Page 1 Nexo cordless Wi-Fi nutrunner by Rexroth Project planning Version AF 3 608 870 A47/10.2019 <Replace this image space with your product image>...
Page 2 © This document, as well as the data, specifications, and other information set forth in it, are the exclusive property of Bosch Rexroth AG. It may not be reproduced or given to third parties without its consent. The title page shows an exemplary configuration. The supplied product may therefore vary from the illustration.
Page 3 3/279 Bosch Rexroth AG | Tightening Technology Nexo cordless Wi-Fi nutrunner by Rexroth Title Project planning Type of Documentation DOK-NEXO-DOKU_V1.400-EN Document Typecode 3 608 870 A47_EN Internal File Reference This documentation describes the Nexo cordless Wi-Fi nutrunner by Rexroth. Purpose of Documentation...
Page 4 Bosch Rexroth AG | Tightening Technology 4/279...
Page 5: Table Of Contents
Tightening Technology | Bosch Rexroth AG 5/279 Contents 3.3.5 Fieldbus control and result storage via WLAN ..39 About this documentation 3.3.6 Process Quality Manager (PQM) ....40 Overview of this documentation .
Page 6 6/279 Bosch Rexroth AG | Tightening Technology 7.7.1 Assignment of PLC signals....165 9.8.6 Firmware ........235 7.7.2...
Page 7: About This Documentation
About this documentation This chapter contains general information on the present documentation. Overview of this documentation (page 8) • Validity of the documentation (page 8) • Additional documentation (page 8) • Representation of information (page 9) •...
Page 8: Overview Of This Documentation
Bosch Rexroth AG | Tightening Technology 8/279 3 608 870 A47 Overview of this documentation This documentation describes the tightening system in the following chapters: Chapter Title Contents About this documentation Scope of this document, abbreviations, representations used, glossary. Safety instructions Safety precautions on how to avoid hazardous situations when using Rexroth tightening systems.
Page 9: Representation Of Information
Tightening Technology | Bosch Rexroth AG 3 608 870 A47 9/279 Representation of information This section shows how the data, e.g. safety instructions, and symbols are represented in the present documentation. 1.4.1 Safety instructions In this documentation, safety instructions precede an instruction when there is the danger of personal injury or damage to equipment.
Page 10: Symbols And Representations
Bosch Rexroth AG | Tightening Technology 10/279 3 608 870 A47 CAUTION Bodily harm or damage to equipment may result. NOTICE Damage to equipment may result. If this information is not observed, the operating procedure may be impaired. 1.4.2 Symbols and representations Table 1–2:...
Page 11: Designations
Tightening Technology | Bosch Rexroth AG 3 608 870 A47 11/279 1.4.3 Designations Compact system 350 with integrated logic. With the integrated logic in the compact system, single CS351 IL channel control can be implemented as a gateway between the PLC fieldbus and the Nexo cordless Wi-Fi nutrunner.
Page 12 Bosch Rexroth AG | Tightening Technology 12/279 3 608 870 A47 The torque threshold is a parameter to help measure the angle of turn for a target or monitoring Torque threshold function. The monitoring function of the angle is started as soon as the measured torque for the bolt reaches the value for the torque threshold for the first time.
Page 13: Abbreviations
Tightening Technology | Bosch Rexroth AG 3 608 870 A47 13/279 1.4.4 Abbreviations The following abbreviations are used in this documentation: Table 1–3: Abbreviations for the components of the Nexo cordless Wi-Fi nutrunner Abbreviation Explanation German Institute for Standardization Electromagnetic Compatibility...
Page 14 Bosch Rexroth AG | Tightening Technology 14/279 3 608 870 A47 Nexo cordless Wi-Fi nutrunner | 3 608 870 A47/2019-10...
Page 15: Safety Instructions
Safety instructions This chapter describes cardinal safety requirements to be met during operation of the Rexroth Tightening System 350 and the Nexo cordless Wi-Fi nutrunner by Rexroth (referred to as Rexroth tightening system below). It contains important information that is necessary for the safe use of the Rexroth tightening system. About this chapter (page 16) •...
Page 16: About This Chapter
Bosch Rexroth AG | Tightening Technology 16/279 3 608 870 A47 About this chapter The product has been manufactured according to the accepted rules of current technology. There is, however, still the risk of personal injury or damage to equipment if this chapter and the safety instructions in this documentation are not complied with.
Page 17: Electrical Safety
Tightening Technology | Bosch Rexroth AG 3 608 870 A47 17/279 Electrical safety • • • • • • Personal safety • • • • • • • • Nexo cordless Wi-Fi nutrunner | 3 608 870 A47/2019-10...
Page 18: Power Tool Use And Care
Bosch Rexroth AG | Tightening Technology 18/279 3 608 870 A47 Power tool use and care • • • • • • • • Battery tool use and care • • • • • • • Nexo cordless Wi-Fi nutrunner | 3 608 870 A47/2019-10...
Page 19: Service
Tightening Technology | Bosch Rexroth AG 3 608 870 A47 19/279 Service • • Safety Instructions for nutrunners • • • • • • WARNING sawing, grinding, drilling and other similar activities may cause cancer, congenital defects or genetic mutations.
Page 20: Intended Use
Bosch Rexroth AG | Tightening Technology 20/279 3 608 870 A47 Use power tools only when they are in good technical order and condition. • You may only commission the power tool if it has been determined that the end product (e.g., machinery or •...
Page 21: Improper Use
Bosch Rexroth AG will not accept any liability for damage caused by improper use. The risks in case of improper use shall be exclusively borne by the user.
Page 22: Symbol On The Product
Bosch Rexroth AG | Tightening Technology 22/279 3 608 870 A47 2.13 Symbol on the product Table 2–1: Meaning of the symbol Symbol Meaning Read all safety instructions and instructions. Non-compliance with the safety instructions and instructions may cause electric shock, fire and/or serious injuries.
Page 23: Introduction
Introduction This chapter gives an initial overview of the functions and application options of the Nexo cordless Wi-Fi nutrunner. Nexo cordless Wi-Fi nutrunner (page 24) • WLAN (Wireless Local Area Network) (page 32) • Connection options of the Nexo cordless Wi-Fi nutrunner (page 34) •...
Page 24: Nexo Cordless Wi-Fi Nutrunner
Bosch Rexroth AG | Tightening Technology 24/279 3 608 870 A47 Nexo cordless Wi-Fi nutrunner The Nexo cordless Wi-Fi nutrunner is designed for tightening operations of category A according to VDI 2862 that are critical in terms of safety. Results are stored and output, thus ensuring complete documen- tation of any information that is relevant for tightening.
Page 25: Nx-Sd Micro Sd Card
Tightening Technology | Bosch Rexroth AG 3 608 870 A47 25/279 3.1.1 NX-SD Micro SD card The scope of delivery of the Nexo cordless Wi-Fi nutrunner includes a Micro SD card that can be inserted into the nutrunner. In state of delivery, this card contains documentations and license information.
Page 26: Nexo-Os Operating System
Bosch Rexroth AG | Tightening Technology 26/279 3 608 870 A47 3.1.4 NEXO-OS operating system On delivery, the NEXO-OS operating system is pre-installed as an integral part of the Nexo cordless Wi- Fi nutrunner. It is used to program tightening jobs and to visualize and analyze measurement values.
Page 27 Tightening Technology | Bosch Rexroth AG 3 608 870 A47 27/279 1 - Status bar Table 3–1: Status bar elements Element Description Shows the current charging condition of the inserted slide-in battery pack. WLAN activated. Indicates the radio communication signal strength WLAN deactivated.
Page 28 Bosch Rexroth AG | Tightening Technology 28/279 3 608 870 A47 Fig. 3–4: Assignment of function keys and fields The main menu can be accessed with the center function key. As of Nexo firmware version 1200, the center position of the program selector triggers the screen of the PLC input signals 0.3, 0.4 and 0.5 applied in the PLC module...
Page 29: Nexo Battery System
Tightening Technology | Bosch Rexroth AG 3 608 870 A47 29/279 3.1.6 Nexo battery system 3.1.6.1 Lithium-ion batteries - Good to know The voltage of an individual battery cell is referred to as cell voltage. The higher the cell voltage the less Cell voltage individual cells are required for a battery with high voltage.
Page 30 Bosch Rexroth AG | Tightening Technology 30/279 3 608 870 A47 NX-BP36V: • Cell voltage 3.6 V multiplied by 10 cells = 36 V battery voltage • Battery capacity = cell capacity = 2 Ah • This results in a battery energy content of 36 V multiplied by 2 Ah = 72 Wh NX-BP2-36V: •...
Page 31: Technical Data Of The Nutrunner
Tightening Technology | Bosch Rexroth AG 3 608 870 A47 31/279 3.1.7 Technical data of the nutrunner Technical data of the Nexo cordless Wi-Fi nutrunner can be found in the "Nexo" operating manual. Optimizations within the series Table 3–2: NEXO angle heads...
Page 32: Wlan (Wireless Local Area Network)
Bosch Rexroth AG | Tightening Technology 32/279 3 608 870 A47 WLAN (Wireless Local Area Network) WLAN is short for wireless local area network. It makes the Ethernet-based communication of a LAN (Lo- cal Area Network) wireless. The typical WLAN standards are specified in standard IEEE 802.11.
Page 33: Diagnosis
Tightening Technology | Bosch Rexroth AG 3 608 870 A47 33/279 3.2.3 Diagnosis Various simple diagnostic tools are available that can be used to capture basic information on the WLAN network. There are Android apps (usually free of charge) for simple analyses. There is also software for Windows computers that offer these functions.
Page 34: Connection Options Of The Nexo Cordless Wi-Fi Nutrunner
Bosch Rexroth AG | Tightening Technology 34/279 3 608 870 A47 Connection options of the Nexo cordless Wi-Fi nutrunner Below, various connection options for the use of the Nexo cordless Wi-Fi nutrunner are described: • Result storage without radio connection (page 34) •...
Page 35: Results Storage Via Wlan
Tightening Technology | Bosch Rexroth AG 3 608 870 A47 35/279 3.3.2 Results storage via WLAN: The results data can be transmitted in the "standard Nexo" format as a *.json file via WLAN from the Nexo cordless Wi-Fi nutrunner to an FTP server (e.g. FileZilla) of the IPC, laptop or database server. As of Nexo firmware version 1200, a HTTP or File Share server can be used for transmission of the results data.
