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OETIKER FAST 3000 Instruction Manual

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OETIKER FAST 3000
Translation of the original
instruction manual
Item No.: 08906397
Issue: 2311_V03_c
Software: V5.1
Instruction manual
OETIKER Schweiz AG
Spätzstrasse 11
CH-8810 Horgen
Switzerland

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Summary of Contents for OETIKER FAST 3000

  • Page 1 OETIKER FAST 3000 Instruction manual Translation of the original OETIKER Schweiz AG instruction manual Spätzstrasse 11 Item No.: 08906397 CH-8810 Horgen Issue: 2311_V03_c Switzerland Software: V5.1...

  • Page 2: Table Of Contents

    Safe methods of working......... . 13 Using the FAST 3000 via an external control system ......13 Conversions, modifications .
  • Page 3 Correct positioning of the FAST 3000 ........
  • Page 4 Controlling the FAST 3000 via an external PLC� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 149...

  • Page 5: Information About This Manual

    They contain important instructions for safe working procedures. For the version FAST 3000 with Light curtain, refer to the corresponding leaflet “Instruction Manual FAST 3000 Light Curtain”. Issue 08.23 08906397 www.oetiker.com...

  • Page 6: Fast 3000

    Touch panel (optional) • Foot pedal (optional) • Closing force verification unit (optional) • Crimping force monitoring devices • emergency stop dongle • Jaws kit for CFM verification on the FAST 3000 (optional) Fig� 1: FAST 3000 www.oetiker.com 08906397 Issue 08.23...

  • Page 7: Rating Plates

    OETIKER FAST 3000 INFoRMATIoN ABoUT THIS MANUAL 1.2.2 Rating plates Fig� 2: Rating plates 1�3 Abbreviations Newton seconds millimeters milliseconds kilogram Crimping Force Monitoring Issue 08.23 08906397 www.oetiker.com...

  • Page 8: Light Curtain

    The safety distance of the safety light curtain must be determined by the integrator. ► eN ISo 13855:2010 must be observed. Stopping time of the oeTIKeR FAST 3000 for calculating the safety distance from the safety light curtain: 0.15 s www.oetiker.com 08906397 Issue 08.23...

  • Page 9: Stickers On The Fast 3000

    INFoRMATIoN ABoUT THIS MANUAL 1�5 Stickers on the FAST 3000 CAUTION Comply with all safety stickers and always exercise great care when using the FAST 3000. Fig� 4: Stickers (1, 2, 3) on the FAST 3000 Wear safety glasses! Crush hazard! Crush hazard! Fig�...

  • Page 10: Basic Safety Instructions

    Use other than for the intended purpose The FAST 3000 is built to current technology and is safe in operation. Residual hazards remain if it used incorrectly or by untrained personnel. The manufacturer bears no responsibility for injuries to personnel and damage to property arising from improper use of the FAST 3000.

  • Page 11: General Safety Instructions

    Maintenance and repair work should be carried out only by qualified specialists. • The FAST 3000 tool may be used only by persons who are familiar with its use and have been informed of the risks. • All relevant accident prevention regulations and other generally recognized health and safety rules must be complied with.

  • Page 12: Covers

    BASIC SAFeTy INSTRUCTIoNS 2�4 Covers CAUTION Use the FAST 3000 only when all covers are correctly fitted. Fig� 6: Protective covers on the FAST 3000 ► Make sure that identification marks and warning instructions on the machine are always present and legible.

  • Page 13: Safe Methods Of Working

    Conversions, modifications • The FAST 3000 may not be modified either in respect of its design or in respect of its safety features without express permission from oeTIKeR. oeTIKeR shall not be held liable for any damages resulting from any unauthorized modifications.
  • Page 14 OETIKER FAST 3000 BASIC SAFeTy INSTRUCTIoNS Personnel Maintenance Operator Electrician mechanic Use/operation Commissioning with the optional two‑hand control × × desk / with the optional touch panel Normal operation Removal/installation of the crimping cut‑off head × Maintenance of the crimping cut‑off head ×...

  • Page 15: Maintenance Work

    OETIKER FAST 3000 BASIC SAFeTy INSTRUCTIoNS The “Maintenance mechanic” is authorized to perform the following activities: • The activities performed by the “operator” • Working in the *Manual operation* operating mode. This allows the tool to be operated manually. •...

  • Page 16: Scope Of Supply Of The Fast 3000 Tool

    Closing force verification unit can CAL 01 calibrator (not shown) / optional 10. Alignment aid 11. Installation tool with crimping force monitoring devices 12. Jaws kit for CFM verification on the FAST 3000 (not shown) / optional www.oetiker.com 08906397 Issue 08.23...

  • Page 17: Available Main Configurations

    Two-hand control desk Part number 13500298 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. Issue 08.23 08906397 www.oetiker.com...
  • Page 18 SCoPe oF SUPPLy oF THe FAST 3000 TooL Option Scope of supply Foot pedal Part number 13500105 Foot pedal to allow hands‑free use of the FAST 3000 during tests or in the laboratory. Test equipment CAL 01 CAL 01 qualified UK / engl-de / SKS01-1500mm Part number 13600384...
  • Page 19 OETIKER FAST 3000 SCoPe oF SUPPLy oF THe FAST 3000 TooL Option Scope of supply Connecting cable cpl� 1m, 2x180° Part number 13500354 Connecting cable cpl� 1�5 m, 2x180° Part number 13500359 For spare parts and auxiliary tools, see section 9.7.

  • Page 20: 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 21 OETIKER FAST 3000 BRIeF DeSCRIPTIoN oF THe FAST 3000 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. Strap detection LeD Indicates whether a strap is present: •...

  • Page 22: Design Of The Fast 3000 Crimping Cut-Off Head

    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 crimping jaws and the cut‑off die may be damaged.

  • Page 23: Two-Hand Control Desk (Option)

    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) Issue 08.23...

