST 3000 is ready for operation when the green indicator lamp on the two-hand control desk is lit. Issued 03.19 08903979...
Page 63: Correctly Positioning The Fast 3000
We emphatically recommend that a suitable jig is employed for the entire application. Free-hand closure can result in the clamps not being properly closed. The base plate of the FAST 3000 must be securely attached to the support frame. This is applicable also to the validation phase of the application.
Page 64 OETIKER FAST 3000 Working with the FAST 3000 Fig. 22 Example of an incorrect non-parallel alignment of the WingGuard -housing and of the crimping cut-off head ® Fig. 23 Impermissible positioning of the WingGuard housing on an application ® Impermissible application of the WingGuard strap clamp on a conical surface Fig.
Page 65 OETIKER FAST 3000 Working with the FAST 3000 Fig. 25 The crimping cut-off head must be at a sufficient distance from the application Fig. 26 Here the crimping cut-off head is at an insufficient distance from the application Impermissible application. The same is true if two WingGuard strap clamps are fitted too close to each other.
Page 66 OETIKER FAST 3000 Working with the FAST 3000 Fig. 27 Do not mount the WingGuard strap clamp on a stepped application ® Fig. 28 Avoid contact between the end face of the strap and the goods being strapped (example: goods being strapped (1)) Issued 03.19...
Page 67: Positioning Of The Fast 3000 Installation Tool With The Alignment Aid
OETIKER FAST 3000 Working with the FAST 3000 6.5.2 Positioning of the FAST 3000 installation tool with the alignment aid WARNING Hazard due to a magnetic field. The alignment aid is held against the crimping cut-off head by a strong magnet. Personnel fitted with a heart pacemaker must maintain a suitable distance from the alignment aid.
Page 68 OETIKER FAST 3000 Working with the FAST 3000 Make sure that the FAST 3000 has sufficient space (~ 50 mm) for attaching the positioning stop (3) to the guide rail. Adjust the height of the tool so that the bubble of the spirit level is exactly central between the two vertical lines (horizontal alignment).
Page 69: Dimensions For Correctly Positioning The Fast 3000
FAST 3000. You can check the correct vertical positioning of the FAST 3000 by reference to the spirit level which is mounted at the top of the tool. To do this, position the crimping cut-off head on the clamp housing of the WingGuard clamp.
Page 70 OETIKER FAST 3000 Working with the FAST 3000 Crimp cut-off head Housing 2-4 mm Application Comment: On request, Oetiker will provide a 3D-CAD model of the FAST 3000. Issued 03.19 08903979 6-70...
Page 71: Normal Operation (Production)
When starting the clamping cycle, keep your fingers away from the clamp. WARNING Crush hazard at moving parts. The FAST 3000 may be used only when all covers are correctly fitted and bolted in place! Issued 03.19 08903979 6-71...
Page 72 OETIKER FAST 3000 Working with the FAST 3000 WARNING Crush hazard due to positioning the hands under the installation tool. Never reach under the installation tool whilst it is in operation. CAUTION Danger due to parts being flung from the machine.
Page 73 OETIKER FAST 3000 Working with the FAST 3000 Push the OETIKER PG270 WingGuard strap clamp ® into the tool as far as possible. A sensor detects the correct positioning and confirms this with two LED lamps on the front cover (slowly flashing green light).
Page 74: Laboratory Mode (Password-Protected)
Hazard due to unqualified personnel. Laboratory mode can be used only under laboratory or test conditions where there is no alternative. The personnel must have been trained to use of the FAST 3000 with an increased level of care. WARNING Crush hazard at the WingGuard strap clamp.
Page 75 Working with the FAST 3000 WARNING Crush hazard at moving parts. The FAST 3000 may be used only when all covers are correctly fitted and bolted in place. WARNING Crush hazard due to positioning the hands under the installation tool.
Page 76: One-Hand Operation
OETIKER FAST 3000 Working with the FAST 3000 6.7.1 One‑hand operation Check that the process parameters are set to the correct values for your application. Activate the one-hand operation: – Switch to “operating mode”, activate “laboratory mode” and “one-hand operation”.
Page 77 OETIKER FAST 3000 Working with the FAST 3000 Push the OETIKER PG270 WingGuard strap clamp ® into the tool as far as possible. A sensor detects the correct positioning and confirms this with two LED lamps on the front cover (slowly flashing green light).
Page 78: Foot Pedal
OETIKER FAST 3000 Working with the FAST 3000 6.7.2 Foot pedal Check that the process parameters are set to the correct values for your application. Activating foot pedal mode – Switch to “operating mode”, activate “laboratory mode” and “foot pedal”.
Page 79 OETIKER FAST 3000 Working with the FAST 3000 Push the OETIKER PG270 WingGuard strap clamp ® into the tool as far as possible. A sensor detects the correct positioning and confirms this with two LED lamps on the front cover (slowly flashing green light).
