OETIKER FAST 3000 User manual

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

2www.oetiker.com Issue 08.23
OETIKER FAST 3000
CONTENT
08906397
Content
1 Information about this manual � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �5
1.1 Symbols and means of representation used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.2 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.2.1 FAST 3000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
1.2.2 Rating plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.3 Abbreviations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.4 Light curtain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
1.4.1 Requirements for the safety light curtain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
1.4.2 Mount safety light curtain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
1.5 Stickers on the FAST 3000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
1.6 Associated documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
2 Basic safety instructions � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 10
2.1 Using the Operating Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
2.2 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.3 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
2.4 Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.5 Special safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.6 Safe methods of working. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
2.7 Using the FAST 3000 via an external control system . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.8 Conversions, modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.9 Qualified personnel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
2.10 Maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.11 Overload protection of the crimping cut-off head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.12 Noise level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3 Scope of supply of the FAST 3000 tool � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 16
3.1 Overview of the main components of the FAST 3000 . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.2 Available main configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.3 Optional extras . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4 Brief description of the FAST 3000 � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 20
4.1 Design of the tool mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.2 Design of the FAST3000 crimping cut-off head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
4.3 Two-hand control desk (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5 Description of the process monitoring of the FAST 3000 24
5.1 Control of the closing force, description the of process parameters . . . . . . . . . . . . . . . . . . . 24
5.1.1 Functional description of control of the closing force . . . . . . . . . . . . . . . . . . . . . . 24
5.1.2 Closing Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.1.3 Closing force tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.1.4 Switch point reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.1.5 Speed phase 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.1.6 Speed phase 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.1.7 Closing force holding time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.1.8 Pulling force sensor check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

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5.2 Crimping monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.2.1 General information on the crimping force monitoring (CFM) . . . . . . . . . . . . . . . . . . 28
5.2.2 Mechanical design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.2.3 CFM: Typical OK force curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.2.4 CFM: Wear detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.2.5 CFM: Sample curves of crimping operations . . . . . . . . . . . . . . . . . . . . . . . . . . .33
5.3 Cut-off monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
6 Working with the FAST 3000 � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 46
6.1 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
6.2 Connections to the control cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6.3 Cable connections to the crimping force monitoring devices . . . . . . . . . . . . . . . . . . . . . . . 49
6.4 Switching on the FAST3000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6.5 Correct positioning of the FAST 3000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
6.5.1 General instructions, positioning the FAST 3000 and WingGuard®clamp housing 52
6.5.2 Positioning the FAST 3000 installation tool using the alignment aid . . . . . . . . . . . . . . . 56
6.5.3 Dimensions for correctly positioning the FAST 3000 . . . . . . . . . . . . . . . . . . . . . . . 58
6.6 Normal operation (production) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
6.7 Laboratory mode (password-protected) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
6.7.1 One-hand operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
6.7.2 Foot pedal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
6.8 Special operating modes (password-protected) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
6.8.1 Deblocking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
6.8.2 “Manual Drive” Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
6.8.3 Setting the force oset to zero . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
6.8.4 Verifying the pulling force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
6.8.5 Verifying the crimping force monitoring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
6.8.6 Adjusting the crimping force monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
6.8.7 Changing the measurement program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
6.8.8 Loading new settings/measurement programs to the CFM units. . . . . . . . . . . . . . . . . 82
7 GUI (Graphical User Interface) � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 84
7.1 Touch Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
7.2 Computer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
7.3 GUI layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
7.4 Menu structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
7.4.1 Welcome screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
7.4.2 Closure data (a password is necessary to change the values) . . . . . . . . . . . . . . . . . . 87
7.4.3 Operating mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
7.4.4 Free state pull force test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
7.4.5 I/O test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
7.4.6 Logbook. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
7.4.7 Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
7.4.8 Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
7.4.9 Error list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
7.4.10 Access rights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
8 Assigning the IP address � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 115
8.1 Industrial communication X21/X22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
8.1.1 Setting the IP address for the EtherNet/IP . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
8.1.2 Setting the IP address for the Profinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
8.2 Touch Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