  • Page 24: Description Of The Process Monitoring Of The Fast 3000

    5�1 Control of the closing force, description the of process parameters The purpose of the FAST 3000 is to close oeTIKeR WingGuard® strap clamps. NOTICE For the recommended values for the process parameters please refer to the technical data sheet of the oeTIKeR PG270 WingGuard strap clamp.

  • Page 25: Closing Force

    OETIKER FAST 3000 DeSCRIPTIoN oF THe PRoCeSS MoNIToRING oF THe FAST 3000 phase 2 phase 4 phase 1 phase 3 2000 1000 Fig� 14: Force control phases (Example, shows a target of closing force of 1850 N) Closing Force Closing force tolerance ( ±100 N around 1850 N)

  • Page 26: Speed Phase 2

    Some applications require a specific applied force and a specific period of time, so that the components are ideally connected. The FAST 3000 allows the user to configure this period of time. In general, soft materials require a longer holding time than harder ones.
  • Page 27 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 28: Pulling Force Sensor Check

    The evaluation is based on a time‑force curve. • The units send oK/not oK signals to the FAST 3000 PLC. The FAST 3000 PLC uses these and other signals to determine whether the overall closing operation was oK or not oK.

  • Page 29: 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� 16: Application of force to on the crimping jaws...
  • Page 30 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 levers of the crimping head. NOTICE Due to the principle of leverage the force is divided between the transmission lever and the spacer plate.

  • Page 31: Cfm: Typical Ok Force Curve

    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.

  • Page 32: Cfm: Wear Detection

    For this reason, the FAST 3000 PLC will perform an additional check: The monitoring devices measure the force levels at entry into the green rectangular box and exit from the box. These force values are transmitted to the FAST 3000 PLC, which calculates the difference between the entry force and exit force.

  • Page 33: 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 34 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: •...
  • Page 35 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 36 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 37 OETIKER FAST 3000 DeSCRIPTIoN oF THe PRoCeSS MoNIToRING oF THe FAST 3000 CFM curve Image of the closed clamp Left No wing formation. Right Issue 08.23 08906397 www.oetiker.com...
  • Page 38 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 39 The FAST 3000 PLC checks that 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 40 OETIKER FAST 3000 DeSCRIPTIoN oF THe PRoCeSS MoNIToRING oF THe FAST 3000 CFM curve Image of the closed clamp Description Right crimping jaw completely broken off. Compared to good jaws: (Illustrated example) The following criteria have led to the NoK evaluation: •...
  • Page 41 OETIKER FAST 3000 DeSCRIPTIoN oF THe PRoCeSS MoNIToRING oF THe FAST 3000 CFM curve Image of the closed clamp Description Right crimping jaw partially broken off: The following criteria have led to the not oK evaluation: • Second envelope curve (eo 2) left (Troubleshooting „Prerr_304: Crimping error CFM1 envelope curve 2“ ) •...
  • Page 42 OETIKER FAST 3000 DeSCRIPTIoN oF THe PRoCeSS MoNIToRING oF THe FAST 3000 CFM curve Image of the closed clamp The following criteria have led to the not oK evaluation: • Second envelope curve (eo 2) right (Troubleshooting „Prerr_308: Crimping error CFM2 envelope curve 2“ )
  • Page 43 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! For information about the correct tightening torque refer to Section 9.3.3 .
  • Page 44 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 1850 N standard setting. CFM force lever higher than 1850 N due to generally low pulling level in the clamping strap.

  • Page 45: 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 1850 N standard setting. Due to the generally higher pulling level in the clamping strap, the CFM force level is lower than with the standard 1850 N setting.

  • Page 46: Working With The Fast 3000

    Hazardous situation due to improper installation� Read and understand the safety instructions, 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 47 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 that the ergonomic factors are recognized and so that the clamps can be closed correctly.

  • Page 48: Connections To The Control Cabinet

    OETIKER FAST 3000 WoRKING WITH THe FAST 3000 6�2 Connections to the control cabinet Fig� 23: Connections to the control cabinet Power supply Connecting cable between the tool mechanism and control cabinet Touch Panel Power supply CFM 24 V etherCat CFM...

  • Page 49: Cable Connections To The Crimping Force Monitoring Devices

    Fig� 24: 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 50: Switching On The Fast 3000

    Further information on controlling the FAST 3000 without the two‑hand control desk see Section 10 . NOTICE 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 51 To initialize the FAST 3000, press the blue flashing button (3) on the two‑hand control desk. Fig� 27: Initialization key 2 Manual operation The FAST 3000 is ready for operation when the green indicator lamp on the two‑hand control desk is lit. Issue 08.23 08906397 www.oetiker.com...

  • Page 52: Correct Positioning Of The Fast 3000

    The following procedure is applicable only if after the installation the housing of the WingGuard strap ® clamp must be in the horizontal position. In all other cases the FAST 3000 must be set up manually. Many different mounting conditions are possible. Therefore, you must check the correct alignment of the WingGuard strap clamp.
  • Page 53 OETIKER FAST 3000 WoRKING WITH THe FAST 3000 Fig� 29: Example of an incorrect installation of the WingGuard with the housing and the crimping cut‑off head not parallel with each other ® Fig� 30: Impermissible positioning of the WingGuard housing on an application ®...
  • Page 54 OETIKER FAST 3000 WoRKING WITH THe FAST 3000 Fig� 32: The crimping cut‑off head must be at a sufficient distance from the application. No collision with the application. Fig� 33: The crimping cut‑off head is colliding with the application. Impermissible application. The same is true if two WingGuard strap clamps are fitted too close to each other.
  • Page 55 OETIKER FAST 3000 WoRKING WITH THe FAST 3000 Fig� 34: Do not mount the WingGuard strap clamp on a stepped application. ® Fig� 35: Avoid contact between the end face of the strap and the goods being strapped (example shown: goods being strapped (1)).