Page 36: Control And Results Storage Via Wlan
Bosch Rexroth AG | Tightening Technology 36/279 3 608 870 A47 3.3.3 Control and results storage via WLAN The Nexo cordless Wi-Fi nutrunner uses the Rexroth Open Protocol for WLAN communication (control). The corresponding software with Open Protocol has to be installed on the IPC, laptop or database server.
Page 37 Tightening Technology | Bosch Rexroth AG 3 608 870 A47 37/279 3.3.3.1 Control via VW-XML master PC As of Nexo firmware version 1200, the VW-XML protocol is supported. VW-XML version 2.1 is supported. Application of the VW-XML protocol outside of VOLKSWAGEN AG is subject to express written agree- ment of VOLKSWAGEN AG.
Page 38: Plc Control And Result Storage Via Wlan
Bosch Rexroth AG | Tightening Technology 38/279 3 608 870 A47 3.3.4 PLC control and result storage via WLAN The Nexo cordless Wi-Fi nutrunner uses the Rexroth Open Protocol for WLAN communication (control). In addition, results (except graph data) can be transmitted using Rexroth Open Protocol. The PLC has to contain function blocks that provide for communication via Rexroth Open Protocol.
Page 39: Fieldbus Control And Result Storage Via Wlan
Tightening Technology | Bosch Rexroth AG 3 608 870 A47 39/279 3.3.5 Fieldbus control and result storage via WLAN With the integrated logic in the CS351 IL compact system, single channel control can be implemented as a gateway between the PLC fieldbus and the Nexo cordless Wi-Fi nutrunner. The CS351 IL and PLC communicate via fieldbus.
Page 40: Process Quality Manager (Pqm)
3.3.6 Process Quality Manager (PQM) Process Quality Manager (PQM) is a software solution of Bosch Rexroth. It is designed to recognize and avoid non-conformities and errors in the production process as soon as possible. PQM offers safe and reliable monitoring and documentation of production processes.
Page 41: Assembly
Assembly This chapter describes the assembly options for the Nexo cordless Wi-Fi nutrunner. Assembly notes (page 42) • Adjusting the angle head (page 43) • Attaching the torque support (page 45) • Attaching the accessories (page 47) •...
Page 42: Assembly Notes
Bosch Rexroth AG | Tightening Technology 42/279 3 608 870 A47 Assembly notes CAUTION The product is not protected against incorrect assembly/disassembly! Risk of injury and damage to the device during subsequent operation.  Assemble/disassemble the product according to the information in the "Nexo" operating instructions and in the correct order.
Page 43: Adjusting The Angle Head
Tightening Technology | Bosch Rexroth AG 3 608 870 A47 43/279 Adjusting the angle head NOTICE Improper handling may cause damage! Damage to the hand-held nutrunner.  Attach the mounting aid only in the clamping area allowed for the torque support (see...
Page 44 Bosch Rexroth AG | Tightening Technology 44/279 3 608 870 A47 Adjust angle head 5 in increments of 45° until it reaches the desired position and use open-end wrench 1 to tighten the union nut at wrench face 2 again. Use open-end wrench 3 at the angle head flange to hold it in place (see figure 4–2).
Page 45: Attaching The Torque Support
Tightening Technology | Bosch Rexroth AG 3 608 870 A47 45/279 Lock the angle screw head 1 in position by turning the counter nut 3 in the direction of arrow C (see figure 4–4). Retighten the counter nut 3 (see figure 4–4).
Page 46 Bosch Rexroth AG | Tightening Technology 46/279 3 608 870 A47 15 ... 19 mm Fig. 4–7: Torque support clamping area Torque for the torque support on pistol grip nutrunners: M = 7 + 1 Nm Fig. 4–8: Clamping piece mounting position...
Page 47: Attaching The Accessories
Tightening Technology | Bosch Rexroth AG 3 608 870 A47 47/279 Example: Minimum clamping width for the torque support on pistol grip nutrunners: > 74 55 ± 0,2 Ø 9 Fig. 4–9: Minimum clamping piece dimensions Attaching the accessories CAUTION...
Page 48 Bosch Rexroth AG | Tightening Technology 48/279 3 608 870 A47 Nexo cordless Wi-Fi nutrunner | 3 608 870 A47/2019-10...
Page 49: Construction Guidelines
Construction guidelines This chapter provides basic information about tightening operations to the extent to which they are relevant for the Nexo cordless Wi-Fi nutrunner by Rexroth. Additional information can be found online at: www.boschrexroth.com/tightening Design of a bolted connection (page 50) •...
Page 50: Design Of A Bolted Connection
Bosch Rexroth AG | Tightening Technology 50/279 3 608 870 A47 Design of a bolted connection The planning of a tightening system starts with the definition of the tightenings that are to be implemented. Basics on bolted connections and tightening technology can also be found in “Tightening Technology”, ISBN 3-478-93073-1, Moderne Industrie publishers.
Page 51: Determination Of The Required Torque To Create A Bolted Connection
Tightening Technology | Bosch Rexroth AG 3 608 870 A47 51/279 5.1.2 Determination of the required torque to create a bolted connection When creating bolted connections, the mounting clamp force (clamping force) required for a secure con- nection of the parts is usually specified. As the clamping force is difficult to measure, the tightening torque or angle of turn is used as a parameter for the clamping force.
Page 52 Bosch Rexroth AG | Tightening Technology 52/279 3 608 870 A47 Settling can be avoided or decreased using the following procedures: • Design modification, e.g. of bearing surfaces, to prevent forces exceeding the yielding points (per- missible surface pressing) of the materials •...
Page 53 Tightening Technology | Bosch Rexroth AG 3 608 870 A47 53/279 5.1.2.6 Clamping force table according to VDI 2230 The following table lists the guide values for mounting clamp forces (F ) and tightening torques (T ) in relation to a friction factor (...
Page 54: Tightening Case (Soft - Hard)
Bosch Rexroth AG | Tightening Technology 54/279 3 608 870 A47 5.1.3 Tightening case (soft – hard) A soft tightening case exists if a relative large angle of turn is needed to reach the tightening torque. This Soft tightening case is always the case if elastic (or soft) materials are being tightened, e.g.
Page 55: Total Duration For All Tightening Steps
Planning assistance 5.4.1 3-D/CAD data All CAD data from Bosch Rexroth are available free of charge from the following internet address. www.boschrexroth.com/tightening Use the links on the website displayed to navigate to the appropriate component. The CAD data are avail- able on the CAD tab.
Page 56 Bosch Rexroth AG | Tightening Technology 56/279 3 608 870 A47 Nexo cordless Wi-Fi nutrunner | 3 608 870 A47/2019-10...
Page 57: Control Signals
Control signals This chapter provides detailed information about the control signals of the tightening controller (PLC) of the Nexo cordless Wi-Fi nutrunner by Rexroth. PLC signals (page 58) • Description of all PLC signals (page 58) •...
Page 58: Plc Signals
Bosch Rexroth AG | Tightening Technology 58/279 3 608 870 A47 PLC signals The default delivery of the Nexo cordless Wi-Fi nutrunner includes a PLC assignment table that has already been configured. The PLC assignment table defines the assignment of the control signals to the physical interfaces of the Nexo cordless Wi-Fi nutrunner.
Page 59 Tightening Technology | Bosch Rexroth AG 3 608 870 A47 59/279 Supported as of Nexo firmware version 1300 3) Supported as of Nexo firmware version 1400 AbortVin Abort Vehicle Identification Number: Cancel current order This signal can be used to cancel a current job when the signal changes from "Low" to "High". This is evaluated as NOK.
Page 60 Bosch Rexroth AG | Tightening Technology 60/279 3 608 870 A47 No zero point test is implemented when program no. 99 is started with the signal Ccw. CcwIgnore Counter clock wise ignore: Ignores the Ccw switch This signal ignores the position of the Ccw switch of the nutrunner. The program selected is always started.
Page 61 Tightening Technology | Bosch Rexroth AG 3 608 870 A47 61/279 DisScan Disable scanner: Block the scanner When the signal DisScan is set to "high", the scanner in the nutrunner is deactivated. The scan icon on the nutrunner display will continue to be displayed. The user is not notified that the scanner is disabled via PLC signal.
Page 62 Bosch Rexroth AG | Tightening Technology 62/279 3 608 870 A47 If the NOKAc signal is assigned to input 0.3, 0.4 or 0.5 in the PLC table, the signal is inverted, i.e. the signal changes to "low" when the functional key is pushed, and to "high" when it is released.
Page 63: Output Signals
Tightening Technology | Bosch Rexroth AG 3 608 870 A47 63/279 6.2.2 Output signals Overview of PLC output signals Signal Function Description Ack0-7 Acknowledge 0-7 Acknowledges program selection ActEnAck Active enable acknowledge Acknowledgement scan process active ActScanAck Active scanner acknowledge...
Page 64 Bosch Rexroth AG | Tightening Technology 64/279 3 608 870 A47 Ack0-7 Acknowledge 0-7: Acknowledges program selection The signal serves to acknowledge the program selection. With the help of these signals, the PLC can determine whether the tightening program was selected successfully.
Page 65 Tightening Technology | Bosch Rexroth AG 3 608 870 A47 65/279 The signal is only updated outside of the tightening operation. CwAck Clock wise acknowledge: Acknowledges a start This signal serves to acknowledge the start of the selected tightening program.
Page 66 Bosch Rexroth AG | Tightening Technology 66/279 3 608 870 A47 GradH Gradient too high: Gradient too high Results description after a completed tightening sequence. The gradient is above the defined tolerance window. GradL Gradient too low: Gradient too low Results description after a completed tightening sequence.
Page 67 Tightening Technology | Bosch Rexroth AG 3 608 870 A47 67/279 JobRdy Job ready: The job is ready A job for a tightening channel, tightening cell, KE, or tightening application cannot be started before the system indicates that it is "ready" with the JobRdy signal (signal JobRdy = "high").