Page 80: Special Operating Modes (Password-Protected)
When starting functions, keep your fingers away from the clamp. WARNING Crush hazard at moving parts. Use the FAST 3000 only when all covers are correctly fitted. and bolted into place. WARNING Hazard due to positioning the hands under the installation tool.
Page 81: Unlocking
NOTE In certain situations, tool initialization cannot be performed since it might lead to mechanical damage. Use the unlocking function of the FAST 3000 only when tool initialization cannot be performed. Switch to the “operating mode” tab. If the emergency stop-button is set, unlatch it.
Page 82: Manual Mode Operation Of Drives
OETIKER FAST 3000 Working with the FAST 3000 6.8.2 Manual mode operation of drives Activating operating mode. – Switch to “operating mode” and activate “manual drive”. – In order to access manual drive mode you must be logged in. Control the drives by pressing one of the pre-defined positions (1, 2).
Page 83: Setting The Force Offset To Zero
OETIKER FAST 3000 Working with the FAST 3000 6.8.3 Setting the force offset to zero NOTE Under various conditions the force measured by the force load cell in the clamping unit can vary due to changes in temperature. To compensate for this you can set the measured to zero when there is no force measured by the unloaded force load cell.
Page 84: Verifying The Closing Force
OETIKER FAST 3000 Working with the FAST 3000 6.8.4 Verifying the closing force NOTE To check the correct operation of the force load cell, verify the measured force at least once a week, using an Oetiker CAL 01. If the force is set to 1850 N, the force measured by the CAL 01 must be within a tolerance of ± 100N of that value.
Page 85: Crimping Force Monitoring Verification
To check the correct operation of the CFM force load cell, we recommend that the measured force is verified at least once a week, using an Oetiker CAL 01. If the force is set to 800 N, the force measured by the CAL 01 must be within a tolerance of ± 150 N of that value.
Page 86 OETIKER FAST 3000 Working with the FAST 3000 NOTE During the verification, do not hold the SKS firmly in the hand, since this can corrupt the measured result. Activate the force verification. Switch to the “Settings” tab. In order to access CFM force verification mode you must be logged in.
Page 87: Adjusting The Crimping Force Monitoring
OETIKER FAST 3000 Working with the FAST 3000 Set the “force target value” to the desired value, e.g. 800 N. Position the SKS 01 with the correctly installed CFM verification jaws under the crimping cut-off head, as shown in the photo on the right.
Page 88 OETIKER FAST 3000 Working with the FAST 3000 NOTE If the closing force deviates from the factory setting of 1850 Nm you may have to teach new reference curves. Each monitoring device must be set separately. Select “Settings” and “Tool Parameters” on the FAST 3000 touch panel.
Page 89 OETIKER FAST 3000 Working with the FAST 3000 Select “Evaluation”. If the message “Retain the curve” appears on the screen, select “No”. Select “Delete the curve”. Close a WingGuard strap clamp. ® 10. If the WingGuard strap clamp closes correctly, ®...
Page 90 21. On the touch panel of the FAST 3000: Be sure to set “CFM Production mode” to “On”. 22. Log out of the FAST 3000 and also log out of the FAST 3000 as Superuser. Adjusting the crimping force monitoring tolerance...
Page 91 OETIKER FAST 3000 Working with the FAST 3000 NOTE If the closing force deviates from the factory setting of 1850 Nm you may have to teach new reference curves. Each monitoring device must be set separately. Select “Setup” on the welcome screen.
Page 92 OETIKER FAST 3000 Working with the FAST 3000 Select the EO that you wish to change (01 or 02 for the envelope curves). Select the button “Forwards” Adjust the evaluation tolerance by editing DY. 10. Select “Recalculate”. 11. If necessary, repeat steps 7 to 10 for further EOs (use the “Back”...
Page 93: Loading New Settings/Measurement Programs To The Cfm Units
OETIKER FAST 3000 Working with the FAST 3000 6.8.7 Loading new settings/measurement programs to the CFM units For communication with the CFM units both participants (PC and device) must be within the same network. A PC must be available for loading settings and programs.
Page 94 OETIKER FAST 3000 Working with the FAST 3000 Only on the CFM device for the right‑hand side: 11. Select “Setup” (8). 12. Select the measurement programs for which the name are to be changed (9). 13. Switch to the “General” tab (10).
Page 95: Gui
OETIKER FAST 3000 Control and monitoring of the FAST 3000 can be performed either by means of the optional touch panel, a laptop or computer. WARNING Danger of starting up unexpectedly Only one operator control unit may be used for the FAST 3000. For reasons of safety, simultaneous control by the optional touch panel and a computer is not permitted.
