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Bosch Bluetooth Operating Instructions 9/2008

1. Overview Ex OnnecT 029 EXACT 4 0 crew No __Date Time _ _ COM Info Counter Status Error Duration Rat 029 EXACT 4 i 18 06 2007 11 55 42 MANUAL 1 5 OK 400ms R pee 5 5 2 18 06 2007 11 55 48 _ MANUAL 215 OK _ 400ms R C 11 56 22 EN 18 06 2007 11 56 07 MANUAL 315 Nok f J250ms_ R t 18 06 2007 11 56 10 MANUAL 3 5 OK _ _ 300ms_ R Deg 5 18 06 2007 11 56 15 MANUAL 475 NOK it pss0oms R 6 18 06 2007 _ 11 56 17 MANUAL 415 NOK 1 400 ms R 7 18 06 2007 11 56 18 MANUAL 4 5 OK 200 ms R 8 18 06 2007 11 56 22 MANUAL 5 5 OK 200 ms R 3 Er 18 06 2007 11 56 22 Total 515 OK 40250 ms f f Unlock Save Print Delete vis thet ieee b J aii 7 1 missing shut off signal 5 overload error 9 new release signal 2 minimum fastener time not reached 6 minimum job time not reached 10 single NOK results in total NOK 3 maximum fastener time exceeded 7 maximum job time exceeded 11 skip current jol 4 double hit error 8 abort through manual lock 12 data memory full Device BT EXACT 4 User Name 029 EXACT 4 Bluetooth Address 00 0 D3 01 03 45 User ID EXACT 4 Serial Number 591000029 User Information BOSCH ee Exit BOSCH Click on the Setup button to program the tool Click on the Identification tab next iix ADAN A OE at Copy settings from other screwdriver Job Settings Identification Screwdri
2. Overview ExAConnecT 029 EXACT 4 0 Screw No __ Date _ Time COM Info Counter Status Error Duration Rot 029 EXACT 4 1 18 06 2007 11 55 42 MANUAL 11 5 loK 400ms R pazze 5 5 2 18 06 2007 11 55 48 MANUAL 275 OK 400ms R 11 56 22 3 12 0 2007 11 56 07 _ MANUAL 3 5 NOK i j250ms__ R_ 5 4 18 06 2007 11 56 10 MANUAL 345 JOK _ j300ms R Desa 5 18 06 2007 11 56 15 MANUAL 415 NOK_ 1 j1850ms R_ 6 B 06 2007 11 56 17 MANUAL 4 5 _ INOK i 400ms___ R_ 7 18 06 2007 11 56 18 MANUAL 415 oK 200ms R 8 18 06 2007 11 56 22 MANUAL 6 5 0K 200 ms R 3 Er 18 06 2007 11 56 22 Total 515 ok 40250 ms Pi x Unlock Save I Print Delete 1 missing shut off signal 5 overload error 9 new release signal minimum fastener time not reached 6 minimum job time not reached 10 single NOK results in total NOK 3 maximum fastener time exceeded 7 maximum job time exceeded 11 skip current jol 4 double hit error 8 abort through manual lock 12 data memory full Device BT EXACT 4 User Name 029 EXACT 4 Bluetooth Address 00 0C D3 01 03 45 User ID EXACT 4 Serial Number 591000029 User Information BOSCH Setup i Kem A Exit BOSCH Click on the Unlock button or the picture of the locked tool to unlock the driver The Ford programming sequence is now complete Important Notes for Ford plants Be sure that the AIS box controlling the BT EXACT tools amp EXAConnecT has the
3. Save to XML File Load from XML File OK Apply Cancel Print View Back to Defaults If you have more than one driver connected you will see them here Click on the driver that is already programmed and click on Copy from selected For the last step of programming be sure to UNLOCK the screwdriver once you have completed programming it Click on the picture of the driver or the unlock box below the picture to unlock Overview ExAConnecT 029 EXACT 4 0 Screw No Date Time COM Info Counter Status Error Duration Rot 029 EXACT 4 1 18 06 2007 11 55 42 MANUAL 1 5 loK 400ms R Reser 5 5 2 18 06 2007 11 55 48 MANUAL 2 5 ok s00ms R 3 18 06 2007 11 56 07 MANUAL 315 NOK id 250ms R 4 18 06 2007 11 56 10 MANUAL 3 5 JOK 300 ms R 5 18 06 2007 11 56 15 MANUAL 415 NOK_ j ji850ms R 6 18 06 2007 11 66 17 MANUAL 4 5 NOK ft 400ms__ R 7 18 06 2007 11 5618 MANUAL 475 ok j200ms R 8 18 06 2007 11 56 22 MANUAL 575 0K 200ms R E fie0e2007 11 56 22 Total 515 OK 40250 ms A Save Print Delete 1 missing shut off signal 5 load error 9 new release signal 2 minimum fastener time not hed 6 minimum job time not reached 10 single NOK results in total NOK 3 maximum fastener ded maximum job tim ceeded 11 skip current job 4 double hit error 8 abort through manual l
4. v Data Bits 8 v Parity N Stop Bits 1 Read from Character Position 0 No of Characters to read 0 all remaining 0 Save Cancel Save to XML File Load from XML File OK Apply Cancel Print View 26 The baud rate setting MUST be 57600 Data bits are 8 parity is N stop bits 1 Character position and no of characters to read is zero 0 Note If the EXAConnecT firmware is updated in the future for any reason the baud rate will be reset to the default of 9600 This will cause the I O module to stop communicating with the EXAConnecT Resetting the baud rate to 57600 after a firmware update will immediately fix the problem Refer to section 35 for troubleshooting Click on save then apply then Ok to exit You must now configure each screwdriver to talk with the PLC as desired Refer to section 12 for this setup procedure The names for all connections in the I O module start with EXT so output one of the I O module would be named EXT OUT1 and input one would be named EXT IN1 Otherwise all configuration instructions are the same as shown in section 12 Be sure to save all your settings when you have completed the setup of the system 15 Changing EXAConnecT antenna power time amp date of the real time clock via Serial cable Version 9 2008 Two pages The EXAConnecT cont
5. No Name NumID Count LockNOK Strategy Rot Mins MaxS MinT MaxT 1 DefautEnty 0 0 0 Nocount Re 0o b o 0 2 No count 2 j1 0 No count R L 0 j0 0 0 a 8 batch J3 8 Oo 1 OK R L 0 0 0 0 4 CF mode 4 j1 0 No count _ R UCF 0 io 0 0 5 crossthread 0 4 0 1 OK R L 500 1000 0 0 6 dummy tool 0 1 0 No count R L O 0 0 0 Save to XML File Load from XML File You can create up to 99 more programs as desired Refer to the section on Creating different Tightening Programs for more details Click on Save then Exit You must now connect and program each tool Click on Access point parameters to setup password protection and the ring buffer EXAConnecT Setup z E x Database Automatic Save via FID Barcode Table Tightening Programs identification Screwdrivers Access Point Parameters 9 WLAN Compatibility TCPAP Settings K Language New Password Confirm Password Allow manual lock unlock Operate Data Buffer as Ring Buffer Size of Data Buffer no of Events Save to AML File Load from XML File T gt D OK Apply Cancel Print Setup WARNING Operate data buffer as ring buffer MUST be set to YES for FIFO logic or the controller will LOCK when it reaches the maximum number of screws selected The memory can hold a maximum of 5 000 screws You can set a password h
6. 18 04 2006 11 33 16 115 OK 600ms R oe Exact 4 5 18 04 2006 11 33 18 245 OK 600ms R w Exact 4 5 18 04 2006 11 33 20 315 OK 600ms R Exact 4 5 18 04 2006 111 33 21 415 OK 600ms R et la Exact 4 5 18 04 2006 11 33 23 i515 IOK 550ms R Exact 4 5 18 04 2006 14 33 23 Total 555 lox 7750ms x Lock all screwdrivers Save Print Delete 1 missing shut off signal 5 overload error 9 new release signal 2 minimum fastener time not reached 6 minimum job time not reached 10 single NOK results in total NOK 3 maximum fastener time exceeded 7 maximum job time exceeded 11 skip current job 4 double hit error 8 abort through manual lock 12 data memory full Device Type ExXAConnecT User Name EXAConnecT Bluetooth Address 00 02 C7 50 EF B1 User ID Bosch Serial Number 588000044 Spermrornre E Applet bosch exact started Internet NOTE If you do NOT obtain a connection within 15 30 seconds you need to verify that you can ping the EXAConnecT to see it Refer to troubleshooting sections 27 29 for assistance Now that your computer is connected refer to the appropriate section on programming the system this can be section 3 on basic configuration or the appropriate customer specific section In most cases section 3 is a good starting point Refer to the sections on customer specific settings for BMW Daimler Ford Chrysler or other customer based programming only if you are working on setup
7. Screwdriver released none OoOO Output for Single Result OK Output for Single Docult NOK Output TOT TRIFESTI UF Output for Total Result NOK Reset Output for Total Result Save to XML File Load from XML File OK Apply Cancel Print View Back to Defaults We recommend setting a very short time interval A time of 100 ms milliseconds should be sufficient for the PLC to acknowledge the event WARNING If you set the output signal time too high the PLC may not see a reset on a new screw because the signal is too long This will result in the PLC missing screw data Follow the same procedure for setting the Output for total result OK NOK and Reset output for total result fields Service and Calibration Copy settings from other screwdriver Identification I Screwdriver Settings Job Settings Output Settings Output for Screwdriver released none b Output for Single Result OK none vj Output for Single Result NOK none F Resggeeuiput tor SmMIakResult after 100ms v Output for Total Result OK f Output for Total Result NOK Reset Output for Total Result Save to XML File Load from XML File OK Apply Cancel Print View Back to Defaults Note that if the PLC will perform ALL counting functions and batch strategies you do NOT need to program these 3 fields
8. Microsoft Office Excel 2003 Microsoft Office Outlook 2003 Microsoft Office PowerPoint 2003 Microsoft Office Word 2003 Windows Media Player Fn Java Web Start gt Microsoft Office Access 2003 E Oracle f r Windows NT gt gt D Synchronize GJ windows Explorer y WordPad 21 You must name the session but the name is not important as you will not save it Connection Description J i a New Connection 21x Enter a name and choose an icon for the connection Hame Blustaetl antenna setup corr Now insure that the settings are correct Your connection MUST be through COM1 Be sure you have no conflicts in COM1 such as a PDA etc COM1 Properties Port Settings 21x Bits per second Data bits Parity Stop bits Flow control Restore sp OF Cancel Apply Click on restore defaults to obtain the values above Now set the system for the correct COM port 1 CT 21x D Bluetooth antenna setup Enter details for the phone number that you want to dial Country region United States of America 1 Y Joo4s Phone number Connect using Agere Systems ACS Modem Agere Systems ACO Modem COM Area code COM TEPIP winsik Enter the password bosch in lower case to access the main menu bt HyperTerminal File Edit view Call Transfer Help lel S eka HE HH The main menu is elelee as shown Fie Ed
9. The green LED indicates that the EXAConnecT has performed a self check booted properly and is ready to use with the firmware loaded There are two conditions for this lamp Condition one The green LED is ON The system is OK and ready to use Condition two The lamp is out This indicates that either the system has not completed a self check on startup or that the firmware operating system could be missing If the firmware is missing you have no way to run the EXAConnecT properly and you MUST flash the firmware back onto the controller See section 32 for details on how to restore the operating system If the error message of E4 is displayed in the multi segment digital display above the LED s you can be sure that you need to flash the system to restore the controller to normal status 49 There are some things to look for when diagnosing this problem e ls the EXAConnecT plugged in to a power source The LED will not light if there is no power to the controller e Are any of the other LED s on If you know that tools were connected or that you have a network connection check to see if these lights are on It is entirely POSSIBLE that you can have a good network connection and a yellow LED but still have NO GREEN LED This is because the network server on the EXAConnecT is separate from the operating firmware that runs the tools e Try rebooting the controller first Unplug it and plug it back in before yo
10. 50 ms increments gt 11 56 22 3 18 06 2007 11 56 07 MANUAL 3 5 NOK 1 250ms R 4 18 06 2007 11 56 10 MANUAL 3 5 0K 300ms R E A Desay a he 062007 111 5615 MANUAL 4 5 INOK i Jissoms JR Repeat protection 100 ms increments 6 18 06 2007 11 56 17 MANUAL 415 NOK 1 400ms R 7 18 06 2007 11 56 18 MANUAL 415 ok j200ms R 8 MANUAL 5 0K 200ms R 18 06 2007 11 56 22 51 F Er Jis06 2007 11 66 22 Total rs 0K 40250 ms y y p Unlock Save Print Delete 1 missing shut off signal 5 overload error 9 new release signal 2 minimum fastener time not reached 6 minimum job time not reached 10 single NOK results in total NOK 3 maximum fastener time exceeded 7 maximum job time exceeded 11 skip current job 4 double hit error 8 abort through manual lock 12 data memory full Device BT EXACT 4 User Name 029 EXACT 4 Bluetooth Address 00 0C D3 01 03 45 User ID EXACT 4 Serial Number 591000029 User Information BOSCH Save to XML File Load from XML File ee amp x see 2 ply Cancel Print View Back to Defaults J Exit BOSCH The default for the double hit detection time is 100 Click on the Setup button to program the tool ms You can adjust this as needed to detect and report a double hit error in the system The Identification tab allows you to view the Bluetooth address of the tool You can also name
11. On Off EO OOU NNA nts S00 700 Theft protection delay 5 s increments Double hit detection time 50 ms incre Repeat protection 100 ms increments Save to XML File Load from XML File OK Apply Cancel Print View Back to Defaults The default for the double hit detection time is 100 ms You can adjust this as needed to detect and report a double hit error in the system This value is reported as error code number four 4 in the system and will allow the screwdriver to keep working but report that screw as being double hit Repeat protection is different and independent from a double hit This field controls the time that the trigger does NOT work after the last screw was run If you set the repeat protection to 700 ms that means the trigger will not run the tool even when depressed until at least 700 ms has passed from the time the trigger was last released This is adjustable down to a minimum of 300 ms Note that if you disable the communication and theft protection by clicking Off the tool will not report data to an EXAConnecT If this is desired see the Making a BT EXACT into a standard EXACT tool in section 10 for details Click on the Job Settings tab to continue Screwdriver Setup ioj x Service and Calibration Copy settings from other screygies n i f identification Screwdriver