Page 68 Bosch Rexroth AG | Tightening Technology 68/279 3 608 870 A47 The signal is only updated outside of the tightening operation. Stick slip Stick slip too high: Number of stick slips too high Results description after a completed tightening sequence. The number of stick slips is above the defined tolerance window.
Page 69: Data Services
Data services This chapter describes the basic principles and the application of the various data services which can be used for data output or for data exchange with a partner controller. Overview of tightening results communication (page 70) • Data output via FTP (page 71) •...
Page 70: Overview Of Tightening Results Communication
Bosch Rexroth AG | Tightening Technology 70/279 3 608 870 A47 Overview of tightening results communication The Nexo cordless Wi-Fi nutrunner can transmit tightening results via the access point to other devices for further processing or storage. The following protocols are available as data services for transferring data between these devices: •...
Page 71: Data Output Via Ftp
Tightening Technology | Bosch Rexroth AG 3 608 870 A47 71/279 Data output via FTP As of Nexo firmware version 1200: The settings for the protocol are made via the NEXO-OS operating system in the Settings  Data  Standard Nexo  FTP menu, see section Settings on page 208.
Page 72: Data Volume And Expected Transfer Time For Tightening Results Files
Bosch Rexroth AG | Tightening Technology 72/279 3 608 870 A47 7.2.2 Data volume and expected transfer time for tightening results files The data volume depends on the following criteria: • Number of graph points configured in the tightening program •...
Page 73: Data Output Via Http
Tightening Technology | Bosch Rexroth AG 3 608 870 A47 73/279 Data output via HTTP As of Nexo firmware version 1200, data output via HTTP is supported. The settings for data output are made via the NEXO-OS operating system in the Settings ...
Page 74: Data Output Via File Share
Bosch Rexroth AG | Tightening Technology 74/279 3 608 870 A47 Data output via File Share As of Nexo firmware version 1200, data output via File Share is supported. The settings for data output are made via the NEXO-OS operating system in the Settings ...
Page 75: Rexroth Open Protocol
Tightening Technology | Bosch Rexroth AG 3 608 870 A47 75/279 Rexroth Open Protocol This chapter describes the communication between the superior computer and tightening controller via the Rexroth Open Protocol. During communication, the superior computer acts as a client and the tightening controller acts as a server.
Page 76: Sequence Diagrams - Examples
Bosch Rexroth AG | Tightening Technology 76/279 3 608 870 A47 7.5.1 Sequence diagrams - examples Loss of radio communication Nutrunner Superordinate system (OP communication partner) TCP connection establishment via port 4545 TCP connection establishment accepted MID 0001 MID 0060 MID 0018 {Prg.
Page 77 Tightening Technology | Bosch Rexroth AG 3 608 870 A47 77/279 Bar code scan Superordinate system Nutrunner (OP communication partner) Scanner reads barcode Send barcode to OP communication partner Generate ID code Send ID code to nutrunner Echo ID code...
Page 78 Bosch Rexroth AG | Tightening Technology 78/279 3 608 870 A47 Job selection by means of sent ID code via OpenProtocol Superordinate system Nutrunner MID 0500 MID 0005 MID 0504 MID 0005 MID 0501 ID code generation MID 0150 Send ID code to nutrunner...
Page 79 Tightening Technology | Bosch Rexroth AG 3 608 870 A47 79/279 Keep alive sequence Superordinate Tightening system system (OP communication partner) Last command in Last command in Keep alive the Open Protocol the Open Protocol timeout of the tightening Keep alive time cycle from...
Page 80: Message Structure
Bosch Rexroth AG | Tightening Technology 80/279 3 608 870 A47 7.5.2 Message structure A message in the Rexroth Open Protocol has an ASCII format structure and consists of: • Header (see Table 7–1) • Data (see Tables 7–2, 7–3 and 7–4)
Page 81 Tightening Technology | Bosch Rexroth AG 3 608 870 A47 81/279 Table 7–2: Message structure in the Open Protocol (data: general) Data Bytes Example: Parameter Value Value range Cell ID Cell value 0001 0000 – 9999 Channel ID Channel value 00 –...
Page 82 Bosch Rexroth AG | Tightening Technology 82/279 3 608 870 A47 The message in the above example would look as follows: Example Header Data End characters |----------------------| |---------------------------------------| |-| 0057 0002 001 1 00000000 01 0001 02 01 03 controller1...
Page 83: Messages
Tightening Technology | Bosch Rexroth AG 3 608 870 A47 83/279 7.5.3 Messages 7.5.3.1 Available messages As of Nexo firmware version 1100, the Open Protocol “Rexroth OP-Ford” is available. Table 7–6: Available messages Description Rexroth Rexroth OP-Ford MID 0001 Communication start...
Page 84 Bosch Rexroth AG | Tightening Technology 84/279 3 608 870 A47 Table 7–6: Available messages Description Rexroth Rexroth OP-Ford MID 0073 Cancel system errors subscription MID 0074 System error in tightening controller acknowledged MID 0075 Acknowledgement System error in tightening controller acknowledged...
Page 85 Tightening Technology | Bosch Rexroth AG 3 608 870 A47 85/279 7.5.3.2 Message specification MID 0001 Communication start Sent by: superordinate computer Activates the command connection. Until this is done, the tightening controller will not respond to any other command.
Page 86 Bosch Rexroth AG | Tightening Technology 86/279 3 608 870 A47 MID 0002 revision 002 Table 7–8: MID 002 revision 002 Parameter Comments Bytes This revision includes the information from revision 001 and the following additional information: Manufacturer code The value consists of three ASCII characters.
Page 87 Tightening Technology | Bosch Rexroth AG 3 608 870 A47 87/279 Meanings of the individual values: • 01: Cell ID • 0003: Cell ID value • 02: Channel number • 04: Channel number value • 03: ID Controller name •...
Page 88 Bosch Rexroth AG | Tightening Technology 88/279 3 608 870 A47 0018 Error no. Data field value 001802 MID 0005 Command accepted Sent by: Tightening controller With this message, the tightening controller confirms that the last request sent by the superior computer has been accepted.
Page 89 Tightening Technology | Bosch Rexroth AG 3 608 870 A47 89/279 Table 7–12: MID 0011 revision 001 Parameter Comments Bytes Number of tightening programs The value consists of three ASCII characters. 000 – 999 Value range Presetting Example: Number of tightening...
Page 90 Bosch Rexroth AG | Tightening Technology 90/279 3 608 870 A47 MID 0013 revision 001 Table 7–13: MID 0013 revision 001 Parameter Comments Bytes Tightening program number The value consists of three ASCII characters. 000 – 999 Value range Presetting...
Page 91 Tightening Technology | Bosch Rexroth AG 3 608 870 A47 91/279 Table 7–13: MID 0013 revision 001 Parameter Comments Bytes Target torque The target torque is multiplied by 100 and then sent as a whole number (rounded to two decimals).
Page 92 Bosch Rexroth AG | Tightening Technology 92/279 3 608 870 A47 MID 0015 Tightening program selected Sent by: Tightening controller A new tightening program is selected in the tightening controller. The message contains the number of the last selected tightening program, as well as the date/time of the last change to the tightening program settings.
Page 93 Tightening Technology | Bosch Rexroth AG 3 608 870 A47 93/279 MID 0018 Select tightening program Sent by: superordinate computer Select tightening program Note: Program selection signals must be listed in the PLC assignment table in the OP module. Revision: 001 Data field: tightening program number, 3 ASCII characters (000–999), 3 bytes...
Page 94 Bosch Rexroth AG | Tightening Technology 94/279 3 608 870 A47 MID 0019 revision 002 Table 7–16: MID 0019 revision 002 Parameter Comments Bytes This revision includes the information from revision 001 and the following additional information: NOK counter value The value consists of two ASCII characters.
Page 95 Tightening Technology | Bosch Rexroth AG 3 608 870 A47 95/279 MID 0031 OK counter upload response Sent by: Tightening controller Transfer of all configured OK counters in the tightening system. Note: - 001, 002 Revision: Data field: Data field lengths...
Page 96 Bosch Rexroth AG | Tightening Technology 96/279 3 608 870 A47 MID 0032 Job data upload request superordinate computer Sent by: Request to upload the parameters of a job. Note: - (supported by Rexroth OP) Revision: Job number, 2 bytes...
Page 97 Tightening Technology | Bosch Rexroth AG 3 608 870 A47 97/279 Table 7–19: MID 0033 revision 001 Parameter Comments Bytes Maximum time for first Maximum time for first tightening: not supported tightening The value consists of four ASCII characters. 0000...
Page 98 Bosch Rexroth AG | Tightening Technology 98/279 3 608 870 A47 Table 7–19: MID 0033 revision 001 Parameter Comments Bytes Tightening programs number Number of tightening programs defined in the job. The value consists of two ASCII characters. 0 – 99...
Page 99 Tightening Technology | Bosch Rexroth AG 3 608 870 A47 99/279 Table 7–20: MID 0033 Revision 002 Parameter Comments Bytes Order Order of processing of the counter steps in the job. – 0: free order (not supported) – 1: forced order Single-program step –...
Page 100 Bosch Rexroth AG | Tightening Technology 100/279 3 608 870 A47 Table 7–20: MID 0033 Revision 002 Parameter Comments Bytes Repeat job Repeat job: – 0: No – 1: Yes The value consists of one ASCII character. 0 – 1...
Page 101 Tightening Technology | Bosch Rexroth AG 101/279 3 608 870 A47 Job info subscription MID 0034 superordinate computer Sent by: A message (upload job info, MID 0035) is sent to the higher-level computer each time a new job is selected and after each tightening has been carried out during the job.
Page 102 Bosch Rexroth AG | Tightening Technology 102/279 3 608 870 A47 Table 7–21: MID 0035 revision 002 Parameter Comments Bytes Number of defined Number of OK tightenings defined in the job. OK tightenings in the job The value consists of four ASCII characters.
Page 103 Tightening Technology | Bosch Rexroth AG 103/279 3 608 870 A47 MID 0035 revision 003 Table 7–22: MID 0035 revision 003 Parameter Comments Bytes Job step Currently executed steps in the job. The value consists of three ASCII characters. 001 - 999...
