OETIKER FAST 3000 User manual

Stationary tool for installing
strap clamps
OETIKER FAST 3000
Translation of the original Operating Instructions
Issued 03.2019
Item no. 08903979
Oetiker Schweiz AG, Horgen,
Switzerland
Operating Instructions

OETIKER FAST 3000 Contents
Issued 03.19 08903979 0-2
Contents
1 Information about this manual....................................................................................................................1-8
1.1 Symbols and means of representation used ........................................................................................ 1-8
1.2 Scope .................................................................................................................................................... 1-9
1.2.1 FAST 3000 ................................................................................................................................ 1-9
1.2.2 Rating plates .......................................................................................................................... 1-10
1.3 Abbreviations ...................................................................................................................................... 1-10
1.4 Stickers on the FAST 3000...................................................................................................................1-11
1.5 Associated documents ........................................................................................................................1-12
2 Basic safety instructions ........................................................................................................................... 2-13
2.1 Using the Operating Instructions ........................................................................................................ 2-13
2.2 Use for the intended purpose ............................................................................................................. 2-13
2.3 General safety instructions ..................................................................................................................2-14
2.4 Covers ................................................................................................................................................. 2-16
2.5 Special safety instructions .................................................................................................................. 2-16
2.6 Safe methods of working .....................................................................................................................2-17
2.7 Using the FAST 3000 via an external control system ..........................................................................2-17
2.8 Conversions, modifications..................................................................................................................2-17
2.9 Qualified personnel ............................................................................................................................. 2-18
2.10 Maintenance work............................................................................................................................... 2-20
2.11 Overload protection of the crimping cut-off head .............................................................................. 2-21
2.12 Noise level ........................................................................................................................................... 2-21
3 Scope of supply of the FAST 3000 tool ....................................................................................................3-22
3.1 Overview of the main components of the FAST 3000 ........................................................................3-22
3.2 Available main configurations ............................................................................................................. 3-23
3.3 Optional extras .................................................................................................................................... 3-25
4 Brief description of the FAST 3000...........................................................................................................4-27
4.1 Design of the tool mechanism ............................................................................................................ 4-28
4.2 Design of the FAST 3000 crimping cut-off head ................................................................................4-30
4.3 Two-hand control desk .......................................................................................................................4-32
5 Description of the process monitoring of the FAST 3000......................................................................5-33
5.1 Control of the closing force, description the of process parameters .................................................5-33

OETIKER FAST 3000 Contents
Issued 03.19 08903979 0-3
5.1.1 Functional description of control of the closing force............................................................5-34
5.1.2 Closing Force .........................................................................................................................5-35
5.1.3 Closing force tolerance ..........................................................................................................5-35
5.1.4 Switch point reduction ...........................................................................................................5-35
5.1.5 Speed phase 1 .......................................................................................................................5-35
5.1.6 Speed phase 2 .......................................................................................................................5-35
5.1.7 Closing force holding time......................................................................................................5-35
5.1.8 Sample curves with different closing force parameters ........................................................5-36
5.1.9 Plausibility test of the closing force sensor............................................................................5-38
5.2 Crimping monitoring............................................................................................................................5-38
5.2.1 General information on the crimping force monitoring (CFM) ...............................................5-38
5.2.2 Mechanical design .................................................................................................................5-39
5.2.3 CFM: Typical OK force curve ................................................................................................. 5-41
5.2.4 CFM: Wear detection .............................................................................................................5-42
5.2.5 CFM: Sample curves of crimping operations ........................................................................5-43
5.3 Cut-off monitoring ...............................................................................................................................5-56
6 Working with the FAST 3000......................................................................................................................6-57
6.1 Commissioning....................................................................................................................................6-57
6.2 Connections to the control cabinet.....................................................................................................6-59
6.3 Cable connections to the crimping force monitoring .........................................................................6-60
6.4 Switching on the FAST 3000...............................................................................................................6-61
6.5 Correctly positioning the FAST 3000 ..................................................................................................6-63
6.5.2 Positioning of the FAST 3000 installation tool with the alignment aid ...................................6-67
6.5.3 Dimensions for correctly positioning the FAST 3000.............................................................6-69
6.6 Normal operation (production)............................................................................................................ 6-71
6.7 Laboratory mode (password-protected)............................................................................................. 6 -74
6.7.1 One-hand operation ............................................................................................................... 6-76
6.7.2 Foot pedal............................................................................................................................... 6-78
6.8 Special operating modes (password-protected) ................................................................................6-80
6.8.1 Unlocking................................................................................................................................6-81
6.8.2 Manual mode operation of drives...........................................................................................6-82
6.8.3 Setting the force offset to zero...............................................................................................6-83
6.8.4 Verifying the closing force ......................................................................................................6-84