12. Only program these fields if the screwdriver will be counting a complete batch In the screwdriver setup menu click on Job settings to configure the input for each tool You will need to go into each tool separately icxi Service and Calibration Copy settings from other scre Identification Screwdriver Settings Job Settings i Job Definition Program Program Number if static dynamic via Barcode Table Job Release dynamic via Protocol Rework Release 1 x left rotation Job Cancelation Manually 4 ln i Save to XML File Load from XML File OK Apply Cancel Print View Back to Defaults Be sure to choose Static as the job program This insures that only the PLC input is accepted Now check the program number assigned to the tool Be sure that it is set to your desired configuration If the tool is set to be unlocked all the time and the PLC will do all the counting it should be set to the program you created named no count 5x Service and Calibration i Copy settings from other screwdriver ss Identification Screwdriver Settings I Job Settings Output Settings pasinina dynamic via Protocol M Program Number if static 1 j Job Release Manually bd Rework Release 1 x left rotation Manually esl Job Cancelation Manual
13. Program Number for Screwdriver 0 4 Program Number for Screwdriver 1 0 Program Number for Screwdriver 2 0 Program Number for Screwdriver 3 lo Program Number for Screwdriver 4 Program Number for Screwdriver 5 0 Program Number for Screwdriver 6 0 New Save Delete NOTE Take values to edit fields by clicking on row in table ee T ae Tightening Program for Screwdriver No Bar seek 22h Sere 1 o p 0 0 0 Save to XML File Load from XML File Exit 14 If you need to make a new table entry just click on new and create the desired table Entry Number Oj x Barcode Mask up to 31 chars any Program Number for Screwdriver 0 Program Number for Screwdriver 1 Program Number for Screwdriver 2 leo Program Number for Screwdriver 3 lg i Program Number for Screwdriver 4 f Program Number for Screwdriver 5 29 Program Number for Screwdriver 6 15 LiT Detete NOTE Take values to edit fields by clicking on row in table Tightening Program for Screwdriver DERSE 4 o b b b b b No p Barcode Mask 1 E O SRE Save to XML File Load from XML File You can define the exact bar code mask you want the system to use and define which of the 99 tightening programs each screwdriver will use when that bar code scan is active Note that in our example ab
14. have the PLC send a rework release to let the tool turn left to remove a screw on a NOK if desired Select the Rework release box and assign an input as needed You can also use the job cancellation function to lock a tool on a PLC input if needed Screwdriver Setup E ioj xj Service and Calibration Copy settings from other screwdriver Identification Screwdriver Settings Job Settings Output Settings Job Definition Program dynamic via Protocol bi Program Number if static 1 Job Release Manually MM Perens oars eft rotation Manually bdl Job Cancelation Select this function and choose an input source as needed The tool can be locked by a PLC via this input regardless of preset count strategy If the tool is locked prematurely error code 11 will be set 4 Manually v When you are done with the first tool save the settings by clicking on apply Click on OK and move to the next screwdriver as needed Note If you are configuring a Bosch digital I O module all functions for setup will be the same as shown here in section 12 The ONLY difference will be that you must choose the external inputs and outputs from the software menus which are clearly marked in the pull down menus as EXT OUT 1 16 and EXT IN 1 16 Save all settings and exit the setup menus 13 Digital I O Module Hard Wir
15. v Program Number if static Job Release Rework Release 1 x left rotation Job Cancelation Manually v Save to XML File Load from XML File OK Apply cancer Print View Back to Defaults You can do this in the screwdriver setup menu of each individual tool Save your settings and test the system for correct operation 22 BMW KISS Q protocol configuration Version 9 2008 One page The BMW protocol is used for all BMW assembly plants worldwide This protocol allows the EXAConnecT to communicate directly with the BMW network via the Ethernet connection KISS Q is an abbreviation for the BMW network system that monitors tool data and screw count To configure the BMW protocol you will need to go to the EXAConnecT setup menu and select the database tab Open the pull down menu and select BMW KISS Q from the list exatonnect Setup Hx Database Automatic Save via FTP COM Port Devices Barcode Table Tightening Programs Identification Screwdrivers Access Point Parameters WLAN Compatibility TCPAP Settings Save to XML File Load from XML File Cancel al Print View You MUST click on apply to confirm that you have selected the correct protocol BEFORE moving to the next steps in the setup process Now Click on the setup button to configure the system for the desired BMW assembly plant You must t
16. 3 Firmware mismatch between I O amp EXAConnecT The firmware in the I O module loads automatically and normally requires no service or reconfiguration by the end user Contact Bosch if there are concerns or questions about I O module firmware 56 NOTE If a new version of EXAConnecT firmware is flash installed onto the EXAConnecT the default baud rate of 9600 will be set in the controller You MUST reset the baud rate in the EXAConnecT to 57600 or there will be NO communication from EXAConnecT to I O module Normally most installations will get power for the I O module from the 24 volt power supply of the EXAConnecT Note that if the I O module gets its power externally from another source the power cannot remain on at the I O module when the EXAConnecT is powered down No damage to the I O would occur but the I O module needs to be powered up at the same time as the EXAConnecT to establish a communication link Bosch recommends that the I O module power be taken only from the EXAConnecT Contact Bosch if further assistance is needed 36 EXAConnecT Status amp Error code message list Firmware Version 1 99 10 Version 9 2008 Five pages All status and error codes are displayed in the double digit 7 segment display of the controller and in the Java software in the tabs EXAConnecT and Overview Error codes which refer to the connectivity or failure of the controller may only be shown in the software If several status o
17. 31 chars any Program Number for Screwdriver 0 Program Number for Screwdriver 1 Program Number for Screwdriver 2 Program Number for Screwdriver 3 Program Number for Screwdriver 4 Program Number for Screwdriver 5 Program Number for Screwdriver 6 New Save Delete NOTE Take values to edit fields by clicking on row in table 0 Barcode Mask T LHRH B RARE 10 TLA D LA Note that the tools pick different programs depending on which type of car comes down the assembly line Screwdriver 0 runs program 10 or 12 depending on bar code and screwdriver 1 runs program 11 or 13 Again up to 99 bar code programs and 99 separate tightening programs can be created and combined as needed Remember that you MUST create tightening programs separately otherwise the bar code tables will have nothing to reference and the setup will be incomplete Refer to section 7 for details on creating tightening programs 9 Screwdriver Setup Advanced Version 9 2008 Two pages As with the stand alone setup each tool must be configured to run properly Advanced settings allow you to control the tools from either a bar code scanner connected to the EXAConnecT a PLC or other 24 volt input or from a customer specific Ethernet protocol Click on the tab of the tool you want to configure Be sure the screwdriver is in range amp locked or you will not be able to program it
18. Check or repair Ethernet connection to host system Check AIS box Ford or other network interface for proper function The error message will disappear once the problem is fixed The AIS box Ford is sending incorrect data or another protocol is sending incorrect data The data packets exist and are being sent but are not understood by the EXAConnecT Corrective action For Ford check the AIS box check to see that the Ethernet speed of the AIS box is correct or install a Turck switch between the AIS box and the EXAConnecT Contact CEC Superior Controls For all other customer protocols check settings and interface of the protocol and network system 61 BOSCH PRODUCTION TOOLS N A 1800 West Central Road Mt Prospect IL 60056 224 232 3200 Specifications subject to Change without notice 62
19. Save your settings and test the system for correct operation 24 Ford Open Protocol Configuration Version 9 2008 Two pages The settings described here are for use in any Ford assembly plant that uses the combination of AIS box and QLS to error proof an operation Each EXAConnecT controller runs up to 7 BT EXACT cordless tools needing only 1 Ethernet connection from controller to AIS box Multiple controllers can be run by a single AIS box if desired Most functions of the EXAConnecT are programmed via its Ethernet connection For setup of time date and antenna strength refer to section 15 on RS 232 serial programming Use a crossover Ethernet cable and female coupling to connect a PC to the EXAConnecT Ethernet cable Power up the EXAConnecT and follow the steps in sections 1 amp 2 to configure your PC to communicate Setup the IP address based on the assigned addresses as listed here When you are completed with this ENTIRE program sequence restart the EXAConnecT and plug the Ethernet connection into the AIS box switch hub You may also choose to setup the desired IP address make the Ethernet connection to the AIS box and then connect a laptop directly to an AIS box for programming of the EXAConnecT It is preferable to have an RJ 45 crossover cable attached to a Turck switch on the AIS box to allow easy access to the EXAConnecT The latest Bosch version of AIS firmware must be loaded to communicate with the E
20. XML File Exit Choose a program number in the program number field Do NOT pick a number already in use Choose a program name you will be able to recognize 10 characters is the maximum The numeric ID field is not normally used It is a sequencing field for some customer specific protocols Leave it blank Select the number of fasteners per job The count here may NOT be zero If you want the program to fail a batch after a specific number of NOK screws input a value in the lock after number of fasteners NOK field Select the count strategy If you want the tools to run unlocked all the time select do not count fasteners If do not count fasteners is selected the tools will unlock automatically after the controller powers on or after a power failure when power is restored NOTE If any other strategy is selected the tools MUST have an input signal bar code scanner or protocol release signal to release them to run 12 Edit Tightening Programs ioj xj Program Number 4 M Name Default Entry Numeric ID o Number of fasteners per job Lock after number of fasteners NOK lo Count Strategy Do not count fasteners Plus 1 if OK Plus 1 if OK or NOK R Reset to 0 if NOK Rotation Min fastener time 50 ms increments Max fastener time 50 ms increments Min job time 250 ms increments 0 Max job time 250 ms increments
21. clear if the FTP server connection is reestablished Be sure to save all your settings before exiting the setup phy Cancel Print View An available FTP demo server program is available from Bosch to show or test the FTP function Contact Bosch or your distributor for details 27 The Blue LED is not lit troubleshooting Version 9 2008 One page The EXAConnecT is equipped with a full system of self diagnostics that can help identify conditions and problems The following pages will help you diagnose conditions and corrections The EXAConnecT has 3 LED lamps to indicate status and a 2 digit multi segment display for error codes The blue LED indicates that the controller sees at least ONE BT EXACT tool within range and that a Bluetooth connection IS ESTABLISHED between at least one tool and the EXAConnecT If the LED is on the controller has a connection to at least one tool If the LED is OFF the controller does not have a Bluetooth connection to a tool This does NOT mean there are no tools configured to that controller it only means that the controller does not currently see any of the tools that either were connected to it or that no tools have been connected to that controller If a tool was CONNECTED but is now missing out of range or has the battery removed the 2 digit display above the LED s would indicate the error messages that show the missing tools CO through C6 45 2
22. demands The system draws less than 200 mA nominal wire size of the 3 prong power cable is 18 gauge Neutral Load hot The power terminal is marked L load N neutral and L ground Wire the system as shown above The Ethernet connection is marked 100MB If the EXAConnecT is connected to a PC use the crossover configuration shown For connection to a network use the 1 1 network connection Pin Color of the leads e g whiteorange orange whitegreen blue white blue green brown Cut and use a standard category 5 Ethernet cable with an RJ 45 jack on the end for easy connections 2 EXAConnecT to PC Connections First step in initial programming Version 9 2008 Two pages One EXAConnecT controller runs up to seven BT EXACT cordless tools A single Ethernet connection from controller to PC is needed for programming Most functions of the EXAConnecT are programmed via its Ethernet connection For setup of time date amp antenna strength refer to section 15 The system does NOT require special software to be loaded on a PC A common browser like Internet Explorer or Firefox is used to go to an I P address for programming and data recovery Connect the EXAConnecT Ethernet cable to your PC Note that the connection MUST be a crossover type to successfully communicate with the controller You MUST be able to change your PC network settings to program an EXAConnecT system