  • Page 56: Positioning The Fast 3000 Installation Tool Using The Alignment Aid

    OETIKER FAST 3000 WoRKING WITH THe FAST 3000 6.5.2 Positioning the FAST 3000 installation tool using the alignment aid WARNING Hazard due to a magnetic field� The alignment aid is held against the crimping cut‑off head by a powerful magnet. Personnel fitted with a heart pacemaker must maintain a suitable distance from the alignment aid.
  • Page 57 ® 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 ®...

  • Page 58: Dimensions For Correctly Positioning The Fast 3000

    The horizontal and tilting movement of the FAST 3000 must not be obstructed by contact with external objects. The crimping cut‑off head of the FAST 3000 must not touch any parts other than the WingGuard ® clamp that is being closed. Disregard of this rule can lead to mechanical damage and poor connection quality of the WingGuard strap clamp.

  • Page 59: 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! Issue 08.23 08906397 www.oetiker.com...
  • Page 60 OETIKER FAST 3000 WoRKING WITH THe FAST 3000 WARNING Hazard due to positioning the hands under the installation tool� Never reach under the installation tool while it is in operation. CAUTION Danger due to parts being flung from the machine�...
  • Page 61 NOTICE Risk of an increased error rate� Do not touch the FAST 3000 until the closure procedure is completed. Start the installation by pressing both the left and right buttons (1) on the two‑hand control desk simultaneously.

  • Page 62: 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 the FAST 3000 with an increased level of care. WARNING Crush hazard at moving parts.
  • Page 63 OETIKER FAST 3000 WoRKING WITH THe FAST 3000 WARNING Hazard due to positioning the hands under the installation tool� Never reach under the installation tool while it is in operation. CAUTION Danger due to parts being flung from the machine�...

  • Page 64: 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 65: Foot Pedal

    WoRKING WITH THe FAST 3000 NOTICE Risk of an increased error rate� Do not touch the FAST 3000 until the closure procedure is completed. Start the installation. Press either the left‑hand or right‑hand button on the two‑hand control desk for at least 2.5 seconds.
  • Page 66 NOTICE Risk of an increased error rate� Do not touch the FAST 3000 until the closure procedure is completed. Start the installation. To do this, depress the foot pedal down to the middle position for at least 2.5 seconds.

  • Page 67: 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 68: Deblocking

    If the emergency stop button was activated, deactivate it. Press the"Deblocking" button (1). The strap of the WingGuard strap clamp will now be cut off by the FAST 3000, but not crimped. The residual piece ® of strap is discarded. Press the blue “initializing” button on the two‑hand control desk.

  • Page 69: Manual Drive" Operation

    OETIKER FAST 3000 WoRKING WITH THe FAST 3000 6.8.2 “Manual Drive” Operation NOTICE Possible damage to the FAST 3000 Inn this mode the overload protection function of the crimping cut‑off head is not active. Fig� 50: Drive manually Activating operating mode.

  • Page 70: Setting The Force Offset To Zero

    OETIKER FAST 3000 WoRKING WITH THe FAST 3000 6.8.3 Setting the force offset to zero NOTICE 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 71: Verifying The Pulling Force

    To verify the correct operation of the load cell, verify the measured force at least once a week with an oetiker CAL 01. At a set force of 1850 N, the force measured by the oeTIKeR CAL 01 must be within a tolerance of ± 50 N.
  • Page 72 OETIKER FAST 3000 WoRKING WITH THe FAST 3000 Press the button at the top of the handle. Press on “Target force” to change the verification force to the desired value. Press on “Verification activation”. Input the force measured by the CAL 01 into the “ext.

  • Page 73: Verifying The Crimping Force Monitoring

    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 1600 N, the force measured by the CAL 01 must be within a tolerance of ±...

  • Page 74: Adjusting The Crimping Force Monitoring

    Use the closing force verification unit to check the closing force (see Section 6.8.4 ). ► Check the positioning of the FAST 3000 installation tool (12 o’clock position) (see Section 6.5 ). For eo 2, the second envelope curve, it is strongly recommended to use a smaller value for Dy, such as 180.
  • Page 75 OETIKER FAST 3000 WoRKING WITH THe FAST 3000 Select “Settings” and “Parameter Tool” on the FAST 3000 touch panel. Select “CFM Teaching mode”. In order to access CFM Teaching mode you must be logged in as Superuser. Fig� 59: Setting parameters...
  • Page 76 OETIKER FAST 3000 WoRKING WITH THe FAST 3000 If the message “Retain the curve" appears on the screen, select “No”. Select “Delete curve”. Close a WingGuard strap clamp. ® If the WingGuard strap clamp closes correctly, ® press “yes”, otherwise press “No”. 10. Repeat steps 11 and 12 four times, in order to record at least five oK reference curves.
  • Page 77 19. After the teaching process, deactivate the mode again. If this is not done, the relevant pop‑pup window will appear periodically. 20. on the touch panel of the FAST 3000: Be sure to set “CFM Production mode” to “on”. Fig� 64: Envelopes 21.
  • Page 78 OETIKER FAST 3000 WoRKING WITH THe FAST 3000 Adjusting the crimping force monitoring tolerance each monitoring device must be set separately. Select “Setup” on the welcome screen. Log in as Superuser (password‑protected). Fig� 65: Measuring program Select “MP Setup”. Select MP‑00.
  • Page 79 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 80: Changing The Measurement Program

    OETIKER FAST 3000 WoRKING WITH THe FAST 3000 6.8.7 Changing the measurement program The active measurement program is always measurement program 0! The measurement program must be configured individually for each monitoring device. NOTICE The purpose of the measurement program 0 is to evaluate the closing force curves.
  • Page 81 OETIKER FAST 3000 WoRKING WITH THe FAST 3000 Select the Measurement program 00. Fig� 72: Measuring programs Select “Insert”. Fig� 73: Measuring programs Confirm the new settings by pressing the check. 10. log out of the monitoring devices. 11. Unlatch the emergency stop button.