Page 96: Gui Layout
OETIKER FAST 3000 GUI Layout The main view of the FAST 3000 visualization is as follows: User management / Language selection / Date & Time Tabs Content of the tabs Status bar Issued 03.19 08903979 7-96...
Page 97: Menu Structure
® WingGuard strap clamp ® 2 Status Shows the status of the two electrical drives of the FAST 3000 3 Operating mode Automatic mode or manual operation of drives; local or PLC 4 Messages Error messages etc. Target closing force...
Page 98: Closure Data (A Password Is Necessary To Change The Values)
OETIKER FAST 3000 7.4.2 Closure data (a password is necessary to change the values) All the settings for the installation of an OETIKER PG270 WingGuard strap clamp are displayed under the ® “Closure data” tab. This tab can be accessed without using a password. Provided you are logged in you can change the values.
Page 99: Operating Mode
Hazard due to unqualified personnel. Laboratory mode can be used only under laboratory or test conditions where there is no alternative. The personnel must have been trained to use of the FAST 3000 with an increased level of care. WARNING Crush hazard at the WingGuard strap clamp.
Page 100 OETIKER FAST 3000 WARNING Crush hazard at moving parts. The FAST 3000 may be used only when all covers are correctly fitted and bolted in place. CAUTION Crush hazard due to positioning the hands under the installation tool. Never reach under the installation tool whilst it is in operation.
Page 101 OETIKER FAST 3000 Laboratory mode (password‑protected) Laboratory mode Activating and deactivating laboratory mode Time laboratory mode Specify the duration in minutes, after which laboratory mode is deactivated automatically Remaining time [min] Time remaining until automatic deactivation of laboratory mode Max. pieces in LabMode...
Page 102 OETIKER FAST 3000 Manual mode (password‑protected) WARNING Crush hazard at moving parts. For maintenance work it may be necessary to operate the tool in the operating mode “Manual operation” and without covers. Do this only if you have no alternative, and take the utmost care when doing so.
Page 103 OETIKER FAST 3000 Manual mode (password‑protected) Lever (left‑hand side) Initializing Initializing the lever: Setting the zero Home position Link in the home position (if there is a WingGuard strap clamp in the clamping ® unit, this is secured.) Insert position...
Page 104: Friction Test
OETIKER FAST 3000 7.4.4 Friction test NOTE The operating mode “Friction test” is available for testing the internal friction of the WingGuard clamp. To do ® this, the WingGuard clamp is closed without any strapping present, and the maximum no-load closing force is ®...
Page 105: Io Test
7.4.5 IO Test The purpose of the “I/O Test” menu is to test the basic functions of the inputs to the FAST 3000. The depiction of the individual inputs are distributed across three pages. When the “I/O Test” menu is open, the individual buttons have no further functions.
Page 106 Deblocking of the tool via Profinet or Ethernet/IP Statusword Status words (status word 1 and status word 2) generated by the tool (32-bit integer value) Control word Control word sent by the external control unit to the FAST 3000. Issued 03.19 08903979 7-106...
Page 107 OETIKER FAST 3000 State communication Green: The controls are connected to a supervisory control unit Status of the Profinet White: The controls are not connected to any other control unit communication Status of the Green (1): The controls are connected to a supervisory control...
Page 108: Logbook
OETIKER FAST 3000 7.4.6 Logbook Process log The data on the most recent clamp closures are shown in the “Data log” tab. This menu can be accessed without using a password. Date/Time Data and time of the installation Identification ID of the closure...
Page 109 OETIKER FAST 3000 Error log / Warning log The most recent errors of the tool are displayed in the “Error log” tab. This menu can be accessed without using a password. Issued 03.19 08903979 7-109...
Page 110 OETIKER FAST 3000 Alarm management The alarm management is a list of the errors and warnings. To open the alarm management, click on the information (1) shown in the status bar. If no alarm is active, the screen appears as follows: Issued 03.19...
Page 111 OETIKER FAST 3000 If alarms are active, the screen can appear as follows: If only one alarm is active, the error is shown as a message in the status bar. If several alarms are active, the message “Several errors active” is shown.
Page 112 OETIKER FAST 3000 Verification log The most recent verification forces are displayed in the “Verification log” tab. This menu can be accessed only by inputting a password. If a value is listed only for force 1, this is a tensioning force verification. The scaling factor is listed for the correlation factor.