23. g w See Pl http 10 10 10 10 i view EXAConnecT 029 EXACT 4 0 dii Screwdriver __ Date Time COM info Coun onnecT 029 EXAC 18 06 2007 14 41 20 oro eee TORUDIE PAEA Oe E h an Be sure that the yellow LED on the EXAConnecT is LIT and BLINKING when you are trying to connect and communicate No yellow light means you do NOT have a connection to the EXAConnecT A solid yellow light means the EXAConnecT is connected but is not yet talking to your PC You MUST have a blinking yellow light while connected Click on the EXAConnecT tab to program the controller then click on setup You must configure the controller first then connect and configure tools m o OG Ou Grow Gan FOES a Address http 10 10 10 10 z Go Exact 4 591000028 0 EXACO a r Date Time COM Info Counter Status Error Duration Rot ALTS I TUUN ZOUU TIVAN TI on E yes in Mode STAND ALONE 18 04 2006 11 31 21 215 OK 650ms R COM1 Barcode Scanner Exact 12 18 04 2006 11 31 38 215 OK 750 ms IR ee i Exact 12 18 04 2006 11 31 44 215 OK 750ms R SOREL mene Angle 15 18 04 2006 11 31 48 215 OK 700ms IR Exact 12 18 04 2006 11 31 53 215 OK s00ms R Exact 12 18 04 2006 11 31 58 215 OK 800ms IR System rezdy Exact 4 5 18 04 2006 11 33 09 515 OK 550ms IR Exact 4 5 18 04 2006 11 33 09 _ Total 515 INOK 7 645000 ms Exact 4 5
24. i New Save Delete New NOTE Take values to edit fields by clicking on row in table No Name NumID Count LockNOK Strategy Rot MinS MaxS MinT MaxT Defaultenty 0 5 0 ok Ra o b o b 2 No count 2 1 o INocount R eL O O 0 0 3 S batch B le lo 1ok_ _ R o bo fo 4 CF mode 4 j jo Nocount ReucFo 0 0 10 5 crossthread 0 4 jo _ 1 0K IR L_ 600 1000 0 0 6 dummy tool jo 1 0 No count R L O 0 0 0 Save to XML File Load from XML File Et Count strategy is set in the pull down box You have four choices Choose the strategy that best fits your requirements Other strategy choices are as follows A strategy of plus one if OK means that the count will only advance when an OK is obtained Example screw count is set to a batch of 3 Screw one of three is OK the count moves to 1 of 3 Screw two is NOK the count holds at 1 of 3 Screw three is OK the count moves to 2 of 3 Screw four is OK the count is 3 of 3 and gives a total OK for the batch A strategy of plus one if OK or NOK means that the count will advance when an OK or NOK is seen Example screw count is set to a batch of 3 Screw one of three is OK the count moves to 1 of 3 Screw two is NOK the count moves to 2 of 3 Screw three is OK the count moves to 3 of 3 The batch FAILS due to the detection of a NOK signal A strategy of Reset to 0 if NO
25. is in the stand alone screwdriver setup in section six and in the advanced screwdriver setup in section eight 8 Creating Bar Code Tables Version 9 2008 Two pages The EXAConnecT can have up to two bar code scanners connected to run all tools as needed If you will be using a scanner to control the tools you will need to create bar code tables to assign tightening programs to any given screwdriver This allows you to configure up to 7 tools to release on a single scan using any of 99 different tightening programs stored in the EXAConnecT controller For details on wiring and setup refer to section 16 Click on the tab marked bar code table t to start EXAConnecT Setup loj xj Database Automatic Save via FTP COMPo Devices V BPrograms identification Screwdrivers Access Point Paramete TCPAP Settings Tightening Program for Screwd river _ N E Sle aie o b p p No i Barcode Mask ey ee 1 RE STE 4 0 Edit Barcode Table Save to XML File Load from XML File OK Apply Cancel Print View Now click on the edit barcode table button and a new window will appear Highlight the default barcode mask to begin editing the siiis Edit Barcode Table lol x Entry Number l1 Barcode Mask up to 31 chars any ARASH STH
26. of fasteners We suggest a very high value like 10 million Just remember that whatever you set this value at the tool will STOP running when it reaches the total number of OK screws programmed here 17 The next calibration date field is inactive You may input any data you wish here as the field is not tied to the real time clock in the controller This tool program sequence must be repeated for each additional screwdriver you wish to connect to the EXAConnecT You do not need to repeat the controller program sequence lf you have more tools to configure like the first tool go to the tab for the next tool then click on the Copy settings from other screwdriver tab Screwdriver Setup Service and Calibration Copy settings from other screwdriver 2 wanEattiage Job Settings Identification Output Settings Copy from selected Save to XML File Load from XML File OK Apply Cancel Print View Back to Defaults If you have more than one driver connected you will see them here Click on the driver that is already programmed and click on Copy from selected For the last step of programming be sure to UNLOCK the screwdriver once you have completed programming it Click on the picture of the driver or the unlock box below the picture to unlock
27. of the tools The standard dynamic mode of Bluetooth is adaptive and needs a certain amount of regular data transfer to work effectively We cannot eliminate every potential for interference from Bluetooth to a wireless LAN in this mode The static mode is completely risk free for a Wireless LAN since we can exclude the Wireless LAN frequencies from standard Bluetooth communication paths Let s assume that we have identified the 3 active LAN channels in a plant and we want to keep the Bosch system from getting too close to these channels We can statically exclude the Bluetooth frequencies that would interfere with Wireless LAN channels 5 through 13 Note that normally we only need to block THREE 3 Bluetooth channels from hitting Wi Fi but in the next example we blocked nine to show that the system Is capable 33 EXAConnecT Setup a hes ing Programs Database Automatic Save via FTP COM Port Devices Bares lt a sor identification Screwdrivers fers WLAN Compatibility TCPSP Access Point Paran WLAN Channel Number Exclude WLAN Channels a ia Exclusion window size Remaining BT Channels shall be gt 20 Automatic Bluetooth reconnect Bluetooth reconnect trigger Manually x Bluetooth reconnect Bluetooth auto reconnect OFF warning none v Saveto XML File Load from XML File OK Apply Cancel Prin
28. on the file named start bat This will open the service tool 2 E AConnectT Service Tool Programm Optionen Hilfe ExaConnectT hinzuf gen Ey EXA iini oo deutsch You may need to change the language of the service tool from German to English Click on optionen sprache English as shown above Now connect the service tool to the controller The example shown below is for a default IP address of 10 10 10 10 This default connection is always in the service tool software You can add more controllers with different IP addresses as needed shown later in this section ExXAConnect Service Tool Program Options Fla Exc SEF mm Help onnecT a Left click once on the default controller box to start the connection process 53 2 EXAConnectT Service Tool Program Options Help Connect Disconnect cery Skakus Query Configuration P Firmware Update Administrate Files Administrate Password Es Connect Reset PrnnethHes A menu window appears with several choices Select connect disconnect and the service tool software will try to connect to the controller The default icon will turn green when the connection is successful If your IP settings are correct the service tool will confirm the connection Connecting Default Default is connected You can open the log window to full size if needed To select
29. password ExAConnecT Service Tool Program Options Help E ExAConnecT E Manage Password Default Default Old Password cD I New Password Confirm New Password ns Apply Cancel Add another EXAConnecT To add a controller with a DIFFERENT IP address from the default of 10 10 10 10 go to options and select add EXAConnecT from the menu amp EXAConnecT Service Tool Program Options Help te p E EX 54 Input the new IP address of the controller you want to save in the window below You can name the controller as needed 2 EXAConnecT Service Tool Program Options Help ConnecT BPW bode q ORERE IP Address 192 165 4 211 Alias Mame Doors left line one gave Cancel This controller will be permanently saved in the directory of your specific service tool software until you delete it The service tool holds up to 250 different EXAConnecT IP addresses Firmware update via service tool The RECOMMENDED method of updating firmware is to flash the files using procedures in section 32 The flash update will ERASE all data screwdrivers and settings You MUST flash if you are migrating from one generation of firmware to another e g from 1 98 to 1 99 If you use the service tool for this type of update you WILL cause performance problems in the system NEVER use the service tool to upgrade from one generation of firmware to another That s
30. password if desired Click on Save then Exit You must now connect and program each tool as desired 25 Screwdriver Setup Ford Protocol Click on the Screwdriver settings tab to configure Version 9 2008 Three pages the repeat protection setup You need to connect the screwdrivers before Set the repeat protection of the tool to 300 ms This programming them Refer to section 4 for screwdriver will allow the operators to work quickly Now auto connect setup or section 5 for manual setup configure the theft protection setting We suggest a minimum time of 5 seconds the tool will now lock Each tool must be configured to run properly Click within 5 seconds after it is out of range on the tab of the desired tool you want to configure lo x Service and Calibration Copy settings from other screwdriver Identification Screwdriver Settings Job Settings Output Settings Be sure that the driver you want to program is in range amp locked or you will not be able to program it Overview EXAConnecT 029 EXACT 4 0 Communication and theft protection ScrewNo Date Time COM Info Counter Status Error Duration Rot Theft protection delay 5 s increments 029 EXACT 4 1 18 06 2007 11 55 42 MANUAL 1175 OK 0ms R peer 5 5 2 18 06 2007 11 55 48 MANUAL 2 5 OK _ fi 400ms__ R Double hit detection time
31. prior to programming and unlocking the tool All other fields in this tab can be left at their defaults There is no need to configure any other settings since these are not used Pile es Screwdriver Settings Job Settings Output Settings Limit absolute number of fasteners 45 554 985 _ Next Calibration date DDMMYY DDMMYY Save to XML File Load from XML File OK Apply Cancel Print View Back to Defaults You MUST set a count for the absolute number of fasteners We suggest a very high value like 10 million Just remember that whatever you set this value at the tool will STOP running when it reaches the total number of OK screws programmed here 10 The next calibration date field is inactive You may input any data you wish here as the field is not tied to the real time clock in the controller This tool program sequence must be repeated for each additional screwdriver you wish to connect to the EXAConnecT You do not need to repeat the controller program sequence lf you have more tools to configure like the first tool go to the tab for the next tool then click on the Copy settings from other screwdriver tab Screwdriver Setup Service and Calibration Copy settings from other screwdriver 2 attie Job Settings Identification Output Settings Copy from selected
32. what command you need right click again on the green default icon 2 EXAConnecT Service Tool Program Options Help Sa Connect Disconnect Crary Status Query Configuration P Firmware Update Administrate Files d Administrate Password Esa Connect Reset Fronerties You can check the configuration of the EXAConnecT and screwdrivers check connectivity status update firmware administrate files delete or load set or delete passwords or restart the EXAConnecT Access point EXAConnecT amp screwdriver query This function allows you to check the settings of the controller or any screwdriver without opening the actual firmware pictured on next page amp EXAConnecT Service Tool Program Options Help fault nnected Connect f Disconnect Query Status Query Configuration Access Point Firmware Update pps Seu Administrate Files ion is 1 99 8 10 May 2007 ered screwdrivers 1 Administrate Password Ex A C onnecT Reset i 3 in ring buffer 16 Properties ash disk Remember that to RETURN to the root setup menu RIGHT click on the default connection and then select the desired function Set clear or reveal a password Right click on administrate password and the menu below is displayed NOTE This is the ONLY place where you can reveal a password If you forgot the password in the EXAConnecT you must come to this menu to view and change the
33. 8 The yellow LED is not lit troubleshooting Version 9 2008 One page The EXAConnecT is equipped with a full system of self diagnostics that can help identify conditions and problems The following pages will help you diagnose conditions and corrections The EXAConnecT has 3 LED lamps to indicate status and a 2 digit multi segment display for error codes The yellow LED indicates data and or a connection to an Ethernet link This can mean a connection from the EXAConnecT to a PC or to a host network e VEE There are three conditions for this lamp Condition one When the yellow LED is OFF as shown above this indicates that the EXAConnecT does NOT see a connection to an Ethernet link Causes of this condition could be 1 The EXAConnecT is not plugged into an Ethernet port PC or network 2 The Ethernet connection is not wired correctly or is loose 3 The PC or network card is turned off Condition two When the yellow LED is SOLID this indicates that there is a connection from 46 EXAConnecT to an Ethernet source like a PC or network Please note that a SOLID LED only indicates that the EXAConnecT sees a connection This does NOT mean that any DATA is being sent to or from the EXAConnecT to the network or PC Under normal conditions the yellow LED will turn on and remain solid when first connected to a PC it will then begin blinking when you open your browser or send data or commands to the EXAConnecT C
34. AIS box For example removal of a battery from the tool will NOT set a red alarm in an AIS box in the same way that a DC electric tool would set an alarm if it was disconnected from the cable A removed battery or tool out of range will set an orange alert The system will set alerts for lost trigger operator released trigger instead of running screw re hit lost communication with tool lost communication with controller etc These errors will display in the AIS Consult with the proper technician from CEC controls or Superior Controls before connecting any EXAConnecT to the Ford Error proofing system Contact your Bosch distributor or Bosch for further assistance if needed 26 FTP Client server configuration Version 9 2008 One page The EXAConnecT can output completed screw data to an FTP client server running on any common PC or network server The data format is in an Excel spreadsheet and can be output based on time of day or number of screws desired per spreadsheet This information can be output simultaneously even when running some Ethernet based customer protocols or when switching the 24 volt I O s Setup of the FTP file transfer protocol is done in the EXAConnecT automatic save via FTP tab 2 EXAConnecT e __ Se loj x Database Automatic Save via FTP CGM Port Devices l Barcode Table Tightening Programs Identificatio nim PSs Point Parameter