Page 104 Bosch Rexroth AG | Tightening Technology 104/279 3 608 870 A47 Cancel job info subscription MID 0037 superordinate computer Sent by: Reset the subscription for the job info. Note: (supported by Rexroth OP) Revision: is empty, 0 bytes Data field: Possible response: Error no.
Page 105 Tightening Technology | Bosch Rexroth AG 105/279 3 608 870 A47 7.5.3.6 Tool messages MID 0040 Tool data upload request Sent by: superordinate computer This function can be used to retrieve the tool data. Note: - Revision: see MID 0041...
Page 106 Bosch Rexroth AG | Tightening Technology 106/279 3 608 870 A47 Table 7–25: MID 0041 revision 001 Parameter Comments Bytes Date of the last maintenance The value consists of 19 ASCII characters: is not supported. 0 – 9, "-" and ":"...
Page 107 Tightening Technology | Bosch Rexroth AG 107/279 3 608 870 A47 MID 0041 revision 002-1 Table 7–26: MID 0041 revision 002-1 Bytes Parameter Comments This revision includes the information from revision 001 and the following additional information: MCE factor The value is multiplied by 1000 and transferred as a whole number (rounded to 3 decimals).
Page 108 Bosch Rexroth AG | Tightening Technology 108/279 3 608 870 A47 Table 7–26: MID 0041 revision 002-1 Bytes Parameter Comments Software version Firmware version of the nutrunner. The value consists of 19 ASCII characters. 0x20 – 0x7F Value range Presetting...
Page 109 Tightening Technology | Bosch Rexroth AG 109/279 3 608 870 A47 MID 0045 Define calibration value request Sent by: superordinate computer Calibration value request Note: - Revision: 001 Data field: Data 11 bytes (revision 001) Possible response Error no. Comment...
Page 110 Bosch Rexroth AG | Tightening Technology 110/279 3 608 870 A47 MID 0150 ID-code download request Sent by: superordinate computer Is used by the superior computer to send an ID code to the tightening controller. Note: OP must be configured as the ID code source.
Page 111 Tightening Technology | Bosch Rexroth AG 111/279 3 608 870 A47 MID 0052 revision 002 Table 7–29: MID 0052 revision 002 Parameter Comments Bytes ID code part 1 Contains the first 25 characters of the ID code (ASCII). The value consists of 25 ASCII characters.
Page 112 Bosch Rexroth AG | Tightening Technology 112/279 3 608 870 A47 MID 0052 revision 999 Table 7–30: MID 0052 revision 999 Parameter Comments Bytes ID code source Source of the ID code: – 0001: Cycle counter – 0002: Open Protocol –...
Page 113 Tightening Technology | Bosch Rexroth AG 113/279 3 608 870 A47 7.5.3.8 Messages on tightening results MID 0060 Last tightening results data subscription Sent by: superordinate computer Tightening results data subscription Note: - Revision: see MID 0061 Data field: is empty, 0 bytes Possible responses Error no.
Page 114 Bosch Rexroth AG | Tightening Technology 114/279 3 608 870 A47 Table 7–31: MID 0061 revision 001 Parameter Comments Bytes Controller name The second part of the channel name is used as the controller name. The value consists of 25 ASCII characters.
Page 115 Tightening Technology | Bosch Rexroth AG 115/279 3 608 870 A47 Table 7–31: MID 0061 revision 001 Parameter Comments Bytes Tightening status – 0: NOK – 1: OK The value consists of one ASCII character. 0 – 5 Value range...
Page 116: Example
Bosch Rexroth AG | Tightening Technology 116/279 3 608 870 A47 Table 7–31: MID 0061 revision 001 Parameter Comments Bytes Target torque (TP) The value is multiplied by 100 and transferred as a whole number (rounded to 2 decimals). The value consists of six ASCII characters.
Page 117: The Value Consists Of 19 Ascii Characters
Tightening Technology | Bosch Rexroth AG 117/279 3 608 870 A47 Table 7–31: MID 0061 revision 001 Parameter Comments Bytes Angle (A) The value is output in degrees. The value consists of five ASCII characters. 00000 – 99999 Value range...
Page 118: The Value Consists Of Two Ascii Characters
Bosch Rexroth AG | Tightening Technology 118/279 3 608 870 A47 MID 0061 revision 002 Table 7–32: MID 0061 revision 002 Parameter Comments Bytes Cell ID This is where the 7th level of the location name is returned. The value consists of four ASCII characters.
Page 119: Fixed Value
Tightening Technology | Bosch Rexroth AG 119/279 3 608 870 A47 Table 7–32: MID 0061 revision 002 Parameter Comments Bytes Tightening program number Number of the current tightening program. The value consists of three ASCII characters. 000 – 999 Value range...
Page 120: Fixed Value
Bosch Rexroth AG | Tightening Technology 120/279 3 608 870 A47 Table 7–32: MID 0061 revision 002 Parameter Comments Bytes OK/NOK counter status Status of the OK/NOK counter. – 0: if not 1 or 2 – 1: Ch x.y CntOK = 1 –...
Page 121 Tightening Technology | Bosch Rexroth AG 121/279 3 608 870 A47 Table 7–32: MID 0061 revision 002 Parameter Comments Bytes Tightening error status Error bits indicate errors in the tightening system and are generated from the following bits in the quality code: –...
Page 122 Bosch Rexroth AG | Tightening Technology 122/279 3 608 870 A47 Table 7–32: MID 0061 revision 002 Parameter Comments Bytes Torque (T) The value is multiplied by 100 and transferred as a whole number (rounded to 2 decimals). The value consists of six ASCII characters.
Page 123 Tightening Technology | Bosch Rexroth AG 123/279 3 608 870 A47 Table 7–32: MID 0061 revision 002 Parameter Comments Bytes Total angle (AT) Total angle (AT): not supported The value consists of five ASCII characters. 00000 Fixed value Min. power redundancy Min.
Page 124 Bosch Rexroth AG | Tightening Technology 124/279 3 608 870 A47 Table 7–32: MID 0061 revision 002 Parameter Comments Bytes Job sequence number Job sequence number is not supported. The value consists of five ASCII characters. 00000 Fixed value Sync tightening ID Cycle counter The value consists of five ASCII characters.
Page 125 Tightening Technology | Bosch Rexroth AG 125/279 3 608 870 A47 MID 0061 revision 003 Table 7–33: MID 0061 revision 003 Parameter Comments Bytes This revision includes the information from revision 002 and the following additional information: Tightening program name Fill in with empty spaces if <...
Page 126 Bosch Rexroth AG | Tightening Technology 126/279 3 608 870 A47 Table 7–34: MID 0061 revision 004 Parameter Comments Bytes ID code part 3 Contains characters 51 – 75 of the ID code. The rest of the characters are filled with space characters.
Page 127 Tightening Technology | Bosch Rexroth AG 127/279 3 608 870 A47 Table 7–36: MID 0061 revision 999 Parameter Comments Bytes Job number Number of the selected OK/NOK counter The job number consists of two ASCII characters. 01 – 99 Value range...
Page 128 Bosch Rexroth AG | Tightening Technology 128/279 3 608 870 A47 Table 7–36: MID 0061 revision 999 Parameter Comments Bytes Tightening status – 0: NOK – 1: OK The value consists of one ASCII character. 0 – 5 Value range...
Page 129 Tightening Technology | Bosch Rexroth AG 129/279 3 608 870 A47 Table 7–36: MID 0061 revision 999 Parameter Comments Bytes Time stamp Date and time of the tightening. The value consists of 19 ASCII characters in the format YYYY-MM-DD:HH:MM:SS. 0 – 9, "-" and ":"...
Page 130 Bosch Rexroth AG | Tightening Technology 130/279 3 608 870 A47 MID 0064 Archived tightening results upload request Sent by: superordinate computer Each tightening result will be provided with a consecutive ID (beginning with 1). With tightening ID 0, the currently available result is uploaded.
Page 131 Tightening Technology | Bosch Rexroth AG 131/279 3 608 870 A47 Table 7–37: MID 0065 revision 001 Parameter Comments Bytes OK counter value Actual value of the OK counter The value consists of four ASCII characters. 0000 – 9999 Value range...
Page 132 Bosch Rexroth AG | Tightening Technology 132/279 3 608 870 A47 Table 7–37: MID 0065 revision 001 Parameter Comments Bytes Angle (A) The value is output in degrees. The value consists of five ASCII characters. 00000 – 99999 Value range...
Page 133 Tightening Technology | Bosch Rexroth AG 133/279 3 608 870 A47 Table 7–38: MID 0065 revision 002 Parameter Comments Bytes Job number Number of the selected OK/NOK counter The job number consists of two ASCII characters. 01 – 99 Value range...
Page 134 Bosch Rexroth AG | Tightening Technology 134/279 3 608 870 A47 Table 7–38: MID 0065 revision 002 Parameter Comments Bytes Tightening status Rexroth OP: – 0: NOK – 1: OK The value consists of one ASCII character. 0 – 5...
Page 135 Tightening Technology | Bosch Rexroth AG 135/279 3 608 870 A47 Table 7–38: MID 0065 revision 002 Parameter Comments Bytes Tapping status of self-tapping Tapping status of self-tapping bolts: not supported. bolts The value consists of one ASCII character. Fixed value Placeholder value The value consists of one ASCII character.
Page 136 Bosch Rexroth AG | Tightening Technology 136/279 3 608 870 A47 Table 7–38: MID 0065 revision 002 Parameter Comments Bytes Power redundancy value Power redundancy value: not supported The value consists of three ASCII characters. Fixed value Self-tapping torque Self-tapping bolts: Not supported.
Page 137 Tightening Technology | Bosch Rexroth AG 137/279 3 608 870 A47 MID 0065 revision 003 Table 7–39: MID 0065 revision 003 Parameter Comments Bytes This revision includes the information from revision 002 and the following additional information: Torque value units –...
Page 138 Bosch Rexroth AG | Tightening Technology 138/279 3 608 870 A47 Table 7–40: MID 0065 revision 004 Parameter Comments Bytes ID code part 4 Only contains empty spaces. The value consists of 25 ASCII characters. Value range Presetting Example: ID code part 4...