Page 113 OETIKER FAST 3000 Servicelogbook In the “Service logbook” the most recently performed Service work / Maintenance work are displayed. This menu can be accessed only by inputting a password. To create a new Service log entry, write the text in the field (1) in the bottom left corner and press “enter” (2).
Page 114: Setting
Select “Light curtain inactive” if no light curtain is present. Control over external PLC Select this button in order to control the FAST 3000 via an external PLC Control over I/O Select this button in order to control the FAST 3000 via I/O Time &...
Page 115 OETIKER FAST 3000 Force verification / Zero offset NOTE Under various conditions the force measured by the force load cell in the clamping unit can vary due to changes in temperature. To compensate for this you can set the measured to zero when there is no force measured by the unloaded force load cell.
Page 116 Indicates that the tensioning strap is locked (the locking must be performed using the button on the handle of the FAST 3000) Target force Set the force in Newtons that the FAST 3000 will use to tension the clamps Verification activation Start the tensioning at the set force...
Page 117 NOTE For verification of the correct operation of the crimping force sensors which measure the crimping forces we recommend that the measured force is verified once a month using an Oetiker CAL 01. (For further Information see Section 6.8.5 .) For crimping force monitoring verification you must be logged in.
Page 118 OETIKER FAST 3000 Setting the date and time To set the date and time using the GUI, select “Settings” and “Tool parameters” on the FAST 3000 touch panel. In the “Tool parameters” menu,, click on the “Date & Time”” button.
Page 119: Information
OETIKER FAST 3000 7.4.8 Information The currently installed software version and the publication date are shown in the “Information” tab. It also contains a list of the Oetiker service addresses. Issued 03.19 08903979 7-119...
Page 120: Error List (Version V2.09)
OETIKER FAST 3000 7.4.9 Error list (version V2.09) For further information on error correction see Section 13 . The following error list is valid for the software version V2.09. Error lists for later software versions can be obtained from OETIKER. Error Description...
Page 121 OETIKER FAST 3000 PrErr_9 Crimping CFM2 NoPass Process error PrErr_10 Crimping CFM2 wear Process error PrErr_11 General error at crimping Process error PrErr_12 Error at cutting off Process error PrErr_13 Force overshoot Process error PrErr_15 Closing force outside tolerance Process error...
Page 122 OETIKER FAST 3000 11099 Servo pulling unit: Checksum error Drive error 11113 Servo pulling unit: Error in the factory settings Drive error 12016 Servo lever: IPM error Drive error 12017 Servo lever: IPM temperature Drive error 12020 Servo lever: Overcurrent...
Page 123: Access Rights
OETIKER FAST 3000 7.4.10 Access rights User Rights “none” = status at Operator Superuser switch‑on Closing force parameter × × Transport/storage × Commissioning without the optional two-hand control desk / without the optional touch panel × × Tool parameters Process protocol...
Page 124: Assigning The Ip Address
OETIKER FAST 3000 Assigning the IP address Assigning the IP address If the tool is to be integrated into a network, make sure that the IP address that is assigned will not generate any conflicts. The factory setting of the IP address is 192.168.10.50. You can use a web browser to access the controller in order to change the IP address.
Page 125: Setting The Date And Time
OETIKER FAST 3000 Assigning the IP address Setting the date and time Select the menu tab “System settings” and input the date and time. The date and time can also be set via the GUI. Issued 03.19 08903979 8-125...
Page 126: Maintenance And Replacement Of Parts
Risk of damage to the force load cell. The FAST 3000 is equipped with a force load cell. This is a precision measuring device. So as not to damage the force load cell, apply only the intended forces to it (do not apply hammer impacts and the like).
Page 127: Maintenance
Danger of death from electric shock. Touching live parts can result in death. Withdraw the mains plug from the electrical socket and secure the FAST 3000 to prevent it being plugged in again accidentally. Wait 15 minutes after switching off the power, to allow the intermediate circuit voltage in the servo amplifier to dissipate.
Page 128 Ensure that the electrical plug connectors which were withdrawn are plugged in again following the maintenance and inspection work. Check all screw connections. Reattach all safety devices immediately. Check all operating functions of the FAST 3000 and the initialize the tool. Issued 03.19 08903979 9-130...
Page 129: Regular Checking Of The Status
Do not continue to use the FAST 3000 if defects have been identified. Check the FAST 3000 for visible damage daily or at the start of each shift, and make sure it is used only when in good condition. This applies particularly to the crimping jaws and operation of the emergency stop.
Page 130: Regular Maintenance Work / Maintenance Schedule