  • Page 82: Loading New Settings/Measurement Programs To The Cfm Units

    A PC must be available for loading settings and programs. The maXymos software is available. The software is part of the FAST 3000 scope of delivery. The CFM settings file must be available in zip format. The file is provided by oetiker.
  • Page 83 OETIKER FAST 3000 WoRKING WITH THe FAST 3000 12. Select the measurement programs for which the name are to be changed (9). 13. Switch to the “General” tab (10). 14. Rename the measurement program by replacing “Le” with “Ri” (11). 15. Confirm with oK (12).

  • Page 84: Gui (Graphical User Interface)

    OETIKER FAST 3000 GUI (GRAPHICAL USeR INTeRFACe) GUI (Graphical User Interface) 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 85: Gui Layout

    OETIKER FAST 3000 GUI (GRAPHICAL USeR INTeRFACe) 7�3 GUI layout The main view of the FAST 3000 visualization is as follows: Fig� 76: Structure GUI User management / Language selection / Date & Time Tabs Content of the tabs Status bar Issue 08.23...

  • Page 86: Menu Structure

    FAST 3000 ® Symbol for the WingGuard ® strap clamp Status Shows the status of the two electrical drives of the FAST 3000 Operating mode Automatic mode or manual operation of drives; local or PLC Messages error messages etc. User...

  • Page 87: Closure Data (A Password Is Necessary To Change The Values)

    OETIKER FAST 3000 GUI (GRAPHICAL USeR INTeRFACe) 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 88: 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 the FAST 3000 with an increased level of care. WARNING Crush hazard at the WingGuard strap clamp�...
  • Page 89 GUI (GRAPHICAL USeR INTeRFACe) WARNING Crush hazard at moving parts� The FAST 3000 may be used only when all covers are correctly fitted and bolted in place. CAUTION Hazard due to positioning the hands under the installation tool� Never reach under the installation tool while it is in operation.
  • Page 90 OETIKER FAST 3000 GUI (GRAPHICAL USeR INTeRFACe) 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�...
  • Page 91 OETIKER FAST 3000 GUI (GRAPHICAL USeR INTeRFACe) Manual mode (password-protected) Fig� 80: Manual driving Motion link (left-hand side) Initializing Initializing the motion link: Setting the zero point Starting position Motion link in the starting position (if there is a WingGuard strap clamp in the ®...

  • Page 92: Free State Pull Force Test

    OETIKER FAST 3000 GUI (GRAPHICAL USeR INTeRFACe) 7.4.4 Free state pull force test NOTICE The operating mode “Free state pull force test” is available for testing the internal friction of the WingGuard clamp. To achieve this, the WingGuard clamp is closed without any strap present, ®...

  • Page 93: I/O Test

    OETIKER FAST 3000 GUI (GRAPHICAL USeR INTeRFACe) 7.4.5 I/O 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 94 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 State communication Status of Green: The controls are connected to a supervisory control unit.
  • Page 95 OETIKER FAST 3000 GUI (GRAPHICAL USeR INTeRFACe) IO Test Communication Industrial Network Signaling display Fig� 84: IO Test Industrial Communication Status word Signal inactive Signal active Signal not used Integer value For every manual function the status word and the control word are displayed as integer values. The status of all bits is also displayed as green or grey.
  • Page 96 OETIKER FAST 3000 GUI (GRAPHICAL USeR INTeRFACe) Fig� 85: IO Test Digital In Output Signals I/O start 1 Hardwire I/o start channel 1 I/O start 2 Hardwire I/o start channel 2 I/O stop 1 Hardwire I/o stop channel 1 I/O stop 2...
  • Page 97 OETIKER FAST 3000 GUI (GRAPHICAL USeR INTeRFACe) Fig� 86: Status EtherCAT devices EtherCAT running Green: Bus etherCAT is running Red: Bus etherCAT is not running PACIO_01 Green: Io module1 oK Red: Io module1 fault PACIO_02 Green: Io module2 oK Red: Io module2 fault...

  • Page 98: Logbook

    OETIKER FAST 3000 GUI (GRAPHICAL USeR INTeRFACe) 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. Fig� 87: LOG process log Date/Time...
  • Page 99 OETIKER FAST 3000 GUI (GRAPHICAL USeR INTeRFACe) Error / warning protocol The most recent errors of the tool are displayed in the “error log” tab. This menu can be accessed without using a password. Fig� 88: LOG ErrorMessages See Sections 7.4.9 and 13.3 for detailed information about the individual error messages.
  • Page 100 OETIKER FAST 3000 GUI (GRAPHICAL USeR INTeRFACe) 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. Fig� 89: GUI Alarmhadling If no alarm is active, the screen appears as follows: Fig�...
  • Page 101 OETIKER FAST 3000 GUI (GRAPHICAL USeR INTeRFACe) If alarms are active, the screen can appear as follows: Fig� 91: GUI Active alarm messages 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”...
  • Page 102 OETIKER FAST 3000 GUI (GRAPHICAL USeR INTeRFACe) Verification log The most recent verification forces are displayed under the “Verification log” tab. This menu can be accessed only by inputting a password. Fig� 93: LOG Verification entries If a value is listed only for force 1, this is a pulling force verification. The scaling factor is listed for the correlation factor to convert the PLC force sensor input signal into the closing force (see section 9.5.2).
  • Page 103 OETIKER FAST 3000 GUI (GRAPHICAL USeR INTeRFACe) 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. Fig� 94: Log Service_log To create a new service log entry, write the text in the field (1) in the bottom left corner and press “enter” (2).