Page 139 Tightening Technology | Bosch Rexroth AG 139/279 3 608 870 A47 Table 7–41: MID 0071 revision 001 Parameter Comments Bytes Tool ready status Only NOK if error comes from tool. – 1: OK – 0: NOK The value consists of one ASCII character.
Page 140 Bosch Rexroth AG | Tightening Technology 140/279 3 608 870 A47 MID 0075 Acknowledgement System error in tightening controller acknowledged Sent by: superordinate computer Acknowledgement for MID 0074 Note: - Revision: 001 Data field: is empty, 0 bytes Possible response: none...
Page 141 Tightening Technology | Bosch Rexroth AG 141/279 3 608 870 A47 Table 7–42: MID 0076 revision 001 Parameter Comments Bytes Tool ready status Only NOK if error comes from tool. – 1: OK – 0: NOK The value consists of one ASCII character.
Page 142 Bosch Rexroth AG | Tightening Technology 142/279 3 608 870 A47 MID 0081 Upload time Sent by: Tightening controller Upload time Note: - Revision: 001 Data field: Date and time YYYY-MM-DD:HH:MM:SS, 19 bytes Possible response: none MID 0082 Set the time in the tightening controller...
Page 143 Tightening Technology | Bosch Rexroth AG 143/279 3 608 870 A47 Table 7–43: MID 0111 revision 001 Parameter Comments Bytes Line 1 Fill in with empty spaces if < 25 characters. The value consists of a maximum of 25 ASCII characters. The tool display can represent up to 15 characters per line.
Page 144 Bosch Rexroth AG | Tightening Technology 144/279 3 608 870 A47 7.5.3.12 Tag ID messages MID 0260 Tag ID request superordinate computer Sent by: Request for a tag ID Note: Revision: is empty, 0 bytes Data field: Possible response Error no. Comment...
Page 145 Tightening Technology | Bosch Rexroth AG 145/279 3 608 870 A47 MID 0264 Cancel tag ID subscription superordinate computer Sent by: Resets the subscription for the tag ID Note: Revision: is empty, 0 bytes Data field: Possible response Error no. Comment...
Page 146 Bosch Rexroth AG | Tightening Technology 146/279 3 608 870 A47 MID 0403 Deactivate automatic/manual mode Sent by: superordinate computer The subscription to the change in operating mode (Logon automatic/manual mode, 0400) is reset. Note: - Revision: 001 Data field: is empty, 0 bytes Possible response Error no.
Page 147 Tightening Technology | Bosch Rexroth AG 147/279 3 608 870 A47 MID 0411 revision 001 Table 7–45: MID 0411 revision 001 Parameter Comments Bytes AutoDisable status Status of the automatic disable on option Disable when OK/NOK number is reached at OK/NOK counter Possible values: –...
Page 148 Bosch Rexroth AG | Tightening Technology 148/279 3 608 870 A47 MID 0501 revision 001 Table 7–46: MID 0501 revision 001 Parameter Comments Bytes This revision outputs the values of the first eight (8) assignable output signals of the OP PLC module. The output is effected in the order in which the signals have been stored by the user.
Page 149 Tightening Technology | Bosch Rexroth AG 149/279 3 608 870 A47 MID 0503 Cancel Output signal change Sent by: superordinate computer The subscription of the changes in the output signals (Logon change in the output signals, 0500) is reset. Note: -...
Page 150 Bosch Rexroth AG | Tightening Technology 150/279 3 608 870 A47 7.5.3.15 Job messages MID 0570 Activate job Sent by: superordinate computer This command can be used to enable the job function of the tightening channel. Note: In the PLC assignment table, the JobEnable signal must be applied to the OP module.
Page 151 Tightening Technology | Bosch Rexroth AG 151/279 3 608 870 A47 MID 0573 Select job number Sent by: superordinate computer This command can be used to select the job number of the tightening channel. Note: In the PLC assignment table, the JobEnable, JobStart and Job0-7 signals must be applied to the OP module.
Page 152 Bosch Rexroth AG | Tightening Technology 152/279 3 608 870 A47 Table 7–52: MID 0801 revision 001 Parameter Comments Bytes Capacity of the battery pack Capacity of the battery pack slide-in module in percent. slide-in module The value consists of three ASCII characters.
Page 153 Tightening Technology | Bosch Rexroth AG 153/279 3 608 870 A47 Table 7–53: MID 0802 revision 001 Parameter Comments Bytes Change in the battery level Selection of the value for the change in capacity of the battery pack slide- in module in percent of maximum capacity (100%). If the capacity...
Page 154 Bosch Rexroth AG | Tightening Technology 154/279 3 608 870 A47 Table 7–54: MID 0803 revision 001 Parameter Comments Bytes State of the battery pack slide- – 0: The battery pack slide-in module is not inserted. in module – 1: The battery level is critical (system is shut down) –...
Page 155 Tightening Technology | Bosch Rexroth AG 155/279 3 608 870 A47 Table 7–55: MID 0806 revision 001 Parameter Comments Bytes Reception quality The value consists of four ASCII characters. -45 – -90 dbm Value range Presetting Example: Reception quality -80 dbm...
Page 156 Bosch Rexroth AG | Tightening Technology 156/279 3 608 870 A47 Table 7–57: MID 0806 revision 001 Parameter Comments Bytes Reception quality The value consists of four ASCII characters. -45 – -90 dbm Value range Presetting Example: Reception quality -80 dbm...
Page 157 Tightening Technology | Bosch Rexroth AG 157/279 3 608 870 A47 The following parameters can be changed: • Speed • First target function: Angle or torque • Angle min. value monitoring (not switching) • Angle max. value monitoring function (switching or not switching) •...
Page 158 Bosch Rexroth AG | Tightening Technology 158/279 3 608 870 A47 Table 7–58: MID 2505 revision 001 Parameter Comments Bytes The value consists of five ASCII characters. – 02052: Speed – 05100: Torque (first target function) – 05102: Torque max. value monitoring function (NOT switching) –...
Page 159 Tightening Technology | Bosch Rexroth AG 159/279 3 608 870 A47 Table 7–58: MID 2505 revision 001 Parameter Comments Bytes Unit The value consists of three ASCII characters. The torque unit must correspond to the setting in the start step.
Page 160 Bosch Rexroth AG | Tightening Technology 160/279 3 608 870 A47 In the tightening program no. 1, the speed in the 1. tightening step (start step = step number 1, 1. Example 2 tightening step = step number. 2) is set to -250 min-1 and the 1. target function is set to torque with a target value of 3.5 Nm.
Page 161 Tightening Technology | Bosch Rexroth AG 161/279 3 608 870 A47 7.5.3.19 Error numbers Table 7–59: Error numbers Error no. Description Invalid data Tightening program not available Tightening program cannot be specified Tightening program not active Activation of ID code upload already available...
Page 162: Rexroth Ipm Protocol
This IPM communication partner is, however, no Bosch Rexroth product. The IPM communication partner is an application package consisting of gateway, server, database and web interface for visualization, analysis and archiving. The application package consists of the following components, see Fig.
Page 163: Message Structure
Tightening Technology | Bosch Rexroth AG 163/279 3 608 870 A47 Browser Web server IPM gateway (1…n) Database Database server IPM server (1…n) Access point Nexo Fig. 7–3: IPM architecture Before transmission of the tightening results and tightening graphs via the Rexroth IPM Protocol, the data are converted into the format used by the IPM process data and analysis system.
Page 164 Bosch Rexroth AG | Tightening Technology 164/279 3 608 870 A47 Table 7–60: Rexroth IPM Protocol message structure Message component Element Element description Comment Data fields Steps Tightening steps Actual values/ Measured actual values like Parameters belonging to characteristics the actual values: –...
Page 165: Vw-Xml Protocol
Tightening Technology | Bosch Rexroth AG 165/279 3 608 870 A47 VW-XML protocol As of Nexo firmware version 1200, the VW-XML protocol is supported. VW-XML version 2.1 is supported. As of Nexo firmware version 1400, the VW-XML version 2.0 is supported.
Page 166: Particularities With Vw-Xml Results Output
Bosch Rexroth AG | Tightening Technology 166/279 3 608 870 A47 7.7.2 Particularities with VW-XML results output The VW corporate requirement specifications "Controlled tightening systems" defines five tightening processes. This section describes the necessary parameterizations of the relevant tightening programs as well as their control functions in the NEXO-OS in order to satisfy the requirements of VW-XML.
Page 167 Tightening Technology | Bosch Rexroth AG 167/279 3 608 870 A47 Table 7–62: Parameterization of the AD process Function in NEXO-OS Parameter in NEXO-OS Parameter in VW Comments corporate requirement specifications Angle max. value monitoring A+ Upper tolerance angle [A+]...
Page 168: Bmw-Tpc Service
Bosch Rexroth AG | Tightening Technology 168/279 3 608 870 A47 BMW-TPC service As of Nexo firmware version 1400, the BMW-TPC service is supported. Application of the BMW-TPC service outside of the BMW AG is subject to express written agreement of BMW AG.
Page 169: Commissioning
Commissioning This document describes the commissioning and necessary configuration of the Nexo cordless Wi-Fi nutrunner by Rexroth. Overview (page 170) • NEXO-OS operating system (page 172) • Configuration (page 173) • Special features of nutrunners with angle compensation (page 173) •...
Page 170: Overview
Bosch Rexroth AG | Tightening Technology 170/279 3 608 870 A47 Overview Before commissioning, check if a new service pack is available in the download section www.boschrexroth.com/tightening. There, you can also find further information on: • Service packs for older versions (if available) •...
Page 171: Overview Of Commissioning Steps
Tightening Technology | Bosch Rexroth AG 171/279 3 608 870 A47 8.1.1 Overview of commissioning steps Optional for right-angle nutrunner NXA: Adjusting the angle head (see page 43) NXV: Attaching a special output drive Attaching the torque support (see page 45)
Page 172: Nexo-Os Operating System
Bosch Rexroth AG | Tightening Technology 172/279 3 608 870 A47 NEXO-OS operating system 8.2.1 Commissioning The following web browsers are supported for the NEXO-OS operating system: • Internet Explorer version 7.0 and higher • Mozilla Firefox version 3.6 and higher •...
