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Tool removed during cycle Fault #2

Tool removed during cycle Fault #2. Conditions for setting Tool cocked prox switch goes open during cycle AND force on load cell drops below limit in fault "Force drop during cycle". Active in Slow Forward and Reverse Revolution processes. Causes for Setting

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Tool removed during cycle Fault #2

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  1. Tool removed during cycleFault #2 Conditions for setting Tool cocked prox switch goes open during cycle AND force on load cell drops below limit in fault "Force drop during cycle". Active in Slow Forward and Reverse Revolution processes. Causes for Setting Release ring pulled prior to cycle being complete Locking mechanism in tool is releasing inadvertently. Troubleshooting Install tool on job and restart. It may be necessary to back off nut before tool can be reinstalled. If tool is releasing the nut without the release ring being pulled then see Cocking System Troubleshooting & Repair Page 2

  2. Fast Run Rotation Limit Exceeded Fault #3 Conditions for setting The nut runner is set up to stop running if it exceeds the maximum number for revolutions allowed. This fault is set if the nut runner reaches this maximum number of revolutions without achieving the pretension target. Fault setting sequence If the PLC receives a cycle complete OK from the nut runner controller during the Fast Run process then this indicates the nut runner ran the maximum number of revolutions allowed. Under normal conditions the PLC will drop the run command when the load cell reading reaches the run fast target. This occurs before the nut runner reaches the maximum number of revolutions so a cycle complete OK signal is not normally sent. Continued next page Page 3

  3. Fast Run Rotation Limit Exceeded Fault #3Troubleshooting Pg 1 • Troubleshooting on the Vehicle • There are 6 known problems that can set this fault code. The best way to troubleshoot is to run the tool on the calibration stand and follow the troubleshooting on the next page. • Park brake cables are disconnected. This allow the nut to run most of the way up the threaded rod with out any tension being developed. • The quick connect system fails and allows the nut to pull out of the tool in the middle of the cycle. If this is being reported then see Quick Connect Troubleshooting& Repair. • If there is a load cell failure the PLC the nut will be run most of the way up the threaded rod. There will be a large amount of tension in cables and the brakes will be fully locked up. In this case see Tool Load Cell Troubleshooting& Repair • If the drive system fails then the nut runner will complete the maximum allowed revolutions but since the drive system is broken the nut will not be run up the threaded rod or only run part way up the threaded rod. In this case see Drive System Troubleshooting & Repair • Application parameters in the nut runner controller set up wrong (Setup Issue) • Tension target force incorrect (Setup Issue) Page 4 Continued next page

  4. Fast Run Rotation Limit Exceeded Fault #3Troubleshooting Pg 2 • Troubleshooting on the Calibration Stand • Run a verification cycle on the calibration stand. • If there is a load cell problem then a different fault code will be set when running on the cal stand. In this case troubleshoot the fault set on the cal stand. • If a run fast limit fault occurs then: • If the nut pulls out of the tool in the middle of the cycle but the tool is still cocked (inputshaft is still retracted) then see Quick Connect Troubleshooting & Repair • If the tool releases the nut in the middle of the cycle (inputshaft is not still retracted) then see Cocking System Troubleshooting & Repair • If the nut is still locked in the tool then see Drive System Troubleshooting & Repair • If no problems are found then there might be a set up issue • Parameters in the nut runner controller set up wrong (Setup Issue) • Tension target force incorrect (Setup Issue) Page 5

  5. Tool MisloadFault #4 Conditions for setting The PLC looks at the load cell force at a specified time after the cycle has started. If the load cell force is below the target force then the job is stopped and this fault is set. • Causes for Setting • Nut was not fully engaged into nose of tool before gun was cocked. • Tool load cell, load cell wiring, or load cell amplifier is faulty • Drive system failure • Fault parameters have not been set properly. • Problem with cables being too long Continued next page Page 6

  6. Tool MisloadFault #4Troubleshooting Troubleshooting If tool is not installed correctly then install correctly and restart job If this is a new installation or there is a product change then fault parameters have to be developed. See Developing Misload Parameters If tool was installed correctly and fault parameters have been developed then run a Verification cycle on the cal stand. If you still get a Tool Misload fault then see: Drive System Troubleshooting & Repair. If a different fault code is set on the cal stand then follow the troubleshooting for that fault code. Page 7