  • Page 104: Settings

    OETIKER FAST 3000 GUI (GRAPHICAL USeR INTeRFACe) 7.4.7 Settings Tool Parameters Fig� 95: Settings Tool Page 1 Fig� 96: Settings Tool Page 2 www.oetiker.com 08906397 Issue 08.23...
  • Page 105 Bypass the external power unlock signal. Control via external PLC Select this button in order to control the FAST 3000 via an external PLC Operating Function: “Operation by Commands are activated either by the external PLC or local (GUI) for the Ext� PLC”...
  • Page 106 Indicates that the pull 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 pull the clamps Activating verification Start the pulling process at the set force...
  • Page 107 Crimping force monitoring verification NOTICE 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.) Fig� 99: Verification crimping force To verify the crimping force monitoring you must at least be logged in as operator.
  • Page 108 OETIKER FAST 3000 GUI (GRAPHICAL USeR INTeRFACe) Setting the date and time The Time & Date can be set by three ways. Connecting to the controller of the Fast3000 Using the GUI (see below) Industrial communication using UTC Unix Time Stamp Fig�...

  • Page 109: Information

    OETIKER FAST 3000 GUI (GRAPHICAL USeR INTeRFACe) 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. Fig� 102: Information page 7.4.9 Error list For further information on error correction see Section 13 .
  • Page 110 OETIKER FAST 3000 GUI (GRAPHICAL USeR INTeRFACe) Error Description Class/Severity number Section War_101 error acknowledged Warning 13.3.1 War_102 Check start button contacts Warning War_103 No power ‑> press start / and init Warning War_104 CFM box warning / error Warning...
  • Page 111 OETIKER FAST 3000 GUI (GRAPHICAL USeR INTeRFACe) Error Description Class/Severity number Section Toerr_201 Strap present ‑> remove & acknowledge Tool error 13.3.2 Toerr_202 Clamping unit not in home position STo‑> Initialize Tool error Toerr_203 Check pulling unit and cut‑off unit...
  • Page 112 OETIKER FAST 3000 GUI (GRAPHICAL USeR INTeRFACe) Error Description Class/Severity number Section Prerr_301 Max. pulling travel exceeded Process error 13.3.3 Prerr_302 Max. pulling time exceeded Process error Prerr_303 Crimping CFM1 envelope 1 Process error Prerr_304 Crimping CFM1 envelope 2 Process error...
  • Page 113 OETIKER FAST 3000 GUI (GRAPHICAL USeR INTeRFACe) Error Description Class/Severity number Section 11052 Servo pulling unit: Z phase not connected Drive error 11053 Servo pulling unit: Low battery level Drive error 11054 Servo pulling unit: Sine eNC Drive error 11055...

  • Page 114: Access Rights

    OETIKER FAST 3000 GUI (GRAPHICAL USeR INTeRFACe) 7.4.10 Access rights User Rights “none” = status at Operator Superuser switch-on Closing force parameter × × Parameter Tool × × Process log error / warning protocol Verification log × × Service logbook ×...

  • Page 115: 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 192.168.10.51.

  • Page 116: Industrial Communication X21/X22

    8.1.2 Setting the IP address for the Profinet The interface for the Profinet is set up using the usual development tools such as Proneta, Tia‑Portal etc. These tools allow the IP to be assigned to the FAST 3000. www.oetiker.com 08906397...

  • Page 117: Touch Panel

    OETIKER FAST 3000 ASSIGNING THe IP ADDReSS 8�2 Touch Panel The de Default IP address of the touch panel is 192.168.10.40. Check that this IP address does not create any conflicts. Change the IP address if necessary. Keep the button on the touch panel depressed for five seconds in order to call up the relevant menu.

  • Page 118: Maintenance And Replacement Of Parts

    Use only original‑spare parts from oeTIKeR. • Maintenance work may be performed on the FAST 3000 only when it is disconnected from the electrical supply. • Following initial commissioning, the FAST 3000 tool should be cleaned daily or weekly, depending on the degree of soiling.

  • Page 119: 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 120: 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 121: 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 required Performed by 100,000 cycles • Crimping jaws kit (part • Replace the crimping jaws...

  • Page 122: 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. Fig� 108: Fat head 9.2.5 A‑service ‑ to be performed every 100,000 cycles CAUTION Replace wear parts (crimping jaws) after 100,000 closures.
  • Page 123 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 124: B-Service - To Be Performed Every 200,000 Cycles

    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 verification at 1850 N. The closing force must lie within ±100 N.

  • Page 125: Replacing Parts

    When the CFM force load cells are not fitted there is a risk of mechanical damage� If the force load cells are not installed in their normal position, never operate the FAST 3000 with a crimping cut‑off head that is equipped for CFM. Failure to comply with this instruction risks mechanical damage to the crimping cut‑off head.
  • Page 126 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. Fig� 114: Sensors caulking monitoring Unscrew the 4 screws on the front face, and pull the crimping cut‑off head off.

  • Page 127: 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.
  • Page 128 ► 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 129 Maintenance section. NOTICE When the FAST 3000 is delivered, the cut‑off die is inserted so that the side marked “1” is the cutting side. Accordingly, a new cut‑off die should be inserted so that the side marked “1” cuts. Comply with the disassembly instructions when dismantling the crimping cut‑off head.

  • Page 130: Replacing The Crimping Wedge

    OETIKER FAST 3000 MAINTeNANCe AND RePLACeMeNT oF PARTS 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 this has already been done, replace the cut‑off die with a new one.

  • Page 131: Replacing The Crimping Jaws Pivot Pin

    OETIKER FAST 3000 MAINTeNANCe AND RePLACeMeNT oF PARTS 9.3.5 Replacing the crimping jaws pivot pin NOTICE The crimping jaw pivot pins may only be replaced using the press‑out and press‑in tools provided for the purpose (see Section  9.7) . Do not use any hammers or punches, since these increase the risk of mechanical damage.
  • Page 132 OETIKER FAST 3000 MAINTeNANCe AND RePLACeMeNT oF PARTS Insert the new crimping jaw pivot pin (3) and insert the marked screw (2). Now tighten the screw, to press the crimping jaw pivot pin in. Stop tightening as soon as resistance is clearly sensed.