OETIKER FAST 3000 Maintenance and replacement of parts 9.2.4 Regular maintenance work / maintenance schedule Service Service interval / Parts to be replaced Maintenance activities Time Performed by required 100,000 cycles • Crimping jaws kit (part • Replace the crimping jaws...
Page 131: A-Service - To Be Performed Every 100,000 Cycles
OETIKER FAST 3000 Maintenance and replacement of parts Greasing points Apply a thin film of grease to all the areas marked yellow. 9.2.5 A‑service ‑ to be performed every 100,000 cycles CAUTION Replace wear parts (crimping jaws) after 100,000 closures.
Page 132: B-Service - To Be Performed Every 200,000 Cycles
After installing and securing the head housing cover, all three slides must be free to move with very little resistance. After assembling the FAST 3000, perform a closing force verification at 1850 N (see Section 6.8.4) . The closing force must lie within ±100 N.
Page 133: Replacing Parts
11. After installing and securing the head housing cover, all three slides must be free to move with very little resistance. 12. After assembling the FAST 3000, perform a closing force at 1850 N. The closing force must lie within ±100 N. 13. Perform ten WingGuard clamp closures.
Page 134: Removing The Crimping Cut-Off Head
9.3.1 Removing the crimping cut‑off head To facilitate installation, move the clamping unit to the ejection position (see Section 6.8.2 ). Switch off the FAST 3000. Unscrew the 4 screws at the side and remove the cover from the head.
Page 135 OETIKER FAST 3000 Maintenance and replacement of parts Before removing the crimping cut-off head, lay the force sensor cables (1) over the FAST 3000. This reduces the risk of inadvertently crushing the force sensor cables. Unscrew the 4 screws on the front face, and pull the crimping cut-off head off.
Page 136: Installing The Crimping Cut-Off Head
CAUTION Damage to the tool due to the use of unauthorized parts or improper handling. Use only original OETIKER spare parts. Crimping jaws other than those designated may not be installed in the crimping cut-off head. Use no impact tools when disassembling or reassembling the crimping cut-off head. The assembly is part of a measurement system which can be damaged by improper handling.
Page 137 Comply with the following instructions: When assembling the crimping cut-off head and installing it on the FAST 3000 mechanism, make sure that the crimping jaw rollers are located in the crimping wedge guides as shown in the left-hand photo. Failure to comply with this instructions can lead to mechanical damage to the crimping cut-off head.
Page 138 OETIKER FAST 3000 Maintenance and replacement of parts Push down the spacer plate by hand alternately at the points indicated. Tightening torque the M6 screws: 7-9 Nm (62-80 Ibf in) Replacing the cut‑off die NOTE Do not use the respective side of the cut-off die any longer that the number of cycles specified in the Maintenance section.
Page 139 OETIKER FAST 3000 Maintenance and replacement of parts Push the cut-off die out of the slide. When for the first time the cut-off die is due for replacement it can simply be turned over and the other side used. If that had already been done, replace the cut-off die with a new one.
Page 140: Replacing The Crimping Wedge
OETIKER FAST 3000 Maintenance and replacement of parts Comply with the disassembly instructions when dismantling the crimping cut-off head (see “Dismantling the crimping head”) Replace the crimping jaws. Reassemble the crimping cut-off head. 9.3.4 Replacing the crimping wedge For details of dismantling the crimping cut-off head see Sections 9.3.1 and 9.3.3.
Page 141 OETIKER FAST 3000 Maintenance and replacement of parts Mount the pivot pin press-out tool on the crimping cut-off head as shown in the picture on the right. Comply with the sequence of tightening operations. Tighten the marked screw (1) and press the first pivot pin out.
Page 142: Replacing The Clamping Lever
9.3.6 Replacing the clamping lever CAUTION Damage to the tool due to the use of unauthorized parts. Use only original OETIKER spare parts. For further information on the part numbers of spare parts see Section 9.7 CAUTION Damage to the tool due to incorrect closure of clamps.
Page 143 OETIKER FAST 3000 Maintenance and replacement of parts NOTE Do not use the clamping lever any longer that the number of cycles specified in the Maintenance section. Move the lower drive into the ejection position. Press the emergency stop button.
Page 144 OETIKER FAST 3000 Maintenance and replacement of parts Move the clamping lever forwards. Push the clamping lever to one side, take it off and replace it with a new one. Reassemble everything. To do this, perform the above steps in the reverse order.
Page 145: Checking And Adjusting The Position Of The Strap Detection Sensor
OETIKER FAST 3000 Maintenance and replacement of parts Checking and adjusting the position of the strap detection sensor NOTE To check whether the strap sensor is set correctly, perform steps 1 to 6. Move the lower drive into the service position (Operating mode -> Manual operation -> Service position).