OETIKER FAST 3000 Contents
Issued 03.19 08903979 0-4
6.8.5 Crimping force monitoring verification ...................................................................................6-85
6.8.6 Adjusting the crimping force monitoring ................................................................................6-87
6.8.7 Loading new settings/measurement programs to the CFM units .........................................6-93
7 GUI ................................................................................................................................................................7-95
7.1 Touch Panel......................................................................................................................................... 7-95
7.2 Computer ............................................................................................................................................ 7-95
7.3 GUI Layout .......................................................................................................................................... 7-96
7.4 Menu structure .................................................................................................................................... 7-97
7.4.1 Welcome screen..................................................................................................................... 7-97
7.4.2 Closure data (a password is necessary to change the values).............................................. 7-98
7.4.3 Operating mode...................................................................................................................... 7-99
7.4.4 Friction test ............................................................................................................................7-104
7.4.5 IO Test....................................................................................................................................7-105
7.4.6 Logbook.................................................................................................................................7-108
7.4.7 Setting .................................................................................................................................. 7-114
7.4.8 Information.............................................................................................................................7-119
7.4.9 Error list (version V2.09).........................................................................................................7-120
7.4.10 Access rights .........................................................................................................................7-123
8 Assigning the IP address ......................................................................................................................... 8-124
8.1 Setting the date and time .................................................................................................................. 8-125
9 Maintenance and replacement of parts................................................................................................. 9-128
9.1 General safety instructions for maintenance and repair work.......................................................... 9-128
9.2 Maintenance...................................................................................................................................... 9-129
9.2.1 Before maintenance work..................................................................................................... 9-129
9.2.2 After maintenance work ....................................................................................................... 9-129
9.2.3 Regular checking of the status............................................................................................. 9-131
9.2.4 Regular maintenance work / maintenance schedule ........................................................... 9-132
9.2.5 A-service - to be performed every 100,000 cycles.............................................................. 9-133
9.2.6 B-service - to be performed every 200,000 cycles ............................................................. 9-134
9.3 Replacing parts ................................................................................................................................. 9 -135
9.3.1 Removing the crimping cut-off head.................................................................................... 9-136
9.3.2 Installing the crimping cut-off head...................................................................................... 9-138