  • Page 133: Replacing The Clamping Levers

    9.3.6 Replacing the clamping levers 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 134 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. Fig� 130: Clamping lever Reassemble everything. To do this, perform the above steps in the reverse order.

  • Page 135: Checking And Adjusting The Position Of The Strap Detection Sensor

    OETIKER FAST 3000 MAINTeNANCe AND RePLACeMeNT oF PARTS 9�4 Checking and adjusting the position of the strap detection sensor NOTICE To check whether the strap sensor is set correctly, perform steps 1 to 6. NOTICE For information about the part numbers of the two strap strips, see Section 9.7.
  • Page 136 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 set screw (3) about one turn. Press the strap sensor down until it rests on the strap section.

  • Page 137: Setting The Closing Force Sensor

    OETIKER FAST 3000 MAINTeNANCe AND RePLACeMeNT oF PARTS 9�5 Setting the closing force sensor NOTICE If the factor “Force sensor scaling” is set incorrectly this will cause the WingGuard strap clamps to ® be closed with a closing force that is either too high or too low.

  • Page 138: Adjusting The Load Cell

    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: Fig� 134:...

  • Page 139: 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 140: Tools And Consumable Materials Required For Maintenance

    OETIKER FAST 3000 MAINTeNANCe AND RePLACeMeNT oF PARTS 9�7 Tools and consumable materials required for maintenance Tool error / Part Application Consumable materials number Spare parts kit for the 13500112 A‑service crimping jaws (Service pack A) Service pack B 13500157 B‑Service...
  • Page 141 OETIKER FAST 3000 MAINTeNANCe AND RePLACeMeNT oF PARTS Tool error / Part Application Consumable materials number Crimping cut-off head 13500215 Crimping cut‑off head for for CFM quick maintenance Crimping cut-off tool + 13500352 Spare part Profinet control cabinet - – 13500374...
  • Page 142 OETIKER FAST 3000 MAINTeNANCe AND RePLACeMeNT oF PARTS Tool error / Part Application Consumable materials number Press-out tool 13500341 Press out the crimping jaws Pull strap 13500347 Closing force verification Installation aid for the 13500288 Facilitates the installation crimping cut-off head...
  • Page 143 OETIKER FAST 3000 MAINTeNANCe AND RePLACeMeNT oF PARTS Tool error / Part Application Consumable materials number Proximity switch IFRM 06001786 Spare part 03P3501/KS35L (Clamping unit strap sensor) Damper, complete 13500318 Spare part Sensor clamping bushing 13500346 Spare part Clamping unit rail...
  • Page 144 OETIKER FAST 3000 MAINTeNANCe AND RePLACeMeNT oF PARTS Tool error / Part Application Consumable materials number Contact module NC 06001814 Spare part Servo amplifier 06001892 Spare part L7NHA004U Measurement amplifier 06002147 Spare part 1-BM40IE Digital input / output card 06001891...
  • Page 145 OETIKER FAST 3000 MAINTeNANCe AND RePLACeMeNT oF PARTS Tool error / Part Application Consumable materials number PAC120 Ethernet/IP PLC 06004387 Spare part PACIO Extender Module 06004389 Spare part EtherCAT Drive GSM20 complete 13500271 Spare part (with connection plugs) Force monitoring device...
  • Page 146 OETIKER FAST 3000 MAINTeNANCe AND RePLACeMeNT oF PARTS Tool error / Part Application Consumable materials number Alignment aid 13500343 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...
  • Page 147 OETIKER FAST 3000 MAINTeNANCe AND RePLACeMeNT oF PARTS Tool error / Part Application Consumable materials number Jaws checking mirror 13500351 Spare part Sensor plug connector M8 13500115 extension cable for the strap sensor Handle, complete 13500178 Safety sticker set for the...
  • Page 148 OETIKER FAST 3000 MAINTeNANCe AND RePLACeMeNT oF PARTS Tool error / Part Application Consumable materials number MICROLUBE GBU-Y 131 Greasing the crimping grease cut‑off head, Clamping unit and strap Brush Applying grease Feeler gauge Closure gap verification 0-150 mm www.oetiker.com 08906397...

  • Page 149: 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 150: Settings For The Profinet Hw Configuration

    OETIKER FAST 3000 CoNTRoLLING THe FAST 3000 VIA AN eXTeRNAL PLC 10.1.2 Settings for the Profinet HW configuration The GDSML file for configuration of the supervisory control system can be found on the USB stick supplied. The following settings must be performed in the configuration of the supervisory control system: •...