Page 146 OETIKER FAST 3000 Maintenance and replacement of parts Once again insert the strap section bearing the “LED on” legend into the slot in the pulling unit. Using a 1.5 mm hexagon drive key, undo the threaded pin (2) about one turn.
Page 147: Setting The Closing Force Sensor
Perform five force verifications with a target force of 1850 N and make a note of the values. Calculate the average of these five values. (for instance 1950 N) Select “Settings” on the FAST 3000 touch panel and select the “Tool parameters” sub-menu: Issued 03.19...
Page 148: Replacing The Control Cabinet Or Tool Mechanism
Remove the defective components (from the tool mechanism or control cabinet). If you have to send the defective component back to Oetiker for repair, make sure you send back all the necessary components.
Page 149: Tools And Consumable Materials For Maintenance
OETIKER FAST 3000 Maintenance and replacement of parts Tools and consumable materials for maintenance Tool error / Part Applications Consumable materials number Spare parts kit for the 13500112 A-service crimping jaws (Service pack A) Service pack B 13500157 B-service Service pack C...
Page 150 OETIKER FAST 3000 Maintenance and replacement of parts Tool error / Part Applications Consumable materials number Spare parts kit for 13500113 Spare part clamping lever Crimping cut‑off head 13500215 Crimping cut-off head for for CFM quick maintenance Crimping cut‑off tool +...
Page 151 OETIKER FAST 3000 Maintenance and replacement of parts Tool error / Part Applications Consumable materials number Press‑out tool 13500204 Press out the crimping jaws Tensioning strap 13500233 Closing force verification Installation aid for the 13500288 Facilitates the installation of crimping cut‑off head...
Page 152 OETIKER FAST 3000 Maintenance and replacement of parts Tool error / Part Applications Consumable materials number Force measurement 13500264 The force measurement jaws jaws set set is used to determine the remaining radial force on the set WingGuard strap ®...
Page 153 OETIKER FAST 3000 Maintenance and replacement of parts Tool error / Part Applications Consumable materials number Clamping unit rail 13500218 Spare part Contact module NO 06001813 Spare part Contact module NC 06001814 Spare part Servo amplifier 06001892 Spare part L7NHA004U...
Page 154 06001877 Spare part Miniature force sensor 06001864 Spare part 2.5kN (crimping force sensor) Alignment aid 13500214 Positioning of the FAST 3000 Cable for the force 06001878 Cable for connecting the monitoring device 2 m crimping force sensor to the crimping force monitoring devices Issued 03.19...
Page 155 OETIKER FAST 3000 Maintenance and replacement of parts Tool error / Part Applications Consumable materials number Jaws checking mirror 13500266 Spare part Safety sticker set for the 08904156 Spare part FAST 3000 Hexagon key wrench Strap sensor 1.5 mm Hexagon key wrench Safety proximity sensor, …...
Page 156: Controlling The Fast 3000 Via An External Plc
10.1 Control via a field bus (Ethernet/IP or Profinet) The FAST 3000 can be controlled via an external control system based on the Ethernet/IP or Profinet field bus. Connect the supervisory control system to the respective LAN port of the FAST 3000 control cabinet.
Page 157: Settings For The Profinet Hw Configuration
• 6 x Input unsigned32 • 1 x Output unsigned32 Examples of HW configuration of the Profinet module on the FAST 3000 in a Siemens S7 1212C Fig. 33 10.1.3 Field bus mapping (software version V2.09) Description Data type R‑DW0...
Page 158 OETIKER FAST 3000 Controlling the FAST 3000 via an external PLC Description Data type R‑DW0 Bit12 Bit13 PLC: PCL and EtherCAT ready Tool R Bool R‑DW0 Bit13 Bit14 PLC: Feedback external PLC: Enable power Tool R Bool R‑DW0 Bit14 Bit15...
Page 159 OETIKER FAST 3000 Controlling the FAST 3000 via an external PLC Description Data type R‑DW17 Max. pieces in laboratory mode Laboratory mode R Int R‑DW18 Remaining pieces in laboratory mode Laboratory mode R Int R‑DW19 Home position motion lever Parameter motion lever R Real R‑DW20...
Page 160 OETIKER FAST 3000 Controlling the FAST 3000 via an external PLC R Real 2 places of decimals Description Data type W‑DW0 Bit0 Bit1 Start cycle Normal mode W Bool W‑DW0 Bit1 Bit2 Stop cycle Normal mode W Bool W‑DW0 Bit2...
Page 161: Control Via 24-V I/O Signals
As an alternative to the bus the FAST 3000 can be controlled via 24-V signals. Details of the connection for external control at the control cabinet of the FAST 3000 can be found in the circuit diagram on pages 350, 351, 352. For further information about activating control via I/O see Sections 7.4.5 and 7.4.7 (Settings, Tool Parameters).
Page 162: Decommissioning, Transport, Storage, Recommissioning