  7. Reverse Revolutions Time OutFault #5 Conditions for setting When the PLC sends the nut runner the command to run reverse revolutions a timer is started. If the nut runner does not send back a job OK or a job NOK within 10 seconds then the cycle is aborted and this fault is set • Causes for Setting • Power failure in the nut runner • Nut runner, nut runner cable, or nut runner controller failure Troubleshooting Check power supply to nut runner if power supply is good then Cycle Power to nut runner controller (orange box). If problem persists then see: Troubleshooting Nut Runner Controller Note: New nut runners and controller must be configured to operate with this system. See Configuring New Nut Runner or Controller Page 8

  8. Tool Load Cell Maximum Force ExceededFault #6 Conditions for setting The PLC constantly monitors the load cell force. If the force ever goes above the maximum allowed target then the cycle stops and this fault code is set. • Causes for Setting • Tool load cell, load cell wiring, or load cell amplifier is faulty • Cal Stand load cell, load cell wiring, or load cell amplifier is faulty • Nut runner controller not configured correctly • Nut runner is running out of control and not responding to PLC commands Troubleshooting Most likely problem is a faulty load cell wiring or amplifier. See: Load Cell Troubleshooting & Repair. If a new nut runner controller was installed then make sure configuration is correct. See Configuring New Nut Runner and Controller Page 9

  9. Calibration Load Cell Maximum Force ExceededFault #7 Conditions for setting The PLC constantly monitors the cal stand load cell force. If the force ever goes above the maximum allowed target then the cycle stops and this fault code is set. This fault is not active in Auto or Manual Calibration modes. • Causes for Setting • Cal stand load cell, load cell wiring, or load cell amplifier is faulty • Tool load cell, load cell wiring, or load cell amplifier is faulty • Nut runner controller not configured correctly • Nut runner is running out of control and not responding to PLC commands Troubleshooting Most likely problem is a faulty load cell wiring or amplifier. See: Load Cell Troubleshooting & Repair. If a new nut runner controller was installed then make sure configuration is correct. See Configuring New Nut Runner and Controller Page 10

  10. Calibration Load Cell Outside Zero Offset RangeFault #8 Conditions for setting When zero offset button is pressed the cal stand load cell reading is greater than 10 Lbs. This is an indication that there is force already applied to the cal stand or the cal stand load cell is faulty. • Causes for Setting • Force is being applied to the cal stand when the zero offset is pressed • Cal stand load cell, load cell wiring, or amplifier is faulty. • Cal stand load cell requires re-calibration. Troubleshooting If no force is being applied to the cal stand load cell then see Cal Stand Load Cell Troubleshooting & Repair Page 11

  11. Current Load Cell Reading Too High to Start CalibrationFault #10 Conditions for setting The PLC looks at the tool load cell force and cal stand load cell when the cycle start button is pressed. If the load cell force is above 10 lbs then the job is stopped and this fault is set. • Causes for Setting • Load is being applied to tool prior to calibration cycle start. • Faulty Load cell, load cell wiring, or load cell amplifier. Troubleshooting Remove tool from stand, make sure nut is backed off so that no load is on cal stand. Press Fault reset and Zero Offset button. Install tool to cal stand and restart cycle being sure there is no load being applied to the threaded rod. If problem persists then check load cell readings on PV calibration screen. If calibration load cell is reading high then see: Cal Stand Load Cell Troubleshooting & Repair. If tool load cell reading is high then see: Tool Load Cell Troubleshooting & Repair Page 12

  12. Calibration Mode Jog Forward TimeoutFault #13 Conditions for setting Calibration cycle runs for 20 seconds without achieving target force • Causes for Setting • Tool not properly installed on calibration stand. • Faulty load cell, load cell wiring, or load cell amplifier Troubleshooting If tool is properly connected then see: Cal Stand Load Cell Troubleshooting & Repair Page 13