  • Page 151: Field Bus Mapping

    OETIKER FAST 3000 CoNTRoLLING THe FAST 3000 VIA AN eXTeRNAL PLC 10.1.3 Field bus mapping Adress 8‑Bit Description Data Type Recommendation Range value R-DW0: 0 ... 3 Status information Status word R-DW0: Bit0 Part oK Normal Mode R Bool Status word R-DW0:...
  • Page 152 OETIKER FAST 3000 CoNTRoLLING THe FAST 3000 VIA AN eXTeRNAL PLC Adress 8‑Bit Description Data Type Recommendation Range value R-DW0: Bit24 Request Deblocking Deblocking R Bool Status word R-DW0: Bit25 Deblocking Routine Deblocking R Bool Status word active R-DW0: Bit26 HMI‑message «Remove...
  • Page 153 OETIKER FAST 3000 CoNTRoLLING THe FAST 3000 VIA AN eXTeRNAL PLC Adress 8‑Bit Description Data Type Recommendation Range value R-Adr66 66 … 67 Setting maximum cutting Parameter motion UInt current link R-Adr68 68 … 71 Home position pulling Parameter pulling...
  • Page 154 OETIKER FAST 3000 CoNTRoLLING THe FAST 3000 VIA AN eXTeRNAL PLC Adress 8‑Bit Description Data Type Recommendation Range value b_StatePull- Bit 4 Function Verification Verification R_Bool VerfiBusy Pulling Force is active Pulling force b_StatePull- Bit 5 Function Verification Verification R_Bool...
  • Page 155 OETIKER FAST 3000 CoNTRoLLING THe FAST 3000 VIA AN eXTeRNAL PLC Adress 8‑Bit Description Data Type Recommendation Range value b_StateCrimp- Bit 7 State Warning Crimp Verification Crimp Uint ForceWarning Force Verification Force b_StateCrimp- Bit 8 State erroe Crimp Force Verification Crimp...
  • Page 156 OETIKER FAST 3000 CoNTRoLLING THe FAST 3000 VIA AN eXTeRNAL PLC Adress 8‑Bit Description Data Type Recommendation Range value b_StatePul- Bit 4 Pulling Unit is powerd Drive Manual R_Bool lingUnitAxis- Mode Powered b_StatePul- Bit 5 Pulling unit is referenced Drive Manual...
  • Page 157 OETIKER FAST 3000 CoNTRoLLING THe FAST 3000 VIA AN eXTeRNAL PLC Adress 8‑Bit Description Data Type Recommendation Range value R-Adr136: 136 … Statusinformation Friction test Uint Statusword Friction Test FrictionTest b_ReqFricVer- Bit 0 It's availible for a request Friction test...
  • Page 158 OETIKER FAST 3000 CoNTRoLLING THe FAST 3000 VIA AN eXTeRNAL PLC Adress 8‑Bit Description Data Type Recommendation Range value R-Adr152: 152 … Position Motion Link Drive Manual DInt i_MotionLink- Mode ActPos R-Adr156: 156 … Actual Position Pulling Friction test DInt...
  • Page 159 OETIKER FAST 3000 CoNTRoLLING THe FAST 3000 VIA AN eXTeRNAL PLC Adress 8‑Bit Description Data Type Recommendation Range value W-DW0: Bit13 Ack.message "Band Normally mode W Bool Steuerwort remove" W-DW0: Bit14 Locking Tool Normally mode W Bool Steuerwort W-DW0: Bit15...
  • Page 160 OETIKER FAST 3000 CoNTRoLLING THe FAST 3000 VIA AN eXTeRNAL PLC Adress 8‑Bit Description Data Type Recommendation Range value b_AbortZBal Bit 5 Command Abort Zero Balance W_Bool Function Zero Balance W_Adr10: 10 … 11 Command Function Friction test UInt Steuerword...
  • Page 161 OETIKER FAST 3000 CoNTRoLLING THe FAST 3000 VIA AN eXTeRNAL PLC Adress 8‑Bit Description Data Type Recommendation Range value W-Adr18: 18 … 19 Target Force Pulling Verification UInt i_TargetFor- Force Verification Pulling force cePullVerifi W-Adr20: 20 … 21 Value CAL01 Verification...
  • Page 162 OETIKER FAST 3000 CoNTRoLLING THe FAST 3000 VIA AN eXTeRNAL PLC R Real 3 decimal fraction R Real 2 decimal fraction Values for process documentation Values for building up experience Bit0: Manual mode Bit1: Automatic Mode Bit2: Labor Mode 2 Hand‑Control Bit3: Labor Mode Foot‑Pedal...

  • Page 163: Addition To Industrial Communication

    OETIKER FAST 3000 CoNTRoLLING THe FAST 3000 VIA AN eXTeRNAL PLC 10.1.4 Addition to industrial communication R-DW43 Warning Hereby the messages from Section 7.4.9 (error list) are transmitted. It is the messages (warnings) 100 to 199. In these cases, 100 is subtracted from the error number, and then the number is bitwise added to the sum.
  • Page 164 OETIKER FAST 3000 CoNTRoLLING THe FAST 3000 VIA AN eXTeRNAL PLC R_DW44 Tool Error Hereby the messages from Section 7.4.9 (error list) are transmitted. It is the messages (tool errors) 200 to 299. In these cases, 200 is subtracted from the error number, and then the number is added bitwise to the sum.
  • Page 165 OETIKER FAST 3000 CoNTRoLLING THe FAST 3000 VIA AN eXTeRNAL PLC R_DW45 Process error Hereby the messages from Section 7.4.9 (error list) are transmitted. It is the messages (process errors) 300 to 399. In these cases, 300 is subtracted from the error number, and then the number is added bitwise to the sum.

  • Page 166: Handling Function

    CoNTRoLLING THe FAST 3000 VIA AN eXTeRNAL PLC 10.1.5 Handling Function 4/20/23, 12:09 PM Handling GUI - FAST 3000 In-life Management - Confluence The individual functions can be handled via the GUI or via industrial communication. From where the individual functions Untitled Diagram-1681983910718.drawio are handled must be set in the GUI.
  • Page 167 OETIKER FAST 3000 4/20/23, 12:04 PM Handling GUI - FAST 3000 In-life Management - Confluence CoNTRoLLING THe FAST 3000 VIA AN eXTeRNAL PLC Untitled Diagram-1681983910718.drawio   Handling GUI Operation via industrial communication When selecting the individual handlings in manual mode via ind. communication, the tool must always be reinitialized FAST 3000 In-life Mana…...

  • Page 168: Overview Of The State Machine In The Plc

    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 169: 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 170: 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 171: 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 • Closing force tolerance: ±100 N •...

  • Page 172: 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 173 If the unblocking function does not to an inserted clamp perform 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. Slacken the fastening screws of the crimping cut‑off head by a few turns and...
  • Page 174 Remove the clamp strap from the crimping cut‑off head. The FAST 3000 is now ready for initialization. Mount the front cover again and switch on the FAST 3000.