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9 Maintenance and replacement of parts � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 118
9.1 General safety instructions for maintenance and repair work . . . . . . . . . . . . . . . . . . . . . . 118
9.2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
9.2.1 Before maintenance work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
9.2.2 After maintenance work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
9.2.3 Regular checking of the status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
9.2.4 Regular maintenance work / maintenance schedule . . . . . . . . . . . . . . . . . . . . . . 121
9.2.5 A-service - to be performed every 100,000 cycles . . . . . . . . . . . . . . . . . . . . . . . 122
9.2.6 B-service - to be performed every 200,000 cycles . . . . . . . . . . . . . . . . . . . . . . . 124
9.3 Replacing parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
9.3.1 Removing the crimping cut-o head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
9.3.2 Installing the crimping cut-o head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
9.3.3 Replacing the crimping jaws and/or the cut-o die. . . . . . . . . . . . . . . . . . . . . . . 127
9.3.4 Replacing the crimping wedge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
9.3.5 Replacing the crimping jaws pivot pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
9.3.6 Replacing the clamping levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
9.4 Checking and adjusting the position of the strap detection sensor . . . . . . . . . . . . . . . . . . . 135
9.5 Setting the closing force sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
9.5.1 Checking the ease of movement of the clamping unit . . . . . . . . . . . . . . . . . . . . . 137
9.5.2 Adjusting the load cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
9.6 Replacing the control cabinet or tool mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
9.7 Tools and consumable materials required for maintenance . . . . . . . . . . . . . . . . . . . . . . . 140
10 Controlling the FAST 3000 via an external PLC� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 149
10.1 Control via afield bus (Ethernet/IP or Profinet). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
10.1.1 Settings for the Ethernet/IP communication protocol . . . . . . . . . . . . . . . . . . . . . 149
10.1.2 Settings for the Profinet HW configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
10.1.3 Field bus mapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
10.1.4 Addition to industrial communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
10.1.5 Handling Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
10.2 Overview of the state machine in the PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
10.3 Control via 24-V I/O signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
11 Decommissioning, transport, storage, recommissioning 169
11.1 Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
11.2 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
11.3 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
11.4 Recommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
11.5 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
12 Technical data � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 171
13 Troubleshooting and error messages� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 172
13.1 General instructions in the event of errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
13.2 What should I do, if …? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
13.3 Error messages and their resolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
13.3.1 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
13.3.2 Tool error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
13.3.3 Process errors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
14 Appendix � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 195
15 Help and Support� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 196

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OETIKER FAST 3000
INFORMATION ABOUT THIS MANUAL
Issue 08.23 08906397
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.
►Always read and observe these safety notices.
►Observe all instructions that are flagged with awarning symbol and warning text.
The following symbols are used in this Instruction Manual:
Hazardous situation�
Disregarding this instruction will lead to death or serious injury.
Indicates ahazard with medium risk, which can lead to death or serious injury!
Indicates ahazard with low risk, which can lead to medium or minor injuries!
Indicates adanger of damage to the device! Indicates information useful for operation!
Symbol Meaning
►... One-step instruction
1. ...
2. ...
3. ...
Multi-step instruction
►Carry out the steps in the order shown.
9... Requirement
• Necessary or labor-saving steps for the successful execution of an action.
Connecting Display or operating elements of the menu or the PC software are highlighted.
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, refer to the corresponding leaflet “Instruction Manual FAST 3000 Light
Curtain”.
WARNING
DANGER
CAUTION
INDICATION

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OETIKER FAST 3000
INFORMATION ABOUT THIS MANUAL
Issue 08.2308906397
1.2.1 FAST 3000
• Control cabinet
• Two-hand control desk (optional)
• Installation tool
• Connecting cable
• 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

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OETIKER FAST 3000
INFORMATION ABOUT THIS MANUAL
Issue 08.23 08906397
1.2.2 Rating plates
Fig� 2: Rating plates
1�3 Abbreviations
N Newton s seconds
mm millimeters ms milliseconds
kg kilogram CFM Crimping Force Monitoring