35. Are S SBRobert E Create Shortcut Delete Rename Local Area Connection Type LAM Connection Status Enabled Broadcom Netktreme Gigabit Ethernet Select internet protocol and click on properties This takes you to the configuration screen Local Area Connection Properties ajx General Sharing Connect using BY Broadcom Netstreme Gigabit Ethernet Components checked are used by thie connection Install i Uninstall CZ Properties gt i 8 TI mm _ EN a m 3 Setup the correct protocol Change it to use the following IP address If you are connecting to a new EXAConneclT setup the IP address and subnet mask EXACTLY as shown The EXAConnecT default IP address is 10 10 10 10 your PC needs to be in the same range but not the same address Enter an IP address of 10 10 10 5 and a subnet mask of 255 255 255 0 Click on OK to accept the changes Wie ORI Rohe th SL Ly C Obtain an P address automatically Use the following IP address IF address Subnet mask 255 255 255 0 J Default gateway Open your internet browser and type 10 10 10 10 The browser will briefly display a Java logo and then open the EXAConnecT software If it does not open quickly refer to sections 28 29 EXA4ConnecT BT Access Point Microsoft Internet Explorer provided by Peacy it View Favorites Tools Help raat TES Search Favorites Media zy B5
36. BT EXACT Tools OPERATING INSTRUCTIONS FOR ALL PROTOCOLS amp CONFIGURATIONS v 9 2008 BOSCH Invented for life Bluetooth EXACT System Programming amp Setup Instructions EXAConnecT TABLE OF CONTENTS Getting started basic setup 1 EXAConnecT wiring EXAConnecT to PC connections Screwdriver auto connect Screwdriver manual connection Screwdriver setup stand alone ce O1 amp OG DN Getting started advanced setup 7 Creating tightening programs amp batch counting 8 Creating bar code tables 9 Screwdriver setup advanced 10 Making a BT EXACT into a standard EXACT optional Basic PLC connections 11 Basic 24V PLC connections 12 Software configuration of I O ports Digital I O module advanced PLC 13 Hard wiring the I O module 14 Software configuration of I O ports RS 232 Programming 15 Changing antenna power time amp date of the real time clock External hardware bar code scanners stack lights reset push buttons etc 16 Bar code scanner wiring setup 17 Stack lights 18 Release push buttons EXAConnecT configuration stand alone 9 10 11 13 14 15 16 17 19 20 21 22 23 25 26 2 28 29 30 32 Wireless LAN blocking to prevent interference 19 Blocking Bluetooth from interfering with Wi Fi frequencies Atlas Copco open protocol 20 EXAConnecT Atlas configuration Bosch protocol 21 EXAConnecT Bosch configuration BMW KISS Q protocol 22 EXA
37. ConnecT Go to the EXAConnecT setup menu click on COM port devices and click on COM1 parameter setup Open the pull down menu and select IO Extension 1x if you are connecting a single I O Module Pleies Database Automatic Save via FTP COM Port Devices Barcode Table Tightening Programs 7 Identification Screwdrivers Access Point Parameters WLAN Compatibility TCPAP Settings Device on COM1 COM Parameter Setup Device on COM2 COM2 Parameter Setup Save to XML File Load from XML File OK Apply Cancel Print View If you were to assign a second I O module just perform a similar operation by selecting the COM1 parameter setup button and select the 2x module from the pull down menu This tells the system that you have two I O modules connected in series You may also use COM2 if COM1 is being used by another device like a bar code scanner Just remember that the I O modules MUST be wired in series as noted in the previous section Configure the baud rate and other data EXAConnecT Setup 10 x Database Automatic Save via FTP COM Port Devices Barcode Table Tightening Programs f identification Screwdrivers Access Point Parameters WLAN Compatibility TCPAP Settings Device on COM1 Barcode Scanner M COM1 Parameter Setup a Baudrate 57600
38. ConnecT BMW configuration Chrysler USA PFCS protocol 23 EXAConnecT PFCS configuration Ford protocol Ethernet to AIS box 24 EXAConnecT Ford configuration 25 Screwdriver setup Ford protocol 33 34 35 36 37 38 39 40 41 43 FTP Client server 26 Setup of server 44 Troubleshooting amp problem diagnosis 27 The blue Bluetooth LED is not lit 45 28 The yellow network LED is not lit 46 29 Why can t connect to the EXAConnecT 47 48 30 The green system LED is not lit or the E4 error code is displayed 49 31 Tools are locked and will not unlock 50 32 Flash installation of firmware 51 33 Hardware buttons and switches 52 34 Using the service tool software 53 55 35 Digital O module diagnosis 56 36 Error message list 57 61 NOTICE TO FIRST TIME USERS You do NOT need to read this entire manual Breathe easy and relax This manual is comprised of small sections that are usually one to three pages long Most pages consist of pictures with as few words as possible You only need to refer to the sections applicable to your task To configure a system for basic operation you need sections 2 3 4 and 6 a total of 6 pages For a customer specific protocol such as Ford you need only sections 2 24 amp 25 Try to think of what you want to do and then look for that function in the section titles You can save yourself a lot of time by reading only what you need and you can solve most any problem by readin
39. If you are NOT an administrator of your PC you will not be able to communicate with the EXAConnecT Begin setup of anew EXAConnecT by changing your network settings Depending on your operating system Windows 2000 XP go to your setup screen for the local area connection as shown g New Office Document E3 Open Office Document IE HP Image Zone t HF Director A Programs 3 Documents ee N Search 2 ae 2 Printers FA Rane SA Taskbar amp Start Menu mp Shut Down Astar Qs Ee eee er Dial up Connections Next go to the primary network connection fe Network and Dial up Connections File Edit View Favorites Tools Advanced Help eg ls Gs gt amp wa Eee de Back mp ty SA Search C3 Folders Address Network and Dial up Connections Make New Connection Lo iC al Area mal tio n fa Network and Dial up 4Local area Confiittion Broadcom Netktreme Gigabit Ee Connections Local Area Con BRobert Bosch Remote Access Dial up Local Area Connection Right click on the primary network connection Select oroperties from the menu EY Network and Dial up Connections File Edit View Favorites Tools Advanced Help qa Gack mp tg Search CH Folders 4 as D x ey Ez Address 2 Network and Dial up Connections Make New Connection LAN LAN LAN Dial up Disable Network and Dial up Local are nes Connections ae Local
40. Java runtime loaded see below to communicate e You must have a working Ethernet card You must be running MS Windows Vista is not supported at this time e You must be able to make changes to your local area connections e f connecting from a PC directly to the EXAConnecT you must insure that the wiring is configured for a crossover connection see section 1 to verify Symptom My PC is connected and my browser is open and running have input a target IP address of 10 10 10 10 but the browser just runs or times out without making a connection to the EXAConnecT The yellow LED is SOLID Corrections e You need to check several things First make sure that the wiring from the EXAConnecT is correct Refer to page 3 to verify the connection e Make sure you have Java loaded on your PC or the system will never connect e Make sure that the default IP address of the EXAConnecT is 10 10 10 10 and that your IP address in your PC network connection is 10 10 10 5 Check the subnet mask too See pages 4 5 to verify e Verify that you can change your IP address If you are not the administrator of your computer you may not be able to change your settings e Make sure that IF another IP address was assigned to the EXAConnecT other than the default you are either in the domain of that IP address or you have moved dip switch ONE into the down position and restarted the controller Flipping the switch down and resta
41. K means that the count will clear when a NOK is obtained Example screw count is set to a batch of 3 Screw one of three is OK the count moves to 1 of 3 Screw two is OK the count moves to 2 of 3 Screw three is NOK the count resets to 0 of 3 and gives a NOK for the batch Now set the allowed tool rotation direction Edit Tightening Programs Oj x Program Number 1 4 Name Defa ult Entry Numeric ID lo Number of fasteners per job 6 Lock after number of fasteners NOK lo Count Strategy Plus 1 if OK v Rotation Right and Left v Right and Left Min fastener time 50 ms increments Max fastener time 50 ms increments Min job time 250 ms increments Max job time 250 ms increments New Save Delete NOTE Take values to edit fields by clicking on row in table No Name Strategy Rot NumID Count LockNoKk Mins maxs MinT MaxT 1 DefaultEntry 0 6 Re 0 w i 2 No count 2 a o Nocount Re o o o o 3 Bbatch B Bb b 10K Re b b lb lo 4 CFmode 4 1 o INocount ReucFo lo jo J0 5 cross thread lo 4 0 1 OK R L 500 1000 if iO 6 dummy tool 0 1 0 INocount R L 0 0 lo 0 Load from XML File Save to XML File Exit Note that you have several choices of rotation If you set the tool to right and left the tool will be allowed to turn f
42. L that the data buffer is set to operate as a ring buffer first in first out or FIFO If this setting is set to NO then the controller will lock all the tools when the total number of events is reached It is imperative that this selection be set to YES The EXAConnecT stores up to 5 000 completed screws OK and NOK for all seven screwdrivers combined Note that you MUST restart the EXAConnecT after a change in the data buffer settings The system will prompt you for this You can restart the controller by unplugging and plugging it back in pressing the reset button section 33 or using the service tool software to restart the controller section 34 Other possible conditions that might lock a tool are controlled in the tool setup menus Go to the 50 screwdriver setup menu and click on the service and calibration tab 2151 Service and Calibration Copy settings from other screwdriver Identification d Screwdriver Settings Job Settings Output Settings Limit absolute number of fasteners Next Calibration date DDMMYY Save to XML File Load from XML File OK Apply Cancel Print View Back to Defaults Note the setting for limit absolute number of fasteners This setting is a soft count of completed OK screws That means that if you set this value to 100 000 the tool will count down backwards from 100 000 until it re
43. Load from XML File Save to XML File OK Apply Cancel Print View Back to Defaults Start by selecting the Output for single result OK box A pull down menu will allow you to choose your output Based on our examples above you would select output one for the first screwdriver 0 Now go to the next pull down box which is Output for single result NOK Service and Calibration Copy settings from other screwdriver Screwdriver Settings Job Settings Identification Output for Total Result OK Output for Total Result NOK Reset Output for Total Result Save to XML File Load from XML File OK Apply al Cancel Print View Back to Defaults Select output two as your choice if this is screwdriver 0 or select whatever output you wish to use based on how you wired the EXAConnecT 21 You must now set the signal ON time to insure that the PLC captures the event The next menu item to program is the Reset output for single result box This sets the time that the signal will remain on and the optical contact closed for both the single OK and single NOK Screwdriver setup n Service and Calibration Copy settings from other screwdriver Identification Screwdriver Settings Job Settings i Peles Output Settings y Output for
44. Overview ExAConnecT 029 EXACT 4 0 ScrewNo Date Time COM Info Counter Status Error Duration Rot 029 EXACT 4 1 18 06 2007 11 55 42 MANUAL 175 oK 400ms R przeze 5 5 2 18 06 2007 11 55 48 MANUAL 215 OK 400 ms R 3 18 06 2007 11 56 07 MANUAL ERE NOK 1 250 ms R 4 18 06 2007 11 56 10 MANUAL 375 lok Booms R 5 18 06 2007 11 56 15 MANUAL 415 NOK _ j jesoms R 6 18 06 2007 11 56 17 MANUAL 4 5 Nok fi 400ms R 7 1 8 06 2007 11 56 18 MANUAL 4 5 OK 200 ms IR 8 18 06 2007 11 56 22 MANUAL 515 0K 200 ms R E feos2007 11 56 22 Total 5r5 0K 40250 ms Save Print Delete 1 missing shut off signal 5 overload error 9 new release signal 2 minimum fastener time not reached 6 minimum job time not reached 10 single NOK results in total NOK 3 maximum fastener time exceeded maximum job time exceeded 11 skip current job 4 double hit error 8 abort through manual lock 12 data memory full Device BT EXACT 4 User Name 029 EXACT 4 Bluetooth Address 00 0C D3 01 03 45 User ID EXACT 4 Serial Number 591000029 User Information BOSCH Setup Exit BOSCH Click on the Unlock button or click on the picture of the locked tool X to unlock the driver Note that some protocols will automatically unlock the tools so this step may not be needed The system is now ready to use 10 Making a BT EXACT into a standard EXACT Version 9 2008 One page Configuring a BI EXACT to act as a standard EXACT
45. P COM Port Devices Barcode Table i Tightening Programs WLAN Compatibility TCPAP Settings identification Screwdrivers Access Point Parameters Device on COM v C COM1 Parameter Setup E Setup COM1 Baudrate Data Bits Parity Stop Bits Read from Character Position No of Characters to read 0 all remaining lo Save Cancel Save to XML File Load from XML File on amiy canco primview 30 You must set the basic baud rate data bits stop bits and other information as needed Be sure to set the correct character position to read from and the number of characters in the scan If you need to connect a second bar code scanner to the EXAConnecT follow the same sequence but choose COM2 for your setup 17 Stack Lights and Connections Version 9 2008 One page If desired stack lights can be directly connected to the EXAConnecT instead of connecting them via a PLC or other higher intelligent device The EXAConnecT can TRIGGER stack lights but it cannot POWER incandescent lights The 24 volt I O s must be used as a switch unless the stack lights are LED lamps that draw less than 4 8 watts each The EXAConnecT has four 4 built in 24 volt input output I O connections These 4 O s can be configured in various ways via the software The I O s are located on the terminal strip 9 inside the box The I O s are optically isolated polarized d