Store the FAST 3000 in a clean dry place and protect it from dust. 11.2 Transport The parts of the FAST 3000 are heavy. Always use appropriate means of transport. Always use two persons when lifting the tool. Use the transport restraint to prevent linear and rotational movement of the tool mechanism during transport.
Page 163 OETIKER FAST 3000 Decommissioning, transport, storage, recommissioning Transport eyes Transport restraint Handle Issued 03.19 08903979 11-165...
Page 164: Storage
OETIKER FAST 3000 Decommissioning, transport, storage, recommissioning 11.3 Storage If the FAST 3000 is to remain out of service for an extended period, it must be decommissioned. • Withdraw the electrical plug. • Clean the FAST 3000 before putting it into storage.
Page 165: Technical Data
OETIKER FAST 3000 Technical data Technical data • For use only indoors • Temperature range 5 °C to 40 °C • Max. relative atmospheric humidity 80 % at temperatures up to 31 °C • 110 V or 220/230 V 50-60 Hz AC, grounded •...
Page 166: Troubleshooting And Error Messages
If the closing operation cannot be started or if functional faults occur during operation, then the technical personnel responsible for maintenance of the FAST 3000 should be contacted. • Errors may only be corrected in a technically correct manner. If in doubt contact Oetiker (www.oetiker.com). 13.2 What should I do, if …? Type of error...
Page 167 Connect the two-hand control panel to the connected to the control cabinet control cabinet. Control cabinet defective Send the unit back to OETIKER. Emergency Stop activated Press and release the Emergency Stop button. Initialize the FAST 3000. Power to the drives not switched on Press the green button on the control cabinet to switch on the power to the drive.
Page 168 If the unblocking function does not perform production due to an inserted clamp correctly, continue with the following steps: Switch the FAST 3000 off securely. Remove one of the front side covers and the cover of the crimping cut-off head.
Page 169 Remove the clamp strap from the crimping cut-off head. The FAST 3000 is now ready for initialization. Mount the front cover and switch on the FAST 3000.
Page 170: Error Messages And Their Resolution
OETIKER FAST 3000 Troubleshooting and error messages 13.3 Error messages and their resolution 13.3.1 ToErr_1: (W) strap present ‑> remove & acknowledge NOTE At each closure cycle a check is performed to determine whether the strap end has fallen from the clamping unit: The strap sensor checks whether the strap end is still present in the ejection position of the clamping unit.
Page 171: Toerr_2: Clamping Unit Not In The Home Position Sto -> Initialize
OETIKER FAST 3000 Troubleshooting and error messages If the strap sensor is covered with particles of metal: Clean the area around the strap detection sensor. To clean the sensor it may be necessary to remove a front cover and push back the clamping unit slide.
Page 172: Prerr_1: Maximum Tensioning Travel Exceeded
OETIKER FAST 3000 Troubleshooting and error messages If the clamping unit position sensor fails the I/O test: Check the function of the sensor. Check the connection of the sensor cable in the tool socket. Check the attachment condition of the force load cell as described in the Service Instructions.
Page 173: Prerr_11: General Error At Crimping
OETIKER FAST 3000 Troubleshooting and error messages The strap has slipped out of the clamping unit: Check the clamping lever, particularly its teeth, and replace it if necessary. Check the clamping unit slide. If it is worn, replace it. Check the clamping lever pivot pin. If it is worn, replace it.
Page 174: Prerr_12: Error At Cutting Off
Arrange for the connecting cable ( see Section 6.1 ) to be better secured. If adjoining parts are obstructing the free movement of the FAST 3000: Ensure that the FAST 3000 can move freely and not accidentally come into contact with other parts. 13.3.5 PrErr_12: Error at cutting off Remedy: Subject the cut-off die to a visual inspection for defects.
Page 175: Prerr_15: Closing Force Outside Tolerance
Use the deblocking function ( see Section 6.8.1 ) to move the tool into a status where initialization can be performed. Use the deblocking function ( see Section 6.8.1 ) If at the next cycle the FAST 3000 operates correctly: Depress the start buttons quickly. Issued 03.19...
Page 176: Toerr_5: Drive Error Active
OETIKER FAST 3000 Troubleshooting and error messages If at the next cycle despite the buttons being quickly the FAST 3000 once again exhibits the same error: Replace the start button contacts. Check the wiring of the buttons. 13.3.9 ToErr_5: Drive error active If the green power enable button on the control cabinet door fails to light up: Press the green power enable button.
Page 177: Prerr_3: Crimping Error Cfm1 Envelope Curve 1
This error occurs when during crimping the force at the crimping jaws increases too early. Remedy: Check the setting of the crimping force monitoring device 1. Check the positioning of the FAST 3000. 13.3.14 PrErr_6: Crimping error CFM1 wear Remedy: Check the crimping jaws for wear.