  13. Calibration Zero Offset Not Complete Before Pressing StartFault #14 Conditions for setting Before starting calibration the load cells must be zeroed by pressing the “Set Zero Offset” button. If the zero offset is not pressed prior to pressing the start trigger then this fault is set. • Causes for Setting • Zero offset not set before starting calibration cycle Troubleshooting Remove tool from calibration stand, press “Set Zero Offset” button, reinstall tool and press the start button Page 14

  14. Calibration Cycle TimeoutFault #15 Conditions for setting Calibration cycle not complete within the 45 second allowed cycle time • Causes for Setting • Unknown error occurs Troubleshooting Cycle power to nut runner and restart calibration. If problem persists the see: Manual Calibration Procedure Page 15

  15. Fast Run Tension Not AchievedFault #16 Conditions for setting Fast run tension is not achieved within the max allowed cycle time. Fast run tension and cycle time are configurable in parameter screen • Causes for Setting • Unknown error occurs Troubleshooting Run tool on calibration stand and follow fault codes set on cal stand. Page 16

  16. Tool not CockedFault #17 Conditions for setting The PLC looks for the prox switch to be closed before it will allow the cycle to start. If the start switch is pressed without the prox switch being closed the alarm is sounded for 5 sec and the cycle will not start. • Causes for Setting • The tool is not cocked when the start switch is pressed. • Defective prox switch or prox switch wiring. Troubleshooting Pull release ring, unclamp anti rotation and reinstall tool and restart job. If tool is properly loaded and cocked and fault still occurs then see Prox Switch Troubleshooting & Repair Page 17

  17. Nut Runner Over Torque WarningFault #18 Conditions for setting If the nut runner exceeds the maximum allowed torque during the tensioning process it will send a job complete NOK signal to the PLC. If the PLC receives this NOK signal during the tensioning part of the process then the process will continue and the job will be evaluated based on the tension achieved. If the tension is within the acceptable range then the job will be accepted and this warning is set. The warning turns on the yellow stack light and sets a PM required code in the PM screen in the PV but does to fail the job. • Causes for Setting • Loss of grease in crows foot, angle head, or thrust bearing in end effector • Broken or worn gears in angle head or crows foot. • Worn thrust bearing in end effector. • Damaged threads on nut or threaded rod in cable system • Internal error in nut runner controller Continued next page Page 18

  18. Nut Runner Over Torque WarningFault #18Troubleshooting • Troubleshooting • On nut runner panel review the history screen to see what nut runner fault was set during this cycle. • To access the history screen: • Plug the keyboard and mouse into the USB port on the bottom of the nut runner control box • From the top menu select “Navigate” then “Statistics” • In the statistics screen select the “Chronological History” tab. • Near the top of the list there should be a job that failed. Find this failed job and look for the reason it failed. • If High Torque fault is set then this is an indication that the angle head, crows foot, and the end effector thrust bearing require PM. See Drive System PM • If some other nut runner fault occurred then cycle power to the nut runner controller. If the problem persists then replace nut runner and nut runner box and send them back for repair. • If no fault is found in the Cooper box then see Drive System PM Page 19

  19. Nut Runner Over Torque FaultFault #19 Conditions for setting If the nut runner exceeds the maximum allowed torque during the tensioning process it will send a job complete NOK signal to the PLC. If the PLC receives this NOK signal during the tensioning part of the process then the process will continue and the job will be evaluated based on the tension achieved. If the tension is below the acceptable range then the job will be failed and this fault set. • Causes for Setting • Loss of grease in crows foot, angle head, or thrust bearing in end effector • Broken or worn gears in angle head or crows foot. • Worn thrust bearing in end effector. • Damaged threads on nut or threaded rod in cable system • Internal error in nut runner controller Continued next page Page 20

  20. Nut Runner Over Torque FaultFault #19Troubleshooting • Troubleshooting • On nut runner panel review the history screen to see what nut runner fault was set during this cycle. • To access the history screen: • Plug the keyboard and mouse into the USB port on the bottom of the nut runner control box • From the top menu select “Navigate” then “Statistics” • In the statistics screen select the “Chronological History” tab. • Near the top of the list there should be a job that failed. Find this failed job and look for the reason it failed. • If High Torque fault is set then this is an indication that the angle head, crows foot, and the end effector thrust bearing require PM. See Drive System PM • If some other nut runner fault occurred then cycle power to the nut runner controller. If the problem persists then replace nut runner and nut runner box and send them back for repair. • If no fault is found in the Cooper box then see Drive System PM Page 21