46. Secure data transfer is critical to proper tool performance The Bluetooth version used by Bosch is 56 bit encrypted security level 3 The Bluetooth wireless communication protocol used by the EXAConnecT and BT EXACT tools prevents other devices from interfering with our tools As the system uses Bluetooth version 1 2 it already has some built in capabilities to avoid wireless LAN s or Wi Fi an most applications However we recognize that some customers will want Bosch to completely avoid the wireless LAN signals in their facilities This function of the software is only to be used if the IT department at a customer determines that they have a concern for interference It is not needed in most cases for most customers Bluetooth systems and Wireless LANs utilize the same 2 4GHz bandwidth for wireless data transfer By using both wireless technologies simultaneously certain frequencies or channels may overlap creating potential interference or disturbance of a LAN Wireless LANs define 13 wide channels and Bluetooth defines 79 tight frequencies throughout the complete bandwidth The wireless LAN uses the spread spectrum method which is much more susceptible to interference by other systems compared to Bluetooth The channel hopping method used by Bluetooth is very resistant to interference There are three conditions where our Bosch system can be programmed to avoid wireless LAN s The first condition is during normal operation
47. Settings Job Settings Output Settings Job Definition Program static i Program Number if static dynamic via Barcode Table Job Reread dynamic via Protocol Rework Release 1 x left rotation Job Cancelation Manually x Load from XML File Save to XML File OK Apply Cancel Print View Back to Defaults Click on the Job Definition box and a pull down menu will be displayed Select the dynamic via bar code table setting if you will be using a bar code scanner and the bar code tables to control the tools If you are using a customer specific protocol e g Ford BMW or Chrysler you can select dynamic via protocol and the tools will operate based on parameters assigned by that protocol If you are using any other program and not using bar codes or protocol just select that program number prior to completing your program and unlocking the tool All other fields in this tab can be left at their defaults There is no need to configure any other settings since these are not used Pile es Screwdriver Settings Job Settings Output Settings Limit absolute number of fasteners 45 554 885 Next Calibration date DDMMYY IDDMMYY E Save to XML File Load from XML File OK Apply Cancel Print View Back to Defaults You MUST set a count for the absolute number
48. TCP connection is down This message will only be shown in the software Corrective action Check the Ethernet cable from the Network or PC to the controller PP daiacavaaror During automatic data backup to an FTP server an FTP error occurred If this was a temporary problem that clears by the next FTP event the status code will automatically clear itself Corrective action Check the Ethernet cables the FTP settings in the setup of the Controller and on the FTP Server itself If this continues to occur contact Bosch 58 3 Critical errors These errors may cause the controller to stop working or lose data A service technician may be required AP is out of memory AP setup write error SD screwdriver setup write error AP setup read error SD setup read error Backup battery empty The memory of the Controller is 100 full of completed screw data Some reserved memory in the controller is still available but no more data can be saved All screwdrivers will be LOCKED Corrective action Save the data with the software to an external hard drive and then delete the data from the controller The settings in the controller could not be saved because of an internal problem Corrective action Try to save the setup again otherwise contact Bosch The screwdriver settings in the controller could not be saved because of an internal problem Corrective action Try to save the setup again otherwise contact Bos
49. XAConnecT An IP address must be assigned to the EXAConnecT The AIS box has an IP address of 192 168 0 180 All IP addresses subnet masks for an AIS box connection are within this range IP Address Subnet mask 192 168 0 185 255 255 255 0 192 168 0 186 255 255 255 0 192 168 0 187 255 255 255 0 192 168 0 188 255 255 255 0 192 168 0 189 255 255 255 0 The IP address should be chosen based on order of devices connected to the AIS box Example the first EXAConnecT in sequence would be 192 168 0 185 the second 186 etc Remember to set the IP address of your laptop within the range of addresses listed here 39 We suggest you WRITE the new IP address on the side of the EXAConnecT for reference See section 5 for instructions on how to change the EXAConnecT I P address Now go to the setup menu of the EXAConnecT and open the tab marked Database Click on the pull down menu and select Ford Open a onL sarg Database Autom je ee i oj xj ati Save viaFTP COM Port Devices Barcode Table Tightening Programs rewdrivers Access Point Parameters WLAN Compatibility TCPAP Settings STAND ALONE You MUST click on Apply to enable the configuration menu for the next step Now click on Setup to get to the next menu 2 EXAConnecT Setup 15 xj Database Automatic Save viaFTP COM Port Devices Barcode Table Tightening Pr
50. You can run different tightening programs coming from the Atlas protocol for one screwdriver on the same EXAConnecT As an option the minimum and maximum fastener times can be defined in the tightening programs in the EXAConnecT If they are defined and used they will be transferred to the Atlas protocol as angle values in the result telegram Ist Min Max The angle value is given in milliseconds If the tightening time window was missed the angle status of too short or too long is displayed and the result is NOK Remember that this is not a REAL angle value but a time over angle substitute Specific notes for use when choosing the Do not count strategy Some customers may use default tightening program one with the count strategy set to Do not count Their system counts locks and unlocks the screwdriver accordingly In this configuration we are only passing through information The setup value for Number of fasteners is not used In the monitor software with every lock command from the server a total NOK message is displayed along with error code 8 lock via manual abort This is necessary since it was already in the logic of the Atlas system The real total result needs to be controlled and counted in the Atlas server The EXAConnecT does not know this real value and therefore cannot display it To setup the screwdrivers you only need to be sure that you selected the Dynamic via protocol
51. aches zero OK screws Not OK NOK screws are not factored into this count the controller only counts OK screws for this field When the tool reaches zero it LOCKS It does not matter if you try to manually unlock a tool if this number is zero the tool will not run Make sure that this value has not hit zero To reset it just enter a new count and save The system will allow the tool to be unlocked again The system will send an alarm message to the Java software and to a customer specific protocol when the tool reaches a count of 1 000 screws If the alarm is ignored the tool will run down to zero screws and LOCK Reset the count to fix the condition 32 Flash installation of firmware Version 9 2008 one page There may be times when you need to install a new version of firmware There may be other conditions that require you to flash the controller to perform an update or override old firmware There are two ways to load EXAConnecT firmware 1 Use the service tool software to update firmware without disrupting screwdriver settings or other data See section 34 for details 2 FLASH the firmware which wipes the controller clean of all data and tools and insures that no old data remains on the EXAConnecT Using the FLASH firmware is the PREFERRED method of updating firmware as it insures that you are starting with a clean slate for proper operation under all conditions You do not need to have the Java script or yo
52. address of the tool into the controller 2 EXAConnecT Setup pi Ioj x Database Automatic Save via FTP COM Port Devices Barcode Table Tightening Programs Identification Screwdrivers Access Point Parameters WLAN Compatibility TCPAP Settings Found Connected bi awe Inna rveact 4 591000029 x Enter BT adg manualhy poo OK Cancel Save to XML File Load from XML File OK Apply Cancel Print View The Bluetooth address is manually input in the blank fields of the connection menu and then the entry is accepted by clicking on ok The tool is connected to the controller without performing a scan All of these possible configurations are to be used only after discussing the wireless situation in a facility with the customer the distributor and Bosch 20 Atlas Copco Open Protocol Configuration Version 9 2008 One page The EXAConnecT can communicate with several different customer specific protocols These protocols are listed alphabetically starting with Atlas Copco This protocol is configurable in the EXAConnecT as follows In the database menu select the Atlas open protocol from the pull down menu Database Automatic Save via FTP com Port Devices Barcode Table Tightening Programs Identification Screwdrivers Access Point Parameters AN Compatibility Mod
53. aid if you are updating firmware from the same generation e g version 1 98 2 to 1 98 6 or 1 99 4 to 1 99 10 you can use the service tool to perform the update and it will SAVE all the screwdrivers settings and configurations Right click on the default controller and select firmware update EXAConnecT Service Tool Program Options Help E 4 EX4ConnectT Connect Disconnect ction 3 on dyn b arti Murmbe manuall Query Status Query Configuration e E pan Eaa E J 5 u AZE marn The Java will take a moment to load the next screen The window below will appear Look in a 03_Service Tool gt Recent amp Desktop a i My Documents My Computer te File name Open CMa aimee Files of type sno target binary file HEN v Cancel Double click on the files to send folder This will open the folder The file you need is called project hen This is the operating system and firmware for the EXAConnecT Highlight the project hen file and click on open NOTE If the project hen file is NOT in this directory you can browse your computer to locate the file from the window shown above If you do not have the project hen file contact your distributor or Bosch This is the ONLY file that runs the controller All versions of this file have the exact same name so the only way to know the version is by its date The s
54. ame 029 EXACT 4 Bluetooth Address 00 0 D3 01 03 45 User ID EXACT 4 Serial Number 591000029 User Information BOSCH Exit BOSCH Click on the Setup button to program the tool Click on the Identification tab next iojxj T Copy settings from other screwdriver z Identification Screwdriver Settings Job Settings Output Settings Device BT EXACT 4 Bluetooth Address 00 00 D3 01 03 A5 Serial Number 591000 User Name 029 EXACT 4 User ID EXACT 4 User Information BOSCH Save to XML File Load from XML File OK Apply Cancel Print View Back to Defaults You can name the tool give it an ID and put in user information Each field holds 19 characters Click on the Screwdriver settings tab next ix Service and Calibration Soppeetttite norrttrengcrewdriver Identification Job Settings Output Settings Communication and theft protection On Off Theft protection delay 5 s increments 5 Double hit detection time 50 ms increments Repeat protection 100 ms increments Set the repeat protection of the tool to 300 ms This will allow the operators to work quickly Now configure the theft protection setting We suggest a minimum time of 5 seconds the tool will now lock within 5 seconds after it is out of range If you input a longer time here the
55. any other settings since these are not used Click on the Service and Calibration tab to finish Pees Service and Calibration Copy settings from other screwdriver Identification Screwdriver Settings Job Settings Output Settings 45 554 985 DDMMYY Limit absolute number of fasteners Next Calibration date DDMMY Y Save to XML File Load from XML File OK Apply l Cancel Print View Back to Defaults You MUST set a count for the absolute number of fasteners We suggest a very high value like 10 million Just remember that whatever you set this value at the tool will STOP running when it reaches the total number of OK screws programmed here The next calibration date field is inactive You may input any data you wish here as the field is not tied to the real time clock in the controller This tool program sequence must be repeated for each additional screwdriver you wish to connect to the EXAConnecT You do not need to repeat the controller program sequence If you have more tools that will be configured the same as the first tool simply go to the tab for that new tool then click on the Copy settings from other screwdriver tab Piei Service and Calibration Copy settings from other screwdriver f Identification Screwdriver Settings Job Settings V Output Settings Copy from selecte
56. ation and theft protection by clicking Off the tool will not report data to an EXAConnecT If this is desired see Making a BT EXACT into a standard EXACT tool in section 10 for details Bosch recommends that you print amp save all individual screwdriver settings Printing the settings gives you a record of all programmed data AND provides the Bluetooth address of the screwdriver for manually connecting tools Click on the Job Settings tab to continue Pele Service and Calibration Copy settings from other screyygae X identification Screwdriver Settings Job Settings Output Settings WLL via Barcode Table R dynamic via Protocol Manually v Job Definition Program Program Number if static Job Retea Rework Release 1 x left rotation Job Cancelation Manually x Save to XML File Load from XML File l OK Apply Cancel Print View Back to Defaults Click on the Job Definition box and a pull down menu will be displayed Be sure that Static is chosen to allow the tool to use only the no count program for running BE SURE THAT YOU HAVE SELECTED THE DEFAULT STATIC PROGRAM NUMBER ONE 1 if you originally set 1 to no count The tool needs to run from the default program of no count if you want it to run without locking If you are using any other program just select that program number