OETIKER FAST 3000 Contents
Issued 03.19 08903979 0-5
9.3.3 Replacing the crimping jaws and/or the cut-off die............................................................. 9-138
9.3.4 Replacing the crimping wedge............................................................................................. 9-142
9.3.5 Replacing the crimping jaws pivot pin ................................................................................. 9-142
9.3.6 Replacing the clamping lever ............................................................................................... 9-144
9.4 Checking and adjusting the position of the strap detection sensor ................................................. 9-147
9.5 Setting the closing force sensor ....................................................................................................... 9-149
9.5.1 Adjusting the load cell .......................................................................................................... 9-149
9.6 Replacing the control cabinet or tool mechanism ............................................................................ 9 -150
9.7 Tools and consumable materials for maintenance ........................................................................... 9-151
10 Controlling the FAST 3000 via an external PLC .................................................................................. 10 -158
10.1 Control via a field bus (Ethernet/IP or Profinet) .............................................................................. 10 -158
10.1.1 Settings for the Ethernet/IP communication protocol ....................................................... 10 -158
10.1.2 Settings for the Profinet HW configuration ........................................................................ 10-159
10.1.3 Field bus mapping (software version V2.09) ...................................................................... 10-159
10.2 Control via 24-V I/O signals ............................................................................................................ 10-163
11 Decommissioning, transport, storage, recommissioning................................................................. 11-164
11.1 Decommissioning.............................................................................................................................11-164
11.2 Transport ..........................................................................................................................................11-16 4
11.3 Storage.............................................................................................................................................11-166
11.4 Recommissioning.............................................................................................................................11-166
11.5 Disposal............................................................................................................................................11-16 6
12 Technical data ......................................................................................................................................... 12-167
13 Troubleshooting and error messages .................................................................................................. 13-168
13.1 General instructions in the event of errors...................................................................................... 13-168
13.2 What should I do, if …? ................................................................................................................... 13-168
13.3 Error messages and their resolution ................................................................................................13-172
13.3.1 ToErr_1: (W) strap present -> remove & acknowledge........................................................13-172
13.3.2 ToErr_2: Clamping unit not in the home position STO -> Initialize .....................................13-173
13.3.3 PrErr_1: Maximum tensioning travel exceeded ...................................................................13-174
13.3.4 PrErr_11: General error at crimping .....................................................................................13-175
13.3.5 PrErr_12: Error at cutting off ................................................................................................13-176
13.3.6 ToErr_4: Position sensor defective......................................................................................13-176

OETIKER FAST 3000 Contents
Issued 03.19 08903979 0-6
13.3.7 PrErr_15: Closing force outside tolerance ...........................................................................13-177
13.3.8 War_2: Button contact error................................................................................................13-177
13.3.9 ToErr_5: Drive error active...................................................................................................13-178
13.3.10 ToErr_6: Emergency stop circuit open / ToErr_14: Emergency Stop ..................................13-178
13.3.11 PrErr_3: Crimping error CFM1 envelope curve 1 ................................................................13-179
13.3.12 PrErr_4: Crimping error CFM1 envelope curve 2 ................................................................13-179
13.3.13 PrErr_5: Crimping error CFM1 NoPass ...............................................................................13-179
13.3.14 PrErr_6: Crimping error CFM1 wear ....................................................................................13-179
13.3.15 PrErr_7: Crimping error CFM2 envelope curve 1 ................................................................13-179
13.3.16 PrErr_8: Crimping error CFM2 envelope curve 2 ............................................................... 13-180
13.3.17 PrErr_9: Crimping error CFM2 NoPass .............................................................................. 13-180
13.3.18 PrErr_10: Crimping error CFM2 wear ................................................................................. 13-180
13.3.19 PrErr_13 Force overshoot ................................................................................................... 13-180
13.3.20 PrErr_16 Max force when the light curtain breached ..........................................................13-181
13.3.21 PrErr_17: Max force travel in ejection position ................................................................... 13-182
13.3.22 PrErr_18: Process aborted ................................................................................................. 13-182
13.3.23 PrErr_19: Max force reached on interruption by bus stop ................................................. 13-182
13.3.24 ToErr_7: Light curtain active during the initialization routine.............................................. 13-182
13.3.25 ToErr_8: Verifying the crimping force (phase 1) ................................................................. 13-183
13.3.26 ToErr_9: Verifying the crimping force (phase 2) ................................................................. 13-183
13.3.27 ToErr_10: Verifying the crimping force: No force increase ................................................ 13-184
13.3.28 ToErr_11: Checking the strap waste .................................................................................. 13-184
13.3.29 ToErr_12: CFM general warning / error............................................................................... 13-184
13.3.30 ToErr_13 Check tensioning force sensor ........................................................................... 13-185
13.3.31 ToErr_16 No power to tool during operation ...................................................................... 13-186
13.3.32 War_1 Error acknowledged ................................................................................................ 13-186
13.3.33 War_3 No power supply – press Start -> Init ..................................................................... 13-186
13.3.34 War_4 CFM units warning / error........................................................................................ 13-186
13.3.35 War_5 Service due soon .....................................................................................................13-187
13.3.36 War_6 Service due...............................................................................................................13-187
13.3.37 War_7 Stop triggered by the light curtain............................................................................13-187
13.3.38 War_8 CFM mode teach-in active ......................................................................................13-187
13.3.39 War_9 No power to tool ..................................................................................................... 13-188