  • Page 175: Error Messages And Their Resolution

    If at the next cycle the FAST 3000 operates correctly: ► Depress the start buttons quickly� If at the next cycle despite the buttons being depressed quickly the FAST 3000 once again exhibits the same error: ► Replace the contacts of the start button.
  • Page 176 OETIKER FAST 3000 TRoUBLeSHooTING AND eRRoR MeSSAGeS War_105: Service due soon NOTICE This warning occurs when the service counter reaches the number of cycles limit (Number of cycles for service (default 100,000 cycles) ‑ Service cycles warning (default 100 cycles)). The message is repeated every ten closures.
  • Page 177 OETIKER FAST 3000 TRoUBLeSHooTING AND eRRoR MeSSAGeS War_109: No power to tool NOTICE The power supply to the motion link or to the pulling drive is not activated. Remedy: ► Re‑establish the power supply to the tool. Switch on at the green button on the control cabinet door and initialize the tool.
  • Page 178 OETIKER FAST 3000 TRoUBLeSHooTING AND eRRoR MeSSAGeS War_120: Manual mode: Run command before last run end (Motion link) NOTICE In manual mode ‑> Manual movement function ‑> Pulling unit: A new command was sent before execution of the old run command had been completed.

  • Page 179: Tool Error

    OETIKER FAST 3000 TRoUBLeSHooTING AND eRRoR MeSSAGeS 13.3.2 Tool error ToErr_201: (W) strap present -> remove & acknowledge NOTICE 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 180 OETIKER FAST 3000 TRoUBLeSHooTING AND eRRoR MeSSAGeS ToErr_202 Clamping unit not in home position STO-> Initialize NOTICE Before starting the closure cycle the tool performs a safety check to determine whether the clamping unit is in its starting position. (If for instance the clamping unit is set in motion inadvertently when a finger is present between the clamp and the parts to be connected, this can lead to injuries.) If the...
  • Page 181 Make sure that the ethernet cables correct are correctly connected to the servo drive amplifier in the control cabinet. If the servo drive is experiencing an error: ► Report your cabinet to your local oetiker Power Tool Center. Issue 08.23 08906397 www.oetiker.com...
  • Page 182 OETIKER FAST 3000 TRoUBLeSHooTING AND eRRoR MeSSAGeS ToErr_206 Emergency circuit open / ToErr_214 Emergency stop NOTICE This error occurs when the e‑Stop circuit is open. If the emergency stop‑button is pressed: Unlatch the emergency stop button. If the emergency stop‑button is not pressed: ►...
  • Page 183 OETIKER FAST 3000 TRoUBLeSHooTING AND eRRoR MeSSAGeS ToErr_210: Verifying the crimping force: No force increase NOTICE 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 184 ► Check that the crimping cut‑off head is installed correctly. ► Make sure that no unauthorized parts come into contact with the clamping unit of the FAST 3000 during the closing cycle (see section 6.5.3). ► Check the tool mechanism, in particular that the linear guide of the clamping unit runs easily without jerking, and check the correct alignment of the clamping unit to the crimping head (see section 9.5.1).
  • Page 185 OETIKER FAST 3000 TRoUBLeSHooTING AND eRRoR MeSSAGeS ToErr_216: Tool drive lost power during the cycle NOTICE The power supply to the motion link or to the pulling drive has been interrupted. Remedy: ► Re‑establish the power supply to the tool. Switch on at the green button on the control cabinet door and initialize the tool.
  • Page 186 OETIKER FAST 3000 TRoUBLeSHooTING AND eRRoR MeSSAGeS ToErr_219: Manual mode: More than 1 run command at pulling unit NOTICE In manual mode with the Manual drive function: More than one command was sent to the pulling unit. No run command was performed.

  • Page 187: Process Errors

    OETIKER FAST 3000 TRoUBLeSHooTING AND eRRoR MeSSAGeS 13.3.3 Process errors PrErr_301: Maximum pulling travel exceeded NOTICE The pulling travel can be limited. This can provide a check on whether the correct clamp diameter was used. (There are limitations to this function, since the WingGuard strap end is detected even ®...
  • Page 188 Check the curve settings in the crimping force monitoring device 1. ► Check the FAST 3000 for correct positioning (see section 6.5). ► Check the correct routing of the connecting cable: During closure the crimping cut‑off head must push down against the housing of the WingGuard clamp.
  • Page 189 Check the curve settings in the crimping force monitoring device 2. ► Check the positioning of the FAST 3000 (see section 6.5). ► Check the correct routing of the connecting cable: During closure the crimping cut‑off head must push down against the housing of the WingGuard clamp.
  • Page 190 ► Check the setting of the crimping force monitoring device 2. ► Check the positioning of the FAST 3000. ► Check that the fastening screws of the crimping cut‑off head are tightened to the correct tightening torque (see section 9.3.3 ).
  • Page 191 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. If during the crimping operation the motion link current does not remain within the defined limit values: ►...
  • Page 192 If during the cut‑off operation the motion link current does not remain within the defined limit values: ► Have the current limit valuesfor the motion link (cut‑off) adjusted by the oetiker service team. ► If the drive exhibits an excessive current consumption, repair or exchange it.
  • Page 193 OETIKER FAST 3000 TRoUBLeSHooTING AND eRRoR MeSSAGeS PrErr_315: Closing force outside tolerance NOTICE This error occurs if the closing force lies outside the tolerance range. The closing force is determined as the average of the last 40 measured values (40*2 ms). The tolerance is set by default to +/‑100 N.
  • Page 194 OETIKER FAST 3000 TRoUBLeSHooTING AND eRRoR MeSSAGeS PrErr_317 Max� force during move to throw-off position NOTICE After the strap has been cut off the pulling 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 195: Appendix

    Circuit diagram • Industrial communication • eC 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 Issue 08.23...

  • Page 196: Help And Support

    OETIKER FAST 3000 HeLP AND SUPPoRT Help and Support If you need help or technical support, contact your local oetiker Service Center. For further information see www.oetiker.de. eMeA e‑mail ptsc.hoe@oetiker.com Tel. number +49 7642 6 84 0 America & Canada e‑mail...

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