57. ave to XML File OK Apply Cancel Print View A warning can be sent from the EXAConnecT to a PLC or other device stack light warning buzzer that alerts you that a tool is NOT in the area or is in the middle of a battery change The warning signal is wired the same as any standard 24 volt output and the output is selected in the software menu below Exatonnect setup E Database Automatic Save via FTP COM Port Devices l Barcode Table i Tightening Programs Identification Screwdrivers Access Point Parameters WLAN Compatibility TCPAP Settings WLAN Channel Number T 2 Ss 42 e F as a 10 311 Ae 13 Exclude WLAN Channels D id md bd l al Gal Gaal Lad kal bal bad Exclusion window size O Wide Narrow Remaining BT Channels shall be gt 20 79 Automatic Bluetooth reconnect always Bluetooth reconnect trigger Manually v Bluetooth reconnect Bluetooth auto reconnect OFF warning Print View OK Apply Cancel The Third condition is during the search process to detect screwdrivers in the area The controller 34 performs an Inquiry Scan to find Bosch BT EXACT screwdrivers The complete bandwidth is normally needed for the search of a new tool So to connect a new tool to an EXAConnecT for the first time we have to use the manual mode and input the Bluetooth
58. cess to eliminate this problem Bosch recommends that you print amp save all tool settings See section 6 for details 6 Screwdriver Setup Stand Alone Version 9 2008 Two pages Each tool must be configured to run properly Click on the tab of the tool you want to configure Be sure the screwdriver is in range amp locked or you will not be able to program tt Overview Ex OnnecT 029 EXACT 4 0 crew No Date Time COM Info Counter Status Error Duration Rot 029 EXACT 4 1 18 06 2007 11 55 42 MANUAL 1 5 OK 400 ms R paese 5 5 2 18 06 2007 11 55 48 MANUAL 2 5 OK __ 400ms R_ C 11 56 22 3 18 06 2007 11 56 07 MANUAL 3 5 NOK 1 250ms R z 4 18 06 2007 11 56 10 _ MANUAL 3 5 _ OK _ 300ms__ R 5 18 06 2007 11 56 15 MANUAL 4 6 NOK_ 1 pes0oms R G 18 06 2007 11 56 17 MANUAL 415 NOK 1 400ms R 18 06 2007 11 56 18 MANUAL 415 OK 200 ms IR 8 18 06 2007 11 56 22 MANUAL 515 OK 200 ms R Er 18 06 2007 11 56 22 Total 515 0k 40250 ms Unlock Save Print Delete 1 missing shut off signal 5 overload error 9 new release signal 2 minimum fastener time not hed 6 minimum job time not hed 10 single NOK results in total NOK 3 maximum fastener ti ded maximum job time exceeded 11 skip current jol 4 double hit error 8 abort through manual lock 12 data memory full Device BT EXACT 4 User N
59. ch The controller settings could not be read because of wrong data or wrong version In this mode the controller will only operate with its default settings Corrective action Reconfigure the settings again and save the setup If this error occurs repeatedly contact Bosch The screwdriver settings could not be read because of wrong data or wrong version In this mode the controller will only operate with its default settings Previously connected screwdrivers need to be connected again from scratch Corrective action Connect the screwdrivers again redo all screwdriver settings and save the setup If this error occurs repeatedly contact Bosch The AAA backup battery is monitored for low voltage this code is set when the battery is low During power down loss of unsaved data can occur Caution a low battery can create a condition where the flash disk can be corrupted with bad data from an attempt of the controller to backup completed screws with this condition Corrective action Replace the AAA battery with a LITHIUM battery ONLY Consider de activating the UPS uninterruptible power supply to prevent backup of screw data if you do not wish to save any completed screw data NOTE The monitor hardware of the EXAConnecT is in many cases too sensitive and often reports an EO code when the battery is only slightly discharged Many customers ignore the EO code as it is somewhat of a nuisance Use of firmware version 1 99 14 or high
60. correct version of software This is critical for proper operation of the interface Contact your CEC or Superior Controls plant staff for assistance with AIS box programming AIS box spindle sequencing note If more than one BT EXACT screwdriver must be connected to one EXAConnecT controller reporting to a single AIS box you must connect the tools to the EXAConnecT in one of two ways listed below The first method is to connect the tools one at a time using the auto connect function in section 4 Search and connect each tool in the order of spindle sequence in the AIS box to insure that each tool has the correct index number in QLS The second method is to use the manual screwdriver connection process in section 5 to connect and sequence the tools in the proper spindle sequence as needed within QLS AIS box Ethernet connection note Bosch strongly suggests using a Turck switch when connecting an EXAConnecT to an AIS box This is because some versions of AIS box support a slower speed of network card and may not properly communicate If a system is connected without the Turck switch and error messages U1 and U2 are displayed on the Bosch EXAConnecT you have a connection problem Using the Turck switch eliminates potential communication problems between the systems The EXAConnecT can be adjusted to LIMIT the working range of the tools connected See the section on Changing EXAConnecT antenna power ti
61. crewdrivers firmware and settings stored in the EXAConnecT During the loading process a DOS window will open and remain open for about a minute If this window does NOT remain open and closes immediately after double clicking on formdisk bat this indicates that you are not properly connected to the EXAConnecT Check your settings and IP addresses and try again When finished open your browser check the EXAConnecT settings make changes if needed and reboot the controller The flash update is complete 33 Hardware buttons and switches Version 9 2008 one page The EXAConnecT has only a few mechanical switches on it these are explained in this section There is a push button RESET located on the lower left of the controller Pa T TEP ESY E i Li w om nm L TH m C Pressing this button once will restart and reboot the controller without needing to unplug it Pressing this button two times rapidly will perform a self test of the backup battery monitor that stores completed screw data Performing this function may eliminate the E0 code from the controller display 52 There are two small dip switches located on the EXAConnecT Dip switch number TWO is inactive Dip switch number ONE creates a back door into the EXAConnecT When the switch is in the up position the controller uses whatever IP address was programmed into it When the switch is in the down po
62. d Save to XML File Load from XML File OK Apply Cancel Print View Back to Defaults 42 If you have more than one driver connected you will see them here Just click on the driver that is already programmed and click on Copy from selected to complete the process One last step you may wish to perform is to make a backup of all of your settings Screwdriver Setup lt Screwdriver Setup i y Service and Calibration Copy settings from other screwdriver denti xi gt Glee BR Device Save In c Cordless Bluetooth Bluetoot 4 All screen shots C USA BT System files J AP firmware Customer issues mis PFCS Software c Old PDF info C Service guidelines Ci Service Master tool Serial Nt User Nai User ID User Infi FileName 029 EXACT 4 xml Files of Type Schrauber Setup File XML v Save Cancel OK Apply Cancel Print View Back to Defaults Click on Save to XML file and the save window will appear You may now save the driver settings to a laptop PC or network file The same save to XML can be done on the EXAConnecT controller For the last step of programming be sure to UNLOCK the screwdriver once you have completed programming it Click on the picture of the driver or the unlock box below the picture to unlock
63. during start up showed some inconsistency Only a backup system is now running to provide this error message and for service Regular operation of the Controller is impossible at this time NOTE All data in the flash memory of the Controllers including firmware is now lost Corrective action You MUST re flash the controller and then reinstall the latest firmware 60 Critical errors continued Internal Bluetooth Error Internal system error BT Error Screwdriver lt gt Customer Network or host device not available Wrong telegram length from customer network The Bluetooth interface of the Controller is not available or the Bluetooth Protocol Stack is sending unexpected errors Corrective action Restart the controller If this error occurs repeatedly contact Bosch The software of the Controller had an internal System error and could not run correctly Corrective action Restart the controller If this error occurs repeatedly contact Bosch The screwdriver with the index name of lt gt tools 0 to 6 answered via the BT interface with the wrong format or did not reply Corrective action Change the battery pack of the screwdriver or the screwdriver itself If this error occurs repeatedly contact Bosch The controller has lost the connection to the customer server or customer specific control system e g Ford AIS box Chrysler PFCS server Mercedes PLUS server Jaguar Modbus etc Corrective action
64. e Setup PAP Settings Save to XML File Loadfrom XML File You MUST click on apply to confirm that you have selected the correct protocol BEFORE moving to the next steps in the setup process Now the specific settings of the protocol must be configured Setup is as needed per customer Controller Name max 25 chars 10 x Server TCP Listen Port for SD Index 0 Ro 4545 Server TCP Listen Port for SD Index 1 lo Server TCP Listen Port for SD Index 2 lo Server TCP Listen Port for SD Index 3 lo Server TCP Listen Port for SD Index 4 lo Server TCP Listen Port for SD Index 5 lo Server TCP Listen Port for SD Index 6 lo Timeout on Ack s Save Load settings to from File Save to XML File Load from XML File OK Save Cancel Print View Up to seven screwdrivers can be controlled through a single TCP connection This means the controller uses up to SEVEN TCP servers running with different port numbers 1 to 65535 one for each index of tools 0 through 6 on the same IP address Port numbers are assigned to the screwdriver indexes in the menu above A port number of 0 always means the screwdriver is not used This means the TCP server will not be started for that driver during system startup 35 One parameter set pset is selected for each fastening job which is equal to one tightening program in the EXAConnecT
65. e dynamic Machine ID On Off Main Machine ID dynamic Machine ID for SD 0 dynamic _ Don t send FAIL Machine ID for SD 1 Machine ID for SD 2 Machine ID for SD 3 N Machine ID for SD 4 Machine ID for SD 5 Abie Sac i Machine ID for SD 6 Used Barcode Type VIN O av Keep Alive Cycle Time s 120 Ack Timeout s 5 Data Timeout s 5 No of Transmit Retries 3 TCP connection retry cycle s 20 Save Load settings to from File Save to XML File Load from XML File ok sae Cancel Print View 38 You must input the specific IP address information for the PFCS server the TCP port and all other pertinent data Save the settings and click OK to close the window To setup the screwdrivers you only need to be sure that you selected the Dynamic via protocol setting for each tool used in the EXAConnecT screwdriver setup i xx Service and Calibration i Copy settings from other screwdriver Identification Screwdriver Settings Job Settings Output Settings Job Definition Program Program Number if static Job Release Rework Release 1 x left rotation Job Cancelation Manually v Save to XML File Load from XML File OK Apply an Cancel Print View a Back to Defaults You can do this in the screwdriver setup menu of each individual tool
66. e scanner inputs Item 24 in the diagram is the RS 232 422 converter Item 23 is the bar code scanner or wireless scanner receiver 29 Go to the setup menu of the EXAConnecT and select the COM port devices tab EXAConnecT Setup iaFTP COM Po iN Devices Barcod Database Automatic Sa Screwdrivers WLAN Compatibility TCPAP Settings Identification Device on COM1 COM1 Parameter Setup Device on COM2 COM2 Parameter Setup Save to XML File Load from XML File ox amiy canco Print view Now you will need to configure the desired COM port for a bar code scanner Click on the first pull down box to the right of the device on COM1 box as shown below Select bar code scanner Exaconnect setup E Database Automatic Save via FTP COM Port Devices Barcode Table Tightening Programs Identification Screwdrivers Access Point Parameters WLAN Compatibility J TCPAP Settings Device on COM1 COM1 Parameter Setup bal COQUE al oT Device on COM2 ROL cii COM2 Parameter Setup lO Extension 1x VO Extension 2x Save to XML File Load from XML File ox avon concn _ pnw Now you will need to configure the EXAConnecT to use the bar code scanner data properly Select the COM1 parameter setup box and setup the scanner 25x Database Automatic Save via FT
67. e PLC Think of turning on a light bulb in the EXAConnecT You need a positive and negative to turn on the bulb The release of all tools can also be done by a single input if desired Wire a single input then configure all tools to release on that input in the software menu All tools release on 1 input example Switched 24 volts DC positive from PLC Input 1 back to PLC ground The negative side of the EXAConnecT output must go to a negative voltage input in the PLC Think of turning on a light bulb in the EXAConnecT You need a positive and negative to turn on the bulb 12 Software Configuration of Outputs amp Inputs Version 9 2008 Two pages After completing the input output wiring the tools must be configured to communicate via the EXAConnecT software This must be done once for each tool connected Note You MUST insure that tightening programs exist in the EXAConnecT setup menu prior to completing this section properly In the screwdriver setup menu click on output settings to configure the output for each tool You will need to go into each tool separately sl5 x Gusaer gt Service and Calibration Copy settings from other screwdriver Job Settings Identification Screwdriver Settings Reset Output for Single Result Output for Total Result OK Output for Total Result NOK Reset Output for Total Result with new release v