Page 178: Prerr_8: Crimping Error Cfm2 Envelope Curve 2
This error occurs when during crimping the force at the crimping jaws increases too early. Remedy: Check the setting of the crimping force monitoring device 2. Check the positioning of the FAST 3000. 13.3.18 PrErr_10: Crimping error CFM2 wear Remedy: Check the crimping jaws for wear.
Page 179: Prerr_16 Max Force When The Light Curtain Breached
OETIKER FAST 3000 Troubleshooting and error messages 13.3.20 PrErr_16 Max force when the light curtain breached Remedy: Prevent the light curtain being breached during the cycle. Deactivate the light curtain in the “Settings” menu “Tool Parameters” sub-menu. Issued 03.19 08903979...
Page 180: Prerr_17: Max Force Travel In Ejection Position
OETIKER FAST 3000 Troubleshooting and error messages 13.3.21 PrErr_17: Max force travel in ejection position NOTE After the strap has been cut off the tensioning force is monitored during the journey to the ejection position. During this time the force should be effectively 0 N, otherwise the strap has not been correctly cut off.
Page 181: Toerr_8: Verifying The Crimping Force (Phase 1)
OETIKER FAST 3000 Troubleshooting and error messages Remedy: Prevent the light curtain tripping during the initialization procedure. Deactivate the light curtain in the “Settings” menu “Tool Parameters” sub-menu. 13.3.25 ToErr_8: Verifying the crimping force (phase 1) NOTE The error occurs if an excessive force is present during the first phase (the lever moves at a pre-defined speed into position 1).
Page 182: Toerr_10: Verifying The Crimping Force: No Force Increase
OETIKER FAST 3000 Troubleshooting and error messages 13.3.27 ToErr_10: Verifying the crimping force: No force increase NOTE The error occurs if for a period of 5 seconds during the second phase the crimping force fails to increase. Remedy: Check that the crimping force monitoring devices are switched on.
Page 183: Toerr_13 Check Tensioning Force Sensor
OETIKER FAST 3000 Troubleshooting and error messages 13.3.30 ToErr_13 Check tensioning force sensor NOTE During the clamping cycle the tensioning force sensor checks that the value satisfies certain criteria when the lever is in the home position and when it is in the insertion position.
Page 184: Toerr_16 No Power To Tool During Operation
OETIKER FAST 3000 Troubleshooting and error messages 13.3.31 ToErr_16 No power to tool during operation NOTE The power supply to the lever or to the tensioning drive has been interrupted. Remedy: Restore power supply to the tool. Switch on at the green button on the control cabinet door and initialize the tool.
Page 185: War_5 Service Due Soon
OETIKER FAST 3000 Troubleshooting and error messages 13.3.35 War_5 Service due soon NOTE When the service counter falls below a pre-defined limit, the message appears periodically every ten closures. Remedy: Perform the service and reset the service counter. 13.3.36 War_6 Service due NOTE When the service counter falls below a pre-defined limit, the message appears periodically every two closures.
Page 186: War_9 No Power To Tool
OETIKER FAST 3000 Troubleshooting and error messages Remedy: Activate the “CFM Production Mode setting” in the “Settings” menu “Tool Parameters” sub-menu. 13.3.39 War_9 No power to tool NOTE The power supply to the lever or to the tensioning drive is not activated.
Page 187: War_11 Remove Strap
OETIKER FAST 3000 Troubleshooting and error messages 13.3.41 War_11 Remove strap NOTE This warning appears during initialization. For safety reasons it may happen that during initialization the pulling unit moves to the ejection position and then the message appears that surplus pieces of the clamping strap must be removed.
Page 188: Appendix
Circuit diagram • Industrial communication • EU Declaration of Conformity • Oetiker production checklist • FAST 3000 capability measurements • Control cabinet test certificate • HBM force sensor test certificate • Kistler test certificates • Operating Instructions for crimping force monitoring devices Issued 03.19...
Page 189: Help And Support
OETIKER FAST 3000 Help and Support Help and Support If you need help, contact the appropriate Oetiker service center. Further information can be found at www.oetiker.de. Headquarters Switzerland China T +41 44 728 55 55 T +86 22 2697 1183 info.ch@oetiker.com...

OETIKER FAST 3000 Operating Instructions Manual

1 Information about this Manual

2 Basic Safety Instructions

3 Scope of Supply of the FAST 3000 Tool

4 Brief Description of the FAST 3000

5 Description of the Process Monitoring of the FAST 3000

6 Working with the FAST 3000

7 Gui

8 Assigning the IP Address

9 Maintenance and Replacement of Parts

10 Controlling the FAST 3000 Via an External PLC

11 Decommissioning, Transport, Storage, Recommissioning

12 Technical Data

13 Troubleshooting and Error Messages

14 Appendix

15 Help and Support

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