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OETIKER FAST 3000
INFORMATION ABOUT THIS MANUAL
Issue 08.2308906397
1�4 Light curtain
Fig� 3: Light curtain
1.4.1 Requirements for the safety light curtain
According to the following standards, atwo-channel safety light curtain must be used:
• EN ISO 13849-1:2015: at least Cat. 3, PL d
• EN 62061+A1:2009: at least Cat. 3, SIL 2
Possible safety light curtain: Keyence GL-R (GL-R08H)
Stopping time of the OETIKER FAST 3000
for calculating the safety distance from the
safety light curtain 0.15 s
1.4.2 Mount safety light curtain
NOTICE
►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

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OETIKER FAST 3000
INFORMATION ABOUT THIS MANUAL
Issue 08.23 08906397
1�5 Stickers on the FAST 3000
CAUTION
XComply with all safety stickers and always exercise great care when using the FAST 3000.
Fig� 4: Stickers (1, 2, 3) on the FAST 3000
1 Wear safety glasses!
2 Crush hazard!
3 Crush hazard!
Fig� 5: 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 field
3 Permanent magnet
1�6 Associated documents
• EC Declaration of Conformity, see Appendix ( Section 14 )
• Other associated documents, see Appendix ( Section 14 )

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OETIKER FAST 3000
BASIC SAFETY INSTRUCTIONS
Issue 08.2308906397
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 Intended use
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®270 strap clamps.
• 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.
• The installation of the light curtain is the responsibility of the operator.
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 bears sole responsibility.
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.
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.

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OETIKER FAST 3000
BASIC SAFETY INSTRUCTIONS
Issue 08.23 08906397
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.
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
• 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.

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OETIKER FAST 3000
BASIC SAFETY INSTRUCTIONS
Issue 08.2308906397
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.
2�5 Special safety instructions
Only specially trained personnel are authorized to carry out maintenance and repair work on electrical equipment.
►Before starting maintenance and repair work, switch off all units and disconnect the entire tool from the power
supply.
►Check the crimping jaws and cut-off die as part of the preventive maintenance routine and replace them if
necessary.

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OETIKER FAST 3000
BASIC SAFETY INSTRUCTIONS
Issue 08.23 08906397
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.
• The operator must install asuitable light curtain!
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.
• The installation of the light curtain is the responsibility of the operator.
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.
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. The machine may be used only in accordance with
the Operating Instructions. Any other use is prohibited. The levels of authorization for use are as follows:
Personnel
Use/operation
Operator Maintenance
mechanic Electrician
Installation/decommissioning × 9 9
Transport/storage × 9 9
Commissioning without the optional two-hand control
desk / without the optional touch panel × × 9

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OETIKER FAST 3000
BASIC SAFETY INSTRUCTIONS
Issue 08.2308906397
Personnel
Use/operation
Operator Maintenance
mechanic Electrician
Commissioning with the optional two-hand control
desk/ with the optional touch panel ×9×
Normal operation 9 9 9
Removal/installation of the crimping cut-off head × 9 9
Maintenance of the crimping cut-off head × 9 9
“Manual mode” operation × 9 9
Troubleshooting × 9 9
Removal of the covers × 9 9
Opening the control cabinet × × 9
Replacing parts × 9 9
Explanation: 9= permitted × = not permitted
“Operator”:
• is familiar with the specified safety instructions and regulations
• knows the relevant 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.
“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 relevant 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 relevant procedures described in this document
The "Operator" is authorized to perform the following activities:
• Use of the tool in normal operation
• Cleaning the working area

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OETIKER FAST 3000
BASIC SAFETY INSTRUCTIONS
Issue 08.23 08906397
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.
• 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
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.
Compliance with maintenance and repair instructions is mandatory.
2�11 Overload protection of the crimping cut-off head
CAUTION
Do not remove the overload protection of the crimping cut-off head�
Using the tool without overload protection and CFM force load cells can lead to mechanical damage.
Fig� 7: Overload protection (1) of the crimping cut‑off head
2�12 Noise level
In normal operation amaximum noise level of 75 dBA can be expected.
1