Page 173: Assigning Ip Addresses For The Nexo Cordless Wi-Fi Nutrunner
Tightening Technology | Bosch Rexroth AG 173/279 3 608 870 A47 8.2.2 Assigning IP addresses for the Nexo cordless Wi-Fi nutrunner IP addresses for the Nexo cordless Wi-Fi nutrunner are assigned via the NEXO-OS operating system. For more information, refer to section WLAN (page 240).
Page 174: Function And Accuracy Check Of The Nutrunner
Bosch Rexroth AG | Tightening Technology 174/279 3 608 870 A47 Tool motion against tightening direction (-ΔW) Tool motion in tightening direction (+ΔW) Tightening direction Compensation of the tool motion Fig. 8–2: Tool motion compensation in/against the spin direction If the angle head output drive axis is not aligned with the tightening axis, an angle head compensation error occurs.
Page 175: Operating System Nexo-Os
Operating system NEXO-OS This chapter describes the NEXO-OS operating system for the Nexo cordless Wi-Fi nutrunner with its menus and functions. General information about the NEXO-OS operating system (page 176) • Starting the program (page 177) • Function overview (page 182) •...
Page 176: General Information About The Nexo-Os Operating System
Bosch Rexroth AG | Tightening Technology 176/279 3 608 870 A47 General information about the NEXO-OS operating system The operating system for the Nexo cordless Wi-Fi nutrunner is a web application. On delivery of the Nexo cordless Wi-Fi nutrunner, it is pre-installed as an integral part of the nutrunner.
Page 177: Updating The Firmware Version
Tightening Technology | Bosch Rexroth AG 177/279 3 608 870 A47 9.1.2 Updating the firmware version To start updating the firmware version, go to the Settings  Firmware menu item of the NEXO-OS operating system, see section Firmware on page 235.
Page 178 Bosch Rexroth AG | Tightening Technology 178/279 3 608 870 A47 Display of actual values and actual graph As of Nexo firmware version 1200, the user does not need to be logged into the NEXO-OS operating system for display of the actual values and the actual graph: Open a web browser on your computer.
Page 179: Main Window Of The Nexo-Os Operating System
Tightening Technology | Bosch Rexroth AG 179/279 3 608 870 A47 9.2.1 Main window of the NEXO-OS operating system After the user has successfully logged in to the NEXO-OS operating system, the screen displays the main window. Fig. 9–2: NEXO-OS operating system – main window The main window of the NEXO-OS operating system is subdivided into the following areas: •...
Page 180 Bosch Rexroth AG | Tightening Technology 180/279 3 608 870 A47 (4) Status bar Table 9–3: Status bar elements Element Description As of Nexo firmware version 1100: Next to the symbol, the name of the channel set during configuration of the nutrunner is...
Page 181: Exiting The Program
Tightening Technology | Bosch Rexroth AG 181/279 3 608 870 A47 In the following cases, the connection is not disconnected automatically: • You are currently active, i.e. you exchange data with the hardware (retrieve or transmit data). This includes e.g.: –...
Page 182: Function Overview
Bosch Rexroth AG | Tightening Technology 182/279 3 608 870 A47 Function overview The following table shows the available menus and their functions. Menu Menu item 1 Menu item 2 Description Page Analysis Actual values Displays the previous tightening result...
Page 183 Tightening Technology | Bosch Rexroth AG 183/279 3 608 870 A47 Menu Menu item 1 Menu item 2 Description Page Settings Encryption Enabling HTTPS (page 245) (Continuation) Settings for the tightening position illumination of (page 246) the nutrunner ID assignment...
Page 184: Analysis
Bosch Rexroth AG | Tightening Technology 184/279 3 608 870 A47 Analysis The Analysis menu contains the following menu items: • Actual values (page 184) • Stored values (page 184) • Actual graph (page 185) • Stored graphs (page 185)
Page 185: Actual Graph
Tightening Technology | Bosch Rexroth AG 185/279 3 608 870 A47 9.4.3 Actual graph Analysis  Actual graph Use this menu item to display the results of the current tightening job, if any, in a graphical diagram. The measurement values are displayed against the angle (Angle button) or against the time (Time button).
Page 186 Bosch Rexroth AG | Tightening Technology 186/279 3 608 870 A47 Button Filter Click on the button to display the Filter editor dialog. In the dialog you can edit, delete or add further filters to the corresponding filters. Table 9–8:...
Page 187: Mode
Tightening Technology | Bosch Rexroth AG 187/279 3 608 870 A47 Mode As of Nexo firmware version 1100, the mode function is supported. Use this menu item to set the nutrunner’s operating mode for various operational conditions. With this menu item you can also specify the settings for the ID code to identify a set of results data and the configuration of a superordinate ID input step (outside of the job function).
Page 188: Mode Steps
Bosch Rexroth AG | Tightening Technology 188/279 3 608 870 A47 9.5.2 Mode steps A mode always begins with the start step and ends with the end step; the two steps are preset. Table 9–11: Available mode steps Element Designation...
Page 189 Tightening Technology | Bosch Rexroth AG 189/279 3 608 870 A47 Options Table 9–13: Start step dialog Element Description Indication how long the text will be displayed at the tool display. Display time Default setting: 1 second ID code source Table 9–14:...
Page 190 Bosch Rexroth AG | Tightening Technology 190/279 3 608 870 A47 9.5.3.3 ID input In this step, define the settings for the treatment of the ID input. Double clicking the ID input step or the respective icon opens the corresponding dialog for entering the parameters.
Page 191 Tightening Technology | Bosch Rexroth AG 191/279 3 608 870 A47 ID code source Under ID code source, the settings defined in the start step under ID code source are displayed. ID input options Table 9–17: ID input step dialog - ID input options panel...
Page 192 Bosch Rexroth AG | Tightening Technology 192/279 3 608 870 A47 Scan options The field is only displayed, if Scanner is selected as ID input source. Table 9–19: ID input step dialog - scan options panel Element Description The scan process can be selected using the following option: Trigger scan process –...
Page 193: Job
Tightening Technology | Bosch Rexroth AG 193/279 3 608 870 A47 As of Nexo firmware version 1100, the job function is supported. The job function is used to run process chains. The process chains (e.g. Scan barcode  Enable nutrunner  three tightenings  Block nutrunner) that are usually programmed using a PLC can be directly parameterized in the NEXO-OS operating system as so-called jobs.
Page 194: Job Steps
Bosch Rexroth AG | Tightening Technology 194/279 3 608 870 A47 9.6.2 Job steps A job always begins with the start step and ends with the end step; the two steps are preset in a new job. Different or identical job steps can be inserted between these two steps. Selection, number, and order of these job steps depend on the required tightening process.
Page 195 Tightening Technology | Bosch Rexroth AG 195/279 3 608 870 A47 Options Table 9–24: Start step dialog - options panel Element Description Show text at the nutrunner display You can save a text for all job steps. The text will be displayed on the tool display.
Page 196 Bosch Rexroth AG | Tightening Technology 196/279 3 608 870 A47 Timeout options Table 9–27: ID input step dialog - timeout options panel Element Description Enter the maximum time when an event, e.g. a successful barcode scan, has Timeout to take place. If no event occurs in this time, the step is terminated.
Page 197 Tightening Technology | Bosch Rexroth AG 197/279 3 608 870 A47 ID code Table 9–30: Single program dialog - ID code panel Element Description If the check box is enabled, the results of various Combine multiple ID inputs ID input steps can be combined in an ID code. To create the new ID code, you can define a prefix and a postfix as well as a max.
Page 198 Bosch Rexroth AG | Tightening Technology 198/279 3 608 870 A47 Tightening Table 9–31: Single program dialog - tightening panel Element Description You can save a text for all steps. The text will be displayed on the tool display. Tool display text...
Page 199 Tightening Technology | Bosch Rexroth AG 199/279 3 608 870 A47 9.6.3.4 End step A job ends with the end step. Double clicking the end step or the respective icon opens the corresponding dialog for entering the parameters. General Table 9–33: End step dialog –...
Page 200: Tightening Programs
Bosch Rexroth AG | Tightening Technology 200/279 3 608 870 A47 Tightening programs Use this menu item to create and edit tightening programs. 9.7.1 Definition: Target, monitoring, additional function In the tightening steps, a distinction is made between target, monitoring, and additional functions.
Page 201: Programs Tab Structure
Tightening Technology | Bosch Rexroth AG 201/279 3 608 870 A47 9.7.2 Programs tab structure The header of the Programs tab features the following buttons: Table 9–35: Programs tab Element Description Up to 255 tightening programs and 1 loosening program (program no. 99) can be programmed with a maximum of 12 steps each (including start and end step).
Page 202: Steps Of Tightening Programs
Bosch Rexroth AG | Tightening Technology 202/279 3 608 870 A47 9.7.3 Steps of tightening programs The tightening program always begins with the start step and ends with the end step; in a new tightening program, both are already assigned in the Programs menu. Different or identical job steps can be inserted between these two tightening steps.
Page 203 Tightening Technology | Bosch Rexroth AG 203/279 3 608 870 A47 9.7.4.1 Start step Double clicking the start step or the respective icon of a tightening program will open a dialog where the associated parameters can be entered. Table 9–38:...
Page 204 Bosch Rexroth AG | Tightening Technology 204/279 3 608 870 A47 Parameter Table 9–40: Start step dialog – parameter panel Element Description Is used to select the torque threshold for playing at the start switch in percent Play at start switch of the nominal torque.
Page 205 Tightening Technology | Bosch Rexroth AG 205/279 3 608 870 A47 9.7.4.2 Standard tightening step The standard tightening step fulfills the usual requirements for a tightening step through a selection of target, additional, and monitoring functions. Click the icon to insert a new tightening step in the tightening program before the tightening step selected.
Page 206 Bosch Rexroth AG | Tightening Technology 206/279 3 608 870 A47 Table 9–45: Tightening step dialog - target panel Element Description Is used to select the speed (= set speed) to be used for tightening in this Speed tightening step. A negative speed means counterclockwise rotation, a positive speed means clockwise rotation.
Page 207 Tightening Technology | Bosch Rexroth AG 207/279 3 608 870 A47 Table 9–47: Tightening step dialog - monitoring panel Element Description These monitoring functions can also be selected. Torque, torque min. value, torque max. value, angle, angle min. value, Each of the monitoring limits can be marked as switching. If a limit is angle max.