OETIKER FAST 3000 Contents
Issued 03.19 08903979 0-7
13.3.40 War_10 No power supply – external enable, press Start .................................................. 13-188
13.3.41 War_11 Remove strap ........................................................................................................ 13-189
14 Appendix .................................................................................................................................................. 14 -190
15 Help and Support.................................................................................................................................... 15-191

OETIKER FAST 3000 Information about this manual
Issued 03.19 08903979 1-8
1 Information about this manual
1.1 Symbols and means of representation used
Safety notices are used in this manual to warn of the risk of personal injury or property damage.
XAlways read and observe these safety notices.
XObserve all notices that are agged with a safety alert symbol and text.
The following symbols are used in these Operating Instructions:
DANGER
Hazardous situation.
Failure to observe this notice will lead to death or serious injury.
WARNING
Hazardous situation.
Failure to observe this instruction may lead to death or serious injury.
CAUTION
Hazardous situation.
Failure to observe this notice may lead to minor injury.
NOTE
Information relating to the understanding or optimization of working practices.
Symbol Meaning
X... One-step instruction
1. ...
2. ...
3. ...
Multi-step instruction
XCarry out the steps in the order shown.
9... Requirement
• Necessary or labor-saving steps for the successful execution of an action.

OETIKER FAST 3000 Information about this manual
Issued 03.19 08903979 1-9
1.2 Scope
These Operating Instructions apply to all Oetiker FAST 3000 (stationary tool for installing strap clamps) and
describe the method of operation together with the correct procedures for commissioning, operation, maintenance,
decommissioning, recommissioning, storage and transport.
They contain important instructions for safe working procedures.
For the version FAST 3000 with Light curtain the corresponding leaet “Manual FAST 3000 Light Curtain” has to be
considered.
1. 2 .1 FAST 3000
• Control cabinet
• Two-hand control desk (optional)
• Installation tool
• Connecting cable
• Touch panel (optional)
• Foot pedal (optional)
• Closing force verication unit (optional)
• Crimping force monitoring devices
• Emergency stop dongle
Fig. 1 FAST 3000

OETIKER FAST 3000 Information about this manual
Issued 03.19 08903979 1-10
1.2.2 Rating plates
Fig. 2 Rating plates
1.3 Abbreviations
NNewton sseconds
mm millimeters ms milliseconds
kg kilogram CFM Crimping Force Monitoring

OETIKER FAST 3000 Information about this manual
Issued 03.19 08903979 1-11
1.4 Stickers on the FAST 3000
CAUTION
XComply with all safety stickers and always exercise great care when using the FAST 3000.
Fig. 3 Stickers (1, 2, 3) on the FAST 3000
1 Wear safety glasses!
2 Crush hazard!
3 Crush hazard!

OETIKER FAST 3000 Information about this manual
Issued 03.19 08903979 1-12
Fig. 4 Stickers (1, 2) on the crimping cut-off head and alignment aid
1 General warning signs: Never use a FAST 3000
without force sensors.
2 Warning sign: Magnetic eld
3 Permanent magnet
1.5 Associated documents
• EC Declaration of Conformity, see Appendix ( Section 14 )
• Other associated documents, see Appendix ( Section 14 )

