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