  21. Reverse Revolutions not CompleteFault #20 Conditions for setting The nut runner control panel sends a job NOK signal to the PLC during the reverse revolutions sequence. The cycle stops and fault is set. • Causes for Setting • Nut runner went over torque • Some other nut runner fault Continued next page Page 22

  22. Reverse Revolutions not Complete Fault #20Troubleshooting • Troubleshooting • On nut runner panel review the history screen to see what nut runner fault was set during this cycle. • To access the history screen: • Plug the keyboard and mouse into the USB port on the bottom of the nut runner control box • From the top menu select “Navigate” then “Statistics” • In the statistics screen select the “Chronological History” tab. • Near the top of the list there should be a job that failed. Find this failed job and look for the reason it failed. • If High Torque fault is set then this is an indication that the angle head, crows foot, and the end effector thrust bearing require PM. See Drive System PM • If some other nut runner fault occurred then cycle power to the nut runner controller. If the problem persists then see: Troubleshooting Nut Runner Controller • If no fault is found in the Cooper box then see Drive System PM Page 23

  23. Tool & Cal Load Cells Excessive Difference Fault #21 Conditions for setting Tool load cell reading and calibration load cell reading are more than 100 lbs apart during the calibration cycle. • Causes for Setting • Calibration load cell unplugged from panel • Calibration or tool load cell is severelyout of calibration. • Calibration or tool load cell is faulty Continued next page Page 24

  24. Tool &Cal Load Cells Excessive Difference Fault #21Troubleshooting • Troubleshooting • Check to be sure cal stand load cell is plugged in. If unplugged then plug in and rerun cycle. • See Load Cell Troubleshooting & Repair. Page 25

  25. Cannot Start Auto Sequence With Other Tool In CycleFault #23 Conditions for setting Only one tool can run auto cycle at a time. If both tools are in Auto Cycle and one tool is in cycle and then the start button is pressed on the other tool then this fault is set and the cycle is blocked from starting on the second tool Troubleshooting Be sure the second tool is in either Verification, Calibration, Manual Calibrate, or Manual mode before pressing cycle start button. Page 26

  26. Final Tension Over Force FaultFault #32 Conditions for setting If the final tension achieved is over the maximum allowable force this fault is set • Causes for Setting • Faulty tool load cell, load cell wiring, or load cell amplifier. • Faulty nut runner controller • Parameters set up wrong Troubleshooting Check accept delta limit in the parameter screen this should not be set to less than 50 lbs See Tool Load Cell Troubleshooting & Repair If problem is not found then change nut runner controller Page 27

  27. Final Tension Under Force FaultFault #33 Conditions for setting If the final tension achieved is under the minimum allowable force this fault is set • Causes for Setting • Nut runner shuts down due to over torque condition • Faulty tool load cell, load cell wiring, or load cell amplifier. • Faulty nut runner controller • Parameters set up wrong Troubleshooting Check accept delta limit in the parameter screen this should not be set to less than 50 lbs See Nut Runner Over Torque Fault #18 See Tool Load Cell Troubleshooting & Repair Page 28

  28. Calibration Failed Conditions for setting Load cell gain factor is >1.5 or < .75 During the calibration cycle the PLC the compares the force measured by the calibration stand and the force measured by the tool. It then calculated a gain factor that is applied to the tool load cell so that the force readings match. If this gain factor is outside to allowable limits then it is an indication that the tool load cell is not working properly. • Causes for Setting • Tool misbuilt – Load cell installed upside down will trigger this fault • Faulty tool load cell, load cell wiring, or load cell amplifier • Faulty cal stand load cell, load cell wiring, or load cell amplifier Page 29

  29. Calibration FailedTroubleshooting • Troubleshooting • Check to be sure cal stand load cell is plugged in. If unplugged then plug in and rerun cycle. • See Load Cell Troubleshooting & Repair. Page 30

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