OETIKER FAST 3000 Basic safety instructions
Issued 03.19 08903979 2-13
2 Basic safety instructions
2.1 Using the Operating Instructions
• Make sure that these Operating Instructions are always kept close at hand ready for use.
• Pass these Operating Instructions on to the next owner or user.
• Please read these Operating Instructions carefully before commissioning the FAST 3000 tool.
– Familiarize yourself with all settings and their functions.
– Anyone involved in setting up, commissioning, maintaining or repairing the unit must have read and
understood the Operating Instructions and in particular the safety instructions.
2.2 Use for the intended purpose
CAUTION
The FAST 3000 with its associated parts is intended solely for the controlled closure of OETIKER PG270
WingGuard®strap clamps. It may not be used to close clamps other than Oetiker WingGuard®strap clamps 270.
• The unit may be used only for the intended purpose and under technically safe and fault-free conditions.
• Correct usage also covers observance of these Operating Instructions and compliance with the technical data.
• Any use not in accordance with the prescribed usage shall be regarded as incorrect usage.
• The use of the FAST 3000 in areas subject a risk of explosions is not permitted.
• The FAST 3000 can be used as a stand-alone tool or be integrated into an assembly cell.
• If the FAST 3000 is integrated into an assembly cell it can be used without the optional two-hand control desk
and without the optional touch panel. In such cases the integrator is responsible for the safe integration of the
FAST 3000 into the assembly cell.
– For further information on the integration of the FAST 3000 see Section 10.
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. in such cases the operating company is solely responsible.

OETIKER FAST 3000 Basic safety instructions
Issued 03.19 08903979 2-14
Implemented safety concept for safe operation
The FAST 3000 is intended for operation by a single operator. It is prohibited for a third person to start the clamping
cycle.
To exclude the risk that parts of limbs my be crushed between the WingGuard®clamp and the goods being
strapped, the two-hand control requires the use of two hands to start the clamping cycle, which corresponds to a
Performance Level PL d to EN ISO 13849-1.
The clamping cycle is started by depressing the two start buttons simultaneously.
Since after 300 milliseconds the WingGuard®clamp is sufficiently closed that no parts of limbs can be inserted,
the start buttons can be released again once they have been depressed. This excludes the possibility of incorrect
clamping that might be caused by premature release of the start buttons.
In the event of the clamping drive starting up unexpectedly during the insertion phase, an additional sensor ensures
that the pulling unit is immediately disabled.
The safety concept considers the hazards that might arise from the FAST 3000. Other hazards in the surrounding
working area must be considered by the operating company and countered as necessary by measures for personal
safety.
If the FAST 3000 is not controlled via the Oetiker two-hand control, the operating company must ensure safe
integration of the FAST 3000.
2.3 General safety instructions
CAUTION
Hazard due to an unsuitable workplace.
XEnsure sufficient space and sufficient lighting.
• Comply with all operating instructions and maintenance 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. The manufacturer shall not be held liable for damage resulting from unauthorized modifications
to the FAST 3000.
• Use the FAST 3000 only in a clean and dry working environment.
• Use the FAST 3000 only in an area provided with sufficient lighting.
• Provide sufficient space for safe handling and operation.

OETIKER FAST 3000 Basic safety instructions
Issued 03.19 08903979 2-15
Spare parts
In order to ensure the fast and accurate delivery of spare parts, a clear purchase order is essential. It must include
the following information:
• Product name, software version
• Type designation
• Serial number
• Name of the spare part and quantity required
• Spare part number
• Shipping method
• Full address
Details can be found in the OETIKER tools catalog.
Improvements to the machine
In our endeavor to continuously improve the quality of our products, we reserve the right to make improvements
without changing the Operating Instructions. Details of dimensions, weights, materials, performance ratings and
names may therefore be subject to necessary changes. Regarding electrical diagrams, the diagram supplied with
the machine takes precedence in all cases.

OETIKER FAST 3000 Basic safety instructions
Issued 03.19 08903979 2-16
2.4 Covers
CAUTION
Use the FAST 3000 only when all covers are correctly fitted.
Fig. 5 Protective covers on the FAST 3000
XMake sure that identification marks and warning instructions on the machine are always present and legible.
2.5 Special safety instructions
Only specially trained personnel are authorized to carry out maintenance and repair work on electrical equipment.
XBefore starting maintenance and repair work, switch off all units and disconnect the entire tool from the power
supply.
XCheck the crimping jaws and cut-off die as part of the preventive maintenance routine and replace them if
necessary.