68. e external voltage to perform a switching function The GND terminals on the 16 inputs are connected together internally Think of the GND terminals as the negative side of the dry contacts relative to polarity within the dry contacts You can wire a single GND terminal to the negative side of a PLC for all inputs and outputs if they are all being controlled by the PLC in the same way Input Connection Wiring up to 7 tools If it is desired that the tools will be locked and unlocked for a controlled batch count by either the PLC or the EXAConnecT you must setup the system to accept the unlock commands from the PLC The system can be set to release each tool independently for either a single screw or for a batch If a batch is desired the EXAConnecT and Digital I O module can be configured to count that batch You may also choose to have the PLC count the batch Input wiring from I O module to a PLC is as shown The Digital O Module positive input must be wired to the switched positive PLC output GND back to PLC ground Switched 24 volts DC positive from PLC The input GND on the Digital I O module must be wired to a negative voltage input of the PLC There is one GND terminal near every two inputs This is SLIGHTLY different from the EXAConnecT Think of turning on a light bulb in the I O Module You need a positive and negative to turn on the bulb All 16 inputs can be used for up to 7 tools if
69. ecT Input the desired changes click on OK and accept the warning from the system that tells you to restart the EXAConnecT for the changes to take effect Restart the Controller and continue programming You must access the EXAConnecT using the new L P address for the EXAConnecT or you will not be able to communicate Input your new target I P address into your browser and the Java script should run and connect to the new address Continue programming as needed If you need to get back into the EXAConnecT using the default I P address see section 33 for details 3 EXAConnecT Configuration Stand Alone Version 9 2008 One page The settings described here are for use when the system is to be used as a stand alone device The default IP address of the EXAConnecT is 10 10 10 10 You may change it once connected the change will take effect on reboot of the controller Go to the setup menu of the EXAConnecT and open the tab marked Database Click on the pull down menu and select stand alone SEV Scare Setup Ioj xj Database Aut matic Save via FTP COM Port Devices Barcode Table Tightening Programs Screwdrivers Access Point Parameters WLAN Compatibility TCPAP Settings Mode Setup Save to XML File a Load from XML File OK Apply Cancel Print View Click on Apply or Ok to finish You must now configure the tig
70. ent the controller from locking the screwdriver H1 EXAConnecT memory full 75 The memory of the controller is 75 full of completed screw data not active if ring buffer is enabled 57 2 Non critical errors Errors of this group are usually self corrected by the controller If they cannot be fixed they are converted into critical errors The purpose of these messages is to inform the user of a problem The operation of the controller is limited at this time and full functions may not be available C lt gt Screwdriver C lt gt not available The screwdriver named C lt gt tools O to 6 is out of range or lost l power example during battery exchange As long as this status is displayed as CO C1 C2 etc displayed the controller will try to reconnect to the screwdriver Corrective action Bring the screwdriver back into range or replace the battery and re activate the screwdriver by pressing the trigger Scrolling Data is being saved Power to the controller was lost the reset button was pressed or single the service tool software was used to reset the controller The segments controller is now running on battery power amp saving all completed of the AP screw data display Corrective action Check the main power source of the controller Otherwise no action needed as this is a normal function during power down No connection to AP The controller no longer sends keep alive packets to a host protocol or the
71. ents Min job time 250 ms increments Max job time 250 ms increments New Save Delete NOTE Take values to edit fields by clicking on row in table _No Name NumiD Count LockNOK Strategy Rot mins maxs Mint MaxT 1 DefaultEnty 0 5 0 1 0K Re 0 o p 0 2 No count 2 1 0 No count R L__ 0 o 0 0 3 sban Bb e p 10K Re o b o p 4 ICF mode 4 1 0 No count R LICF 0 0 0 0 5 cross thread 0 4 jo 1 OK IR L 500 1 000 0 0 6 dummy tool 0 1 0 No count R L O 0 0 0 Save to XML File Load from XML File Exit Now click on the desired program to edit it If you need to create a new program skip this step and click on the New button to create a new program Max fastener time 50 ms increments 0 Edit Tightening Programs lt lo x Program Number 1 Name D efault Entry Numeric ID o Number of fasteners per job 5 Lock after number of fasteners NOK 0 Count Strategy Plus 1 if OK bi Rotation Right and Left iy Min fastener time 50 ms increments iO Min job time 250 ms increments lo Max job time 250 ms increments J Delete NOTE Take values to edit fields by clicking on row in table No Name Nug Rot MinS MaxS MinT MaxT 1 De
72. eporting the OK signal only with no concern for the NOK not ok signal 24 volts DC positive from PLC jumped across all contacts Output 1 tool zero OK Output 2 tool one OK Output 3 tool three OK Output 4 tool four OK The negative side of the EXAConnecT output must go to a positive voltage input in the PLC Think of the output as a relay you need to provide a path for positive current to flow through it When the output is enabled it allows electricity to pass through sending it back to the PLC Input wiring configuration for two tools reporting OK NOK with PLC release If it is desired that the tools will be locked and unlocked for a controlled batch count by either the PLC or the EXAConnecT you must setup the system to accept the unlock command from the PLC The system can be set to release each tool independently for either a single screw or for a batch If a batch is desired the EXAConnecT can be configured to count that batch You may also choose to have the PLC count the batch if needed Again the system is very flexible and will allow you to use various strategies and connections as needed 20 Two tool release input example Switched 24 volts DC positive from PLC independent for each contact as needed to unlock tools Input 1 back to PLC ground Input 2 back to PLC ground The negative side of the EXAConnecT output must go to a negative voltage input in th
73. er will allow you to deactivate the UPS which will eliminate the EO code 59 Critical errors continued Missing time date setting Wrong time date setting Data loss in AP 5 Missing firmware Flash file system error The internal Real time clock is not set Date and time stamps are impossible to create All screwdrivers will stay locked until the date and time are set Corrective action Set date and time The controller is set to a date before September 1 2004 All screwdrivers will stay locked until the date and time are set Corrective action Set date and time The controller switched to backup power during a power down but could NOT save data because of low voltage NOTE This message will be deleted automatically when new screw data is saved Corrective action Replace the AAA battery with a heavy duty ALKALINE battery ONLY The operating software of the controller is missing the file named PROJECT HEN on the flash drive If the green LED on the AP is lit the system will continue to operate correctly until power down But the controller will not reboot after the next restart If the firmware is detected as missing during a reboot of the controller the E4 error code will be displayed but without a ready signal from the green LED The AP and tools will not work at this point Corrective action You MUST re flash the controller and then reinstall the latest firmware A routine check of the file system
74. ere if desired 4 BT EXACT Screwdriver Auto Connect Version 9 2008 One page Note The desired tools MUST be in range with fully charged batteries to connect to the system Attempting to connect a tool with a dead or low battery will result in failure and frustration This is because the PC board in the tool will shut down the tool in a low voltage condition When the battery is very low the tool may have enough power to allow a Bluetooth connection but then break it due to the power required to keep the connection Working range of a tool is 30 ft with no obstructions Go to the Screwdrivers tab to connect up to 7 tools to oe controller Bioix Database MAS w COM Port Devices Barcode Table Tightening Programs Identificfion Screwdrivers pgs Point Parameters WLAN Compatibility TCPAP Settings Connected Search Connect Remove Manually Save to XML File Load from XML File OK Apply Cancel Print Setup Squeeze the trigger of each tool you want to find and connect Now click on the search button and the controller will take about 30 seconds to find the tools Database Automatic Save via FTP COM Port Devices f Barcode Table g Tightening Programs identification i Screwdrivers Access Point Parameters WLAN Compatibility TCPAP Settings Found Connected Sea
75. eters WLAN Compatibility TCPAP Settings Connected Found N l Search Connect Remove Save to XML File Load from XML File OK Apply Cancel Print Setup Now click on the tab marked manually to add a screwdriver You will see another window open 2 EXAConnecT Setup o x Database Automatic Save via FTP COM Port Devices Barcode Table Tightening Programs Identification Screwdrivers Access Point Parameters WLAN Compatibility TCPAP Settings Found l Connected o lnrnrsveaet 4 591000029 x Enter BT address manually Enter requested index lauto v OK Cancel Save to XML File Load from XML File l OK Apply Cancel Print View You must enter the last 6 digits of the Bluetooth address of the tool Each address is unique Note that there is a catch to this process You MUST already have connected the tool to a controller in order to KNOW the address Since most tools must be calibrated in a tool room prior to being put on an assembly line this information can be placed on a label in the battery area of the tool Input the last 6 digits of the tool here and click OK to allow the EXAConnecT to automatically assign an index number to the tool Depending on conditions you may need to assign the screwdrive
76. f fasteners per job 1 Lock after number of fasteners NOK Count Strategy Rotation Min fastener time 50 ms increments Max fastener time 50 ms increments N Min job time 250 ms increments m e oO Max job time 250 ms increments New Save Delete NOTE Take values to edit fields by clicking on row in table auMnID Count LockNok Rot MinS Maxs 8 batch CF mode cross thread dummy tool folnmiololola Save to XML File Load from XML File Exit Do not be concerned about the count of a batch the AIS box and EXAConnecT will manage this count independently of the tool Click on Access point parameters to setup password protection and the ring buffer EXAConnecT Setup E 5 xj Database Automatic Save via FIs POTIER Barcode Table j Tightening Programs F Identification Screwdrivers EEN Parameters J WLAN Compatibility TCPAP Settings Language New Password Confirm Password Allow manual lock unlock Operate Data Buffer as Ring Buffer Size of Data Buffer no of Events Save to XML File Load from AML File 1 OK Apply Cancel Print Setup Be sure that the ring buffer is set to yes for FIFO logic or the controller will LOCK when it reaches the maximum number of screws selected 5k is max You can set a
77. faultEntry 0 Re p b lo b 2 No count 2 IR L 0 0 J0 3 8 batch 3 ee ok RL o b o p 4 CF mode 4 1 jo No count R UCF 0 0 0 0 5 cross thread 0 4 0 1 OK IRL 500 1000 0 0 6 _ dummytool 0 1 0 Nocount R L 0 oi 0 Save to XML File Load from XML File Exit Note that the highlighted program is now loaded in the programming boxes Edit the program as desired The flexibility of the system allows for many possible configurations and strategies Edit Tightening Programs l loj xj Program Number f Name Default Entry Numeric ID lo Number of fasteners per job F Lock after number of fasteners NOK 0 Count Strategy Plus 1 if OK Rotation Right and Left v Min fastener time 50 ms increments 0 __ i Max fastener time 50 ms increments lo Min job time 250 ms increments lo Max job time 250 ms increments lo gt New Save Delete NOTE Take values to edit fields by clicking on row in table No Name NumlD Count LockNoK Strategy Rot MinS MaxS MinT MaxT 1 Default Entry o 5 1 OK R L_ 0 0 if o 2 No count 2 M 0h Nocount R L O O Q 0 3 B batch 3 8 0 1 OK Re o fo fo iO 4 CF mode 4 1 0 Nocount R LCFO O 0 10 5 cross thread J0 4 J0 1 OK R e 500 1000 0 0 6 dummytool 0 1 0 No count R L 0 io 0 0 Save to XML File Load from
78. g the troubleshooting sections This manual covers most all possible conditions and configurations Remember in most cases you really need only a few sections to configure the system 1 EXAConnecT Wiring Version 9 2008 One page The EXAConnecT controller is delivered to Bosch Authorized distributors without power or Ethernet cables and must be wired prior to delivery The plug end of the cable will vary by country or voltage Most customers that take delivery of a Bluetooth system do not need to read this page it is intended as a reference for our distributors The EXAConnecT is IP54 NEMA 12 rated for dust and moisture resistance Bosch recommends that you use only the cable grommets provided to maintain the integrity of the housing Never drill into the housing to secure the EXAConnecT Mounting holes are provided on the lower end of the housing A brief overview of all key internal components is pictured below A Input power supply connection 100 240 volts AC B Terminal strip for Ethernet RS422 24V I O etc C Reset push button restarts EXAConnecT D RS 232 terminal for setting time amp date E AAA size backup battery for data backup memory F Dip switches only switch one is active G Multi segment display and status LED s The EXAConnecT power supply has an input range of 100 240 volts AC It switches voltage automatically and therefore only needs a power cable that meets country or customer specific