Page 208: Settings
Bosch Rexroth AG | Tightening Technology 208/279 3 608 870 A47 Settings The Settings menu contains the following menu items: • Time & date (p age 208) • User accounts (page 209) • Tool display (page 211) • Data (page 214) •...
Page 209: User Accounts
Tightening Technology | Bosch Rexroth AG 209/279 3 608 870 A47 9.8.2 User accounts Settings  User accounts This menu item is intended for user administration and features additional menu items: • Users (page 209) • Membership (page 210) •...
Page 210 Bosch Rexroth AG | Tightening Technology 210/279 3 608 870 A47 9.8.2.2 Membership Settings  User accounts  Membership Use this menu item to change the participation in a group. All users entered for the NEXO-OS operating system and their participation in a group are displayed in the form of a matrix.
Page 211: Tool Display
Tightening Technology | Bosch Rexroth AG 211/279 3 608 870 A47 9.8.2.5 My account Settings  User accounts  My account This menu item displays the user data of the logged-in user. Table 9–52: My account tab Element Description Click Change password to change your password: Change password 1.
Page 212 Bosch Rexroth AG | Tightening Technology 212/279 3 608 870 A47 Laser warning area Table 9–55: Nutrunner display index card - Laser warning area Element Description Activate Show laser warning to receive the laser warning on the nutrunner Show laser warning display and confirm the reading of the warning.
Page 213 Tightening Technology | Bosch Rexroth AG 213/279 3 608 870 A47 Views on the nutrunner display The following views can be shown on the nutrunner display: Table 9–58: Views on the nutrunner display Screen Description Screen displaying the current tightening results: Actual values –...
Page 214: Data
Bosch Rexroth AG | Tightening Technology 214/279 3 608 870 A47 9.8.4 Data Settings  Data Use this menu item to manage and transfer data of the Nexo cordless Wi-Fi nutrunner: This menu features additional menu items: • Result storage (page 214) •...
Page 215 Tightening Technology | Bosch Rexroth AG 215/279 3 608 870 A47 9.8.4.2 Standard Nexo Use this menu item to define the configuration of the respective connection (FTP, HTTP or File Share) for results output. Under NX-SD card, the sub-directory for filing of tightening results on the NX-SD Micro SD card and the contents of the file are defined.
Page 216 Bosch Rexroth AG | Tightening Technology 216/279 3 608 870 A47 NX-SD card Settings  Data  Standard Nexo  NX-SD card) Under this menu item, the sub-directory for filing of tightening results on the NX-SD Micro SD card and the contents of the file are defined.
Page 217 Tightening Technology | Bosch Rexroth AG 217/279 3 608 870 A47 File Share Settings  Data  Standard Nexo  File Share Use this menu item to define the configuration of the File Share connection for results output. Table 9–63:...
Page 218 Bosch Rexroth AG | Tightening Technology 218/279 3 608 870 A47 Data button Click on the button to display the Data dialog. In the dialog, the parameters for output of tightening results can be configured. Depending on activation, the output of OK tightening and/or NOK tightening results data is realized differently.
Page 219 Tightening Technology | Bosch Rexroth AG 219/279 3 608 870 A47 Parameter of results output The output file includes the following parameters: Fig. 9–4: “Standard Nexo” output format General tightening result parameters (see page 219) Step data: In the results file, all tightening steps of the program are put out individually.
Page 220 Bosch Rexroth AG | Tightening Technology 220/279 3 608 870 A47 Table 9–65: General tightening result parameters and their meaning Parameter Meaning prg nr Number of the tightening program prg name Name of the tightening program prg date Date of the last change in the tightening program...
Page 221 Tightening Technology | Bosch Rexroth AG 221/279 3 608 870 A47 Step result parameters Table 9–66: Step result parameters and their meaning Parameter Meaning result Step result OK/NOK name Step name step type Tightening step type Tightening step row number...
Page 222 Bosch Rexroth AG | Tightening Technology 222/279 3 608 870 A47 Graph parameters Table 9–68: Graph parameters and their meaning Parameter Meaning angle values Table of angle values torque values Table of torque values time values Table of time values...
Page 223 Tightening Technology | Bosch Rexroth AG 223/279 3 608 870 A47 File button Click on the button to display the File dialog. In the dialog, the respective parameters for storage of results data can be edited, deleted or additional memory parameters added.
Page 224 Bosch Rexroth AG | Tightening Technology 224/279 3 608 870 A47 9.8.4.3 Open Protocol Settings  Data  Open Protocol Use this menu item to define the setting for communication with Rexroth Open Protocol of the Nexo cordless Wi-Fi nutrunner.
Page 225 Tightening Technology | Bosch Rexroth AG 225/279 3 608 870 A47 9.8.4.4 Settings  Data  IPM Use this menu item to define the setting for communication with Rexroth IPM Protocol of the Nexo cordless Wi-Fi nutrunner. Table 9–72: IPM tab...
Page 226 Bosch Rexroth AG | Tightening Technology 226/279 3 608 870 A47 Each work sequence (AFO) is represented by one line in the AFO table, see table 9–73. In the AFO table, an unlimited number of AFOs can be inserted and deleted.
Page 227 Tightening Technology | Bosch Rexroth AG 227/279 3 608 870 A47 Table 9–73: Assignment of the combination of channel number and program number Element Description Defines the step number for IPM data output: Step number – Sequential final tightening step=99 Every step receives a sequentially assigned number (1 ...
Page 228 Bosch Rexroth AG | Tightening Technology 228/279 3 608 870 A47 9.8.4.5 VW-XML Settings  Data  VW-XML Use this menu item to define the setting for communication with VW-XML of the Nexo cordless Wi-Fi nutrunner. Table 9–74: VW-XML index card...
Page 229 Tightening Technology | Bosch Rexroth AG 229/279 3 608 870 A47 Table 9–74: VW-XML index card Element Description Interface – TCP/IP port A (control data) Selection of the desired TCP/IP port for data exchange with the tightening controller (default setting: 4700) –...
Page 230 Bosch Rexroth AG | Tightening Technology 230/279 3 608 870 A47 9.8.4.6 BMW-TPC Settings  Data  BMW-TPC Use this menu item to define the setting for communication with BMW-TPC of the Nexo cordless Wi-Fi nutrunner. Table 9–75: BMW-TPC index card...
Page 231 Tightening Technology | Bosch Rexroth AG 231/279 3 608 870 A47 Table 9–77: BMW-TPC index card - LSA panel Element Description Specification of the time span during which a LIFE telegram has to be sent. Live interval Default setting: 20 seconds...
Page 232: Configuration
Bosch Rexroth AG | Tightening Technology 232/279 3 608 870 A47 9.8.5 Configuration Settings  Configuration Use this menu option to call up the current configuration of the nutrunner. To use Rexroth Open Protocol, the cell ID and the channel number must be configured.
Page 233 Tightening Technology | Bosch Rexroth AG 233/279 3 608 870 A47 Table 9–80: Configuration tab Element Description Nutrunner display 90° 45° 0° 360° The angle head rotation can be adjusted in increments of 1° between 0° and 360°. Select the appropriate setting of the angle head.
Page 234 Bosch Rexroth AG | Tightening Technology 234/279 3 608 870 A47 Table 9–80: Configuration tab Element Description Special component – Order number Component order number – Serial number Component serial number – Efficiency Enter the efficiency – Transmission Enter the transmission –...
Page 235: Firmware
Tightening Technology | Bosch Rexroth AG 235/279 3 608 870 A47 9.8.6 Firmware Settings  Firmware This menu item is used to display the firmware version and to start the firmware update. When the firmware is updated, the NEXO-OS operating system is also updated.
Page 236: Plc Signals
Bosch Rexroth AG | Tightening Technology 236/279 3 608 870 A47 9.8.7 PLC signals Settings  PLC signals Use this menu item to create a PLC assignment table. The assignment table describes the assignment of the PLC signals to inputs and outputs.
Page 237: Ok/Nok Counter
Tightening Technology | Bosch Rexroth AG 237/279 3 608 870 A47 9.8.8 OK/NOK counter Settings  OK/NOK counter Use this menu item to define the settings for the OK/NOK counters. The counters for OK and NOK tightening are used to assess a sequence of tightening jobs. Each tightening job is counted according to its evaluation.
Page 238: Quality Code
Bosch Rexroth AG | Tightening Technology 238/279 3 608 870 A47 There is no counter value for program 99, since it is used as a loosen program. 9.8.9 Quality code Settings  Quality code  Configuration of quality codes The quality code (QC) provides information on the results of a tightening job. If an NOK evaluation is output, the cause will also be listed.
Page 239 Tightening Technology | Bosch Rexroth AG 239/279 3 608 870 A47 Table 9–87: Quality code tab - configuration of quality codes Element Description Opens a dialog to add a quality code. Opens a dialog to edit the selected quality code.
Page 240: Wlan
Bosch Rexroth AG | Tightening Technology 240/279 3 608 870 A47 9.8.10 WLAN Settings  WLAN Use this menu item to define the WLAN settings for data exchange with the Nexo cordless Wi-Fi nutrunner. Table 9–89: WLAN tab Element Description On delivery, the Wi-fi functionality of the cordless Wi-Fi nutrunner is disabled.
Page 241 Tightening Technology | Bosch Rexroth AG 241/279 3 608 870 A47 The following table provides an overview of the channels supported for the Nexo cordless Wi-Fi nutrunner and their use: Channel Freq. (MHz) India Argentina/ Malaysia Europe (ETSI)/ (WPC Cert)
Page 242 Bosch Rexroth AG | Tightening Technology 242/279 3 608 870 A47 5200      5220      5240      5260 DFS / TPC DFS / TPC   5280 DFS / TPC DFS / TPC ...
Page 243 Tightening Technology | Bosch Rexroth AG 243/279 3 608 870 A47 Table 9–93: WLAN tab – Encryption Element Description Select the safety method: Method – Uncoded – WPA/WPA2 Personal – WPA/WPA2 enterprise WPA (WiFi Protected Access) is used to encrypt information. This ensures that no other persons than those having the appropriate authorization can access the network.