OETIKER FAST 3000 Basic safety instructions
Issued 03.19 08903979 2-17
2.6 Safe methods of working
• Check the FAST 3000 for visible damage on each occasion before starting production, and make sure it is used
only when in good condition. Make particularly sure to thoroughly check the crimping jaws and emergency
stop!
• Any defects must be reported to a supervisor immediately.
– Do not continue to use the FAST 3000 if defects have been identified.
• During operation of the machine and when performing maintenance, wear safety glasses.
• The FAST 3000 is intended for operation by only a single operator. The closing cycle may not be initiated by a
second person.
• Keep sufficient free space around the product. Users must not be hampered by third persons.
• Arrange the working area of the FAST 3000 for good ergonomics.
• Pressing the emergency stop button on the two-hand control desk disconnects both positioning drives from the
power supply and brings their movement to an immediate halt.
– If the FAST 3000 is controlled via an external PLC, see section 10 .
2.7 Using the FAST 3000 via an external control system
• The integrator is responsible for the safe integration of the FAST 3000.
• The integrator must perform a risk evaluation and implement the system in accordance with the risk evaluation.
• The integration my be performed only by qualified personnel.
• If no two-hand control desk is used, an external emergency stop must be wired in.
• For more information on this subject, see section 10 .
• If you have questions about how to perform integration contact Oetiker.
2.8 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.
• Use only original spare parts and accessories.
• Do not dismantle any safety equipment or features.

OETIKER FAST 3000 Basic safety instructions
Issued 03.19 08903979 2-18
2.9 Qualified personnel
WARNING
Hazards due to operation by unauthorized or unqualified personnel.
This device may be used only by authorized and qualified personnel. Use other than in accordance with the
Operating Instructions is prohibited. The levels of authorization for use are as follows:
Personnel
Use/operation
Operator Maintenance
mechanic Electrician
Installation/decommissioning × 
Transport/storage × 
Commissioning without the optional two-hand
control desk / without the optional touch panel × × 
Normal operation 
Removal/installation of the crimping cut-off head × 
Maintenance of the crimping cut-off head × 
“Manual mode” operation × 
Error correction ×  
Removal of the covers × 
Opening the control cabinet × × 
Replacing parts × 
Explanation: = permitted × = not permitted
“Operator”:
• is familiar with the specified safety instructions and regulations
• knows the applicable procedures described in this document
• is appropriately trained
• is authorized by the competent office
The operating company must ensure that the employee has received the safety instructions and regulations in the
relevant language.

OETIKER FAST 3000 Basic safety instructions
Issued 03.19 08903979 2-19
“Maintenance mechanic”:
• has the knowledge described for the “Operator”
• is familiar with the mechanical techniques required for working on the machines and tools (fastening, cleaning,
lubricating)
• knows the applicable procedures described in this document
• does not use the tool under improper conditions (when maintenance intervals have been exceeded or when
partially disassembled)
“Electrician”:
• has the knowledge described for the “Maintenance mechanic”
• has sound knowledge of mechanical and electrical matters
• has been trained and authorized to work on equipment at potentially fatal voltages (110/230 V AC)
• is aware that bad workmanship can lead to serious injuries to personnel and damage to equipment
• is aware that bad workmanship can lead to the failure of electrical and mechanical components
• is aware that the tool must be in good condition when handed over to another user
• knows the applicable procedures described in this document
The “Maintenance mechanic” is authorized to perform the following activities:
• Use of the tool in normal operation
• Cleaning the working area
The “Service 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.
• Make changes to the closure data
• Removal/installation of the crimping cut-off head and cleaning the associated parts
• Maintenance of the crimping cut-off head by replacing the spare parts, cleaning and lubricating
• Investigation of the crimping cut-off head and the associated parts for wear and damage
• Installation, transport and storage
• Removal of the covers for access to the components

OETIKER FAST 3000 Basic safety instructions
Issued 03.19 08903979 2-20
The “Electrician” is authorized to perform the following activities:
• The activities performed by the “Maintenance mechanic”
• Repair of the tool if it is in a defective condition
• Removal of the covers and opening the control cabinet for access to the components
• Replacement of the parts and maintenance of the electrical wiring
2.10 Maintenance work
The inspection and maintenance intervals specified in the Operating Instructions must be complied with.
Maintenance and repair instructions must be followed accordingly.