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OETIKER FAST 3000
SCOPE OF SUPPLY OF THE FAST 3000 TOOL
Issue 08.2308906397
3 Scope of supply of the FAST 3000 tool
3�1 Overview of the main components of the FAST 3000
Fig� 8: Design of the FAST 3000 tool
1. Connecting cable
2. Control cabinet
3. Two-hand dongle, thin
4. Two-hand dongle (emergency stop two-hand control desk, used if the two-hand control desk is not connected)
5. Touch panel / optional
6. Foot pedal / optional
7. Two-hand control desk / optional
8. Crimping jaws checking mirror
9. 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
2
65
7
1
10
8
11
4
3

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OETIKER FAST 3000
SCOPE OF SUPPLY OF THE FAST 3000 TOOL
Issue 08.23 08906397
3�2 Available main configurations
Configuration Scope of supply
Oetiker FAST 3000 AdvantEdge + CFM - EtherNet/
IP Light curtain 2
Part number 13500396 (IEC) / 13500398 (UL)
Oetiker FAST 3000 with CFM and EtherNet/IP
The tool is supplied with atool carrier
Oetiker FAST 3000 + CFM - PROFINET Light
curtain2
Part number 13500395 (IEC) / 13500397 (UL)
Oetiker FAST 3000 with CFM and PROFINET
The tool is supplied with atool carrier
3�3 Optional extras
Option Scope of supply
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.

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OETIKER FAST 3000
SCOPE OF SUPPLY OF THE FAST 3000 TOOL
Issue 08.2308906397
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
Test equipment for verification of the closure force and
crimping force
Test equipment CAL 01 CAL 01 qualified USA /
engl-es / SKS01-1500mm
Part number 13600385
Test equipment for verification of the closure force and
crimping force
Test equipment CAL 01 CAL 01 qualified CN /
engl-de/ SKS01-1500mm
Part number 13600386
Test equipment for verification of the closure force and
crimping force
Test equipment CAL 01 CAL 01 qualified EURO /
de-engl / SKS01-1500mm
Part number 13600387
Test equipment for verification of the closure force and
crimping force
Verification unit PG135 lockable
Part number 13500299
Adapter jaws for verification of the closing force.
The CAL 01 must be ordered separately.
Jaws kit for CFM verification on the FAST 3000
Part number 13500237
For CFM verification
The CAL 01 must be ordered separately.

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OETIKER FAST 3000
SCOPE OF SUPPLY OF THE FAST 3000 TOOL
Issue 08.23 08906397
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.

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OETIKER FAST 3000
BRIEF DESCRIPTION OF THE FAST 3000
Issue 08.2308906397
4 Brief description of the FAST 3000
The Oetiker FAST 3000 was developed to perform closure of the OETIKER WingGuard®strap clamps.
A production cycle consists of the following steps:
• The operator positions the OETIKER WingGuard®strap clamps on the application.
• The FAST 3000 is pulled in the direction of the application and the strap end of the OETIKER WingGuard®strap
clamp is inserted into in the crimping cut-off head.
• 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.
• After the closing force is achieved, the strap is crimped by the FAST 3000 to create the wings that secure the clamp
against opening. The clamping procedure is monitored by two force load cells. The signal from the force load cells
is evaluated by two force monitoring devices. OK/not OK signals are sent by the monitoring devices to the PLC of
the FAST 3000.
• After crimping procedure has been performed, the strap ends are cut off.
• They are transported to the ejection position, where they fall out of the tool.
• The FAST 3000 returns to the starting position.
NOTICE
More information on the different steps is provided in Section 6.6.
4�1 Design of the tool mechanism
Fig� 9: Tool mechanism
7
6
3
5
4
2
9
1
15
14 9
11
11
12
8
13
10