Page 244 Bosch Rexroth AG | Tightening Technology 244/279 3 608 870 A47 Table 9–94: WLAN tab - roaming Element Description If the function is disabled, the Nexo stays at the same access point until it Active loses connection. Only then it looks for an SSID to establish a new network connection (possibly at another access point).
Page 245: Security
Tightening Technology | Bosch Rexroth AG 245/279 3 608 870 A47 Table 9–95: Buttons Element Description Click Save to save the edited data. Save Click Discard to discard the edited data. Discard Press this button to restart the NEXO-OS. A restart may be required in case Restart of WLAN problems, for example.
Page 246: Led
Bosch Rexroth AG | Tightening Technology 246/279 3 608 870 A47 9.8.12 Settings  LED Use this menu item to specify the color and intensity of the tightening position illumination at the hand- held nutrunner for different nutrunner states. Table 9–97:...
Page 247 Tightening Technology | Bosch Rexroth AG 247/279 3 608 870 A47 Table 9–97: LED tab Element Description Activate this check box in order to enable the tightening position illumination NOK result for an NOK tightening. – Illumination LED Intensity: Use the slider control to define the brightness of the illumination LED.
Page 248: Id Assignment
Bosch Rexroth AG | Tightening Technology 248/279 3 608 870 A47 9.8.13 ID assignment Settings  ID assignment The ASCII code can be linked to a tightening program or a job, i.e. when the code is read, the respective tightening program or the job starts. Specify the required settings in the ID assignment table.
Page 249 Tightening Technology | Bosch Rexroth AG 249/279 3 608 870 A47 Table 9–100: Supported barcode types Barcode type Length Option Code 128 UCC/EAN128 ISBT 128 Code 39 – L1 Trioptic Code – L1;L2 Convert to Code 32 (Italian Pharma Code) –...
Page 250: Defaults
Bosch Rexroth AG | Tightening Technology 250/279 3 608 870 A47 9.8.15 Defaults Settings  Defaults Under this menu item, all settings of the Nexo cordless Wi-Fi nutrunner can be reset to default. Table 9–101: Defaults index card Element Description Click Basic settings button to reset all settings to default.
Page 251: Diagnosis
Tightening Technology | Bosch Rexroth AG 251/279 3 608 870 A47 Diagnosis The Diagnosis menu contains the following menu items: • System information (page 251) • Log book (page 251) • Open Protocol (page 252) • BMW-TPC (page 252) •...
Page 252: Open Protocol
Bosch Rexroth AG | Tightening Technology 252/279 3 608 870 A47 9.9.3 Open Protocol Diagnosis  Open Protocol Use this menu item to display the entries for Open Protocol. If Open Protocol is not activated, the view is empty. Table 9–106:...
Page 253: Web Server Log
Tightening Technology | Bosch Rexroth AG 253/279 3 608 870 A47 Table 9–109: Error list tab Element Description With class 1 and 4 errors, this indicates whether the error still exists (0 = errors exists, not acknowledged). With class 3 and 5 errors, this indicates whether an error was confirmed (= acknowledged) (1 = acknowledged, 0 = not acknowledged).
Page 254 Bosch Rexroth AG | Tightening Technology 254/279 3 608 870 A47 9.9.9.1 WLAN Diagnosis  Network  WLAN Only level changes > 2 dBm are recorded. If errors in the WLAN area are suspected, this menu item shows the respective information.
Page 255: Export Logs
Tightening Technology | Bosch Rexroth AG 255/279 3 608 870 A47 9.9.10 Export logs Diagnosis  Export log Use this menu item to generate a diagnostic report and save it to a data carrier or to the NX-SD Micro SD card inserted in the nutrunner.
Page 256 Bosch Rexroth AG | Tightening Technology 256/279 3 608 870 A47 Nexo cordless Wi-Fi nutrunner | 3 608 870 A47/2019-...
Page 257: Tightening Processes
Tightening processes This chapter describes the tightening processes for the Nexo cordless Wi-Fi nutrun- ner that are the most essential ones in tightening technology. Overview (page 258) • Torque-controlled tightening process (page 259) • Angle-of-turn-controlled tightening process (page 260) •...
Page 258: Overview
Bosch Rexroth AG | Tightening Technology 258/279 3 608 870 A47 10.1 Overview The sections below describe the tightening processes that are presently the most essential ones in tight- ening technology. The tightening program steps described in chapter Operating system NEXO-OS (see page 175) are used to program all standard tightening processes as well as special tightening processes.
Page 259: Torque-Controlled Tightening Process
Tightening Technology | Bosch Rexroth AG 259/279 3 608 870 A47 10.2 Torque-controlled tightening process Torque is the most easily accessible measured variable in tightening technology, which is why this tight- ening process is easy to handle. Here, the torque is controlled and the angle of turn monitored.
Page 260: Angle-Of-Turn-Controlled Tightening Process
Bosch Rexroth AG | Tightening Technology 260/279 3 608 870 A47 Application The torque-controlled tightening process is mainly used for: • transmission assembly • wheel assembly • exhaust manifold assembly As the result value for all data outputs, the maximum torque that occurred after the switch-off is output via the target function.
Page 261 Tightening Technology | Bosch Rexroth AG 261/279 3 608 870 A47 Torque monitoring (T–, T+) is used for error recognition. Their advantages include recognition of: • Lot jumps in bolts and components • defective bolts and components. In this process, the bolt is stretched beyond its yield point until it plastically deforms. Re-usability of the bolt is limited due to lasting cross-section constriction.
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Page 263 Tightening Technology | Bosch Rexroth AG 263/279 3 608 870 A47 Nexo cordless Wi-Fi nutrunner | 3 608 870 A47/2019-10...
Page 264 Bosch Rexroth AG | Tightening Technology 264/279 3 608 870 A47 Nexo cordless Wi-Fi nutrunner | 3 608 870 A47/2019-10...
Page 265: Troubleshooting
Troubleshooting This chapter describes errors which can occur when working with the Nexo cordless Wi-Fi nutrunner and provides troubleshooting advice. Error codes and classes (page 266) • Detecting and acknowledging errors with the NEXO-OS operating system • (page 267) Complete error list (page 268) •...
Page 266: Error Codes And Classes
Bosch Rexroth AG | Tightening Technology 266/279 3 608 870 A47 11.1 Error codes and classes 11.1.1 Overview Errors in the Nexo cordless Wi-Fi nutrunner are displayed via: • The graphical display on the Nexo cordless Wi-Fi nutrunner • The NEXO-OS operating system of the Nexo cordless Wi-Fi nutrunner •...
Page 267: Error Classes
Tightening Technology | Bosch Rexroth AG 267/279 3 608 870 A47 11.1.3 Error classes Errors in the Nexo cordless Wi-Fi nutrunner are classified as follows: Table 11–2: Error classes Error class Error type Remedy System message (no error), e.g. test interval Remedy not required reached.
Page 268: Complete Error List
Bosch Rexroth AG | Tightening Technology 268/279 3 608 870 A47 11.3 Complete error list If no improvement is achieved after the recommended solutions, the nutrunner is to be returned with exact information for repair to Rexroth Service. Before dispatch, contact Rexroth Service (see page 277).
Page 269 Tightening Technology | Bosch Rexroth AG 269/279 3 608 870 A47 Table 11–3: Error description Error Error Description Possible cause/consequence Suggested solution code class Gauge bar status error Too many incorrect measurements re-  Repeat tightening ceived from gauge bar.
Page 270 Bosch Rexroth AG | Tightening Technology 270/279 3 608 870 A47 Table 11–3: Error description Error Error Description Possible cause/consequence Suggested solution code class File system error The internal file system has detected a  Reboot nutrunner memory error. This may be the case after a ...
Page 271 Tightening Technology | Bosch Rexroth AG 271/279 3 608 870 A47 Table 11–3: Error description Error Error Description Possible cause/consequence Suggested solution code class VW-XML: internal error VW-XML protocol was terminated (config-  Check VW-XML configuration uration switched to inactive).
Page 272 Bosch Rexroth AG | Tightening Technology 272/279 3 608 870 A47 Table 11–3: Error description Error Error Description Possible cause/consequence Suggested solution code class 1002 SOLLDAT received is in process Duplicate order data 1003 SOLLDAT received has unsent  Reboot nutrunner LSA results ...
Page 273: Replacing Defective Components
Tightening Technology | Bosch Rexroth AG 273/279 3 608 870 A47 11.4 Replacing defective components WARNING Improper execution of service work Improper performance of service work may result in personal injury, damage to components and jeop- ardization of the tightening system.
Page 274 Bosch Rexroth AG | Tightening Technology 274/279 3 608 870 A47 Nexo cordless Wi-Fi nutrunner | 3 608 870 A47/2019-10...
Page 275: License Agreement
The software of the Nexo cordless Wi-Fi nutrunner contains third party software. This software is not covered by any liability or warranty on the part of Bosch Rexroth AG. For the license conditions of the used software, click on the symbol in the navi- gation panel of the NEXO-OS.
Page 276 Bosch Rexroth AG | Tightening Technology 276/279 3 608 870 A47 Nexo cordless Wi-Fi nutrunner | 3 608 870 A47/2019-10...
Page 277: Service And Sales
If you are located outside of Germany, please contact your nearest Rexroth partner. Service Germany Phone: +49 9352 40 50 60 E-mail: service.svc@boschrexroth.de Sales Germany Bosch Rexroth AG Postfach 1161 71534 Murrhardt Fornsbacher Str. 92 71540 Murrhardt Phone +49 71 92 22 208...
Page 278 Bosch Rexroth AG | Tightening Technology 278/279 3 608 870 A47 Bosch Rexroth AG Training Center Erbach Berliner Straße 25 64711 Erbach/Odenwald Phone: +49 6062 78-600 E-mail: training.erbach@boschrexroth.de Nexo cordless Wi-Fi nutrunner | 3 608 870 A47/2019-10...
Page 279 Postfach 1161 71534 Murrhardt, Germany Fornsbacher Str. 92 71540 Murrhardt, Germany Phone +49 71 92 22 208 Fax +49 71 92 22 181 www.boschrexroth.com/tightening 3 608 870 A47 EN | 2019-10 AF © Bosch Rexroth AG 2019 Subject to revisions!

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