79. ger the tools to choose a different program from the EXAConnecT This selection of program is done just before the tool is unlocked by the bar code scanner the new program is quickly loaded into the tool and then it is released Entry Number Barcode Mask up to 31 chars any Program Number for Screwdriver 0 Program Number for Screwdriver 1 Program Number for Screwdriver 2 Program Number for Screwdriver 3 0 _ Program Number for Screwdriver 4 lo j Program Number for Screwdriver 5 l 0 Program Number for Screwdriver 6 0 New Save Delete NOTE Take values to edit fies by clicking on row in table _ i Tightening Program for Screwdriver __ Barcode Mask MAEVE 22225 322 2 No Save to XML File Load from XML File Exit In this example the barcode always consists of 14 characters The first two characters always are TL This tells the tools to ignore any vehicle that does not have TL in the first 2 characters of the VIN Character 8 is always a B Character 9 is either an R or L indicating right or left drive So this first entry will tell screwdriver 0 to pick program 10 and screwdriver 1 to pick program 11 15 After configuring two separate bar code programs the setup will look like the picture below amp Kdit Barcode Table Entry Number Barcode Mask up to
80. gnal minimum fastener time not reached maximum fastener time exceeded double hit error gt UNa Device EXAConnectT User Name Bluetooth Address 00 02 C7 1D DAa 34 User ID Serial Number 00000000 User Information You must now configure the tightening program EXAConnecT Setup default Click on the Tightening Programs tab Database Automatic Save viaFTP COM Port Devices Barcode Ta Identification Screwdrivers Access Point Parameters Name Count LockNOK Strategy Rot MaxS Default Entry 1 OK R L 0 No count Nocount R L 8 batch 1 OK IR L 0 0 CF mode Nocount R LICF o cross thread 1 OK IR L 1000 0 dummy tool Nocount R L Edit Tightening Programs Save to XML File Load from XML File m OK Apply Cancel Print View The EXAConnecT can store up to 99 programs You must only change the DEFAULT program which is program number one top of the list Click on Edit Tightening Programs to change Now click on the line marked Default Entry to edit it As shown you only need to change the COUNT STRATEGY line to Do not count fasteners This prevents the tool from locking even if the AIS box loses its connection 40 Edit Tightening Programs z oj x Program Number 1 Name Default Entry Numeric ID 0 Number o
81. hen setup the protocol communication path 2 EXAConnecT Setup am 7 Database Automatic Save via FTP COM Port Devices Barcode Table Tightening Programs amp BMW KISS Q Protocol Setup b 0 x IP Address KISS Q Server 10 10 10 10 Server TCP Port 3002 SST station name aba Timeout on emergency request NOTANF ms 20000 AKZ FZS Tester Save Load settings to from File Save to XML File Load from XML File OK Save Cancel Print View Save to XML File Load from XML File OK Apply Cancel Print View You must input the specific IP address information for the Kiss Q server the TCP port and all other a7 pertinent data Save the settings and click OK to close the window To setup the screwdrivers you only need to be sure that you selected the Dynamic via protocol setting for each tool used in the EXAConnecT aox Service and Calibration ig Copy settings from other screwdriver Identification Screwdriver Settings Job Settings Output Settings Job Definition Program Program Number if static Job Release Rework Release 1 x left rotation Job Cancelation Save to XML File Load from XML File OK Apply ale Cancel Print View Back to Defaults You can do this in the screwdriver setup menu of each individual tool Save your settings a
82. htening program default Click on the Tightening Programs tab EXAConnecT Setup Database Automatic Save via FTP Identification Screwdrivers Name Numi Count LockNOK Strategy Rot Default Entry 1 OK R L No count No count R L 8 batch tok Re CF mode No count R LiCF cross thread 1 OK IR L dummy tool t __ Nocount _ R L_ lols Edit Tightening Programs Save to XML File Load from XML File OK Apply Cancel Print View The EXAConnecT can store up to 99 programs You can create as many programs as desired with different strategies and options Click on Edit Tightening Programs to change Click on the line marked Default Entry to edit As shown you can change the COUNT STRATEGY line to Do not count fasteners This prevents the tools from locking aox Program Number 1 Name Default Entry Numeric ID 0 Number of fasteners per job 1 Lock after number of fasteners NOK 0 Count Strategy Rotation Right and Le v Min fastener time 50 ms increments lo Max fastener time 50 ms increments N 0 Min job time 250 ms increments 0 Max job time 250 ms increments NOTE Take values to edit METAS by clicking on row in table
83. ing Advanced PLC Connections Version 9 2008 Three pages The EXAConnecT has a physical limit of four 24V inputs and outputs If more 24V connections are needed the Bosch Digital I O module must be used The module has 16 inputs and 16 outputs The general layout of the I O Module is shown below PG seer PG B q e Ooms Bn tes lo Alla a A a Auau oe eee ee amp EMF ie OCR aO HAAD Bogs QAA2G400044 6244046406444 Fabrimex DC DC Wandler Input 24V Output 5 V ON a ZAO44464 4444444 O4444444 DD DDD DMN IO OD MDD DMO DOI III TIN aja ajz iejo ajea al o ajeje Zz 2 Sle 2 5 5 2 z 5 5 z z E 5 Z z E E s Zj ojolojo Ololo O O18 e 9 ojala Pe Up to two 2 Digital I O modules can be connected to an EXAConnecT in series only for a total of 36 inputs and outputs combined The I O module has a red amp green LED to show status when powered Under normal conditions the module will turn on the green LED after it starts and boots its firmware If the red LED is illuminated refer to the I O module diagnostic pages in section 35 The I O Module must be wired to the EXAConnecT On the EXAConnecT side the COM ports are labeled RS422 Choose the left port for COM1 choose the right port for COM2 COM1 COM2 23 The terminals are labeled OY OZ IA and IB Terminals on the I O module are similarly labeled The Digital I O module takes its power from the EXAConnecT Wi
84. ion Screwdrivers Access Point Parameters WLAN Compatibility TCPAP Settings aax Save to XML File Load from XML File Print View 36 You MUST click on apply to confirm that you have selected the correct protocol BEFORE moving to the next steps in the setup process You must then click on the setup button to define the protocol communication path This is based on parameters defined by your IT department using instructions from another Bosch document zix Database Automatic Save via FTP COM Port Devices Barcode Table Tightening Programs Identification Screwdrivers Access Point Parameters WLAN Compatibility TCPAP Settings BOSCH M Bosch Protocol Setup IP Address Bosch Server 0 0 2 1 5600 Station Name eee Automatic Manual Mode ioi xi Server TCP Port O On Off Save Load settings to from File Save to XML File Load from XML File OK Save Cancel Print View OK Apply Cancel Print View To setup the screwdrivers you only need to be sure that you selected the Dynamic via protocol setting for each tool used in the EXAConnecT x Serice and Calibration Copy settings from other screwdriver i a identification Screwdriver Settings Job Settings Output Settings Job Definition Program
85. is the reconnect time as shown above If desired the controller can be set to look for the tool on all 79 channels for as short as five seconds as long as a minute always or never This setting is dependent on customer demand If the setting of NEVER is chosen the controller MUST be configured to accept the tool by some other input This is done by using a push button or key switch bypass wired into the I O terminals Refer to pages 19 22 for details The push button is configured to RECONNECT the desired tool after a battery replacement If this is the case the Bluetooth reconnect trigger would be assigned to one of the INPUTS selected in the menu below This can also be done by an input signal from COM1 or COM2 such as a bar code or other data source amp EXAConnecT Setup j Iof xj Database Automatic Save via FTP COM Port Devices l Barcode Table Tightening Programs Identification i Screwdrivers Access Point Parameters WLAN Compatibility TCPAP Settings WLAN Channel Number 12 35 4 75 G Fees g AE N AA 13 Exclude WLAN Channels D i a bal a a al ba al la a aal al Exclusion window size O Wide Narrow Remaining BT Channels shall be gt 20 79 Automatic Bluetooth reconnect Bluetooth reconnect trigger Manually by data received on COM1 by data received on COM2 Bluetooth reconnect Bluetooth auto reconnect OFF warning S
86. ived Lost 4 lt Approximate round trip times in milli seconds Minimum Ams Maximum ms Average This request timed out message means that your PC does not see and cannot connect to the controller If the system can properly connect to the controller you will get a reply that looks like the image below EX WINNT system32 cmd exe Microsoft Windows 2668 Version 5 06 2195 CG Copyright 1985 2000 Microsoft Corp C Documents and Settings william_staiger Desktop cd Cox gt ping 10 10 10 18 Pinging 16 16 16 18 with 32 bytes of data Reply from 18 18 16 18 bytes 32 time 4ms TTL 128 16 18 16 18 hytes 32 time lt ifims TTL 128 18 18 16 18 hytes 32 time lt ifims TTL 128 Reply from 16 18 16 18 bytes 32 time lt ifims ITL 128 Ping statistics for i1 i i it Packets Sent 4 Received 4 Lost 4 loss Approximate round trip times in milli seconds Minimum Pms Maximum 4ms Average ims CIN If you can connect here that means your problems are NOT in the Ethernet connection of the controller or your PC The problem lies in your browser settings If you cannot connect here you may need to check your Ethernet settings again Contact Bosch if you cannot resolve your connection problems 30 The green LED is not lit and or E4 is displayed Version 9 2008 One page The EXAConnecT has 3 LED lamps to indicate status and a 2 digit multi segment display for error codes
87. light ground common See section 12 for software configuration of outputs 18 Release Push Buttons amp Key switches Version 9 2008 One page The EXAConnecT can release or lock tools based on input from an external push button type switch or key switch A simple connection to release all tools from a single push button is shown below All tools release on one input co H oO ot The positive side of the EXAConnecT INPUT must go through the push button and then BACK to the positive terminal of the EXAConnecT The negative terminal goes from the negative side of INPUT ONE back to the negative terminal of the EXAConnecT controller Think of turning on a light bulb in the EXAConnecT You need a positive and negative to turn on the bulb You will need to configure each screwdriver to release on the desired input one in the software See section 12 for details This same configuration can be used with key switches proximity switches safety mats or any other trigger device You can also use one screwdriver to release another just by using the I O s and the software As an example screwdriver one could be released by a push button or proximity trigger and then when it completes its job it would release screwdriver two 32 The example below shows how this is wired Follow the numbered sequence for details 24 volts DC from controller to external push button then return to positive contact on i
88. ly L f Save to XML File Load from XML File OK Apply Cancel Print Setup Back to Defaults Note that the Program number box is set to 1 This means that program number one is the selected program for this screwdriver To insure that program one is the right program you want open the setup box of the EXAConnecT and verify the programs and settings you created For details on creating tightening programs refer to the Creating Tightening Programs section 7 You MUST create correct tightening programs FIRST before you begin assigning tools and outputs Job Release Now select Job release to program the input for the desired screwdriver ixi Service and Calibration Copy settings from other screwdriver 1 n r Identification Screwdriver Settings Job Settings Output Settings Job Definition Program static M ar if static 4 Manually v Manually by data received on COM1 by data received on COM2 by signal on IN1 by signal on IN2 by signal on IN3 x left rotation Job Cancelation by signal on IN4 Select the desired input to release the screwdriver as needed If the tool is set to do not count screws it will not need a release signal programmed here But if you want the tool to lock after a batch you must define the release input here If the tool was configured to rotate right only you can
89. me 250 ms increments lo New Save Delete NOTE Take values to edit fields by clicking on row in table No Name Numi Count LockNOK Strategy Rot Mins Max MinT MaxT 1 DefauitEntry ot lo Nocount Re 0o oo 2 Nocount 2 if lo INocount Re 0 o oo 3 8batch Bb lB fo 10K Re o o o io 4 CF mode 4 1 0 No count ae 0 0 0 0 5 _lerossthread 0 l4 Jo 1 OK RL 500 i100 lo lo 6 dummy tool 0 1 0 INo count IR L J0 0 0 0 If you set a minimum and maximum fastener run time and the tool falls outside of this range it will be reported as a NOK and display an error message that the run time was not correct The respective function boxes named min job time and max job time can be used to monitor an entire batch of screws from the release of the tool until the last OK or NOK occurs This can be helpful where line speed or process issues are a concern It can also help to detect when an operator is completing a batch of screws faster than possible thus alerting you to potential situations where an operator is cheating and tightening either the wrong screws or the wrong assembly Once you have created all the different tightening programs you want the screwdrivers to use save them and exit the tightening programs setup Refer to the screwdriver setup pages for instructions on using tightening programs for different screwdrivers This information
90. me amp date of the real time clock via Serial cable in section 15 for details Bosch suggests the use of our color ring marking system to designate tools to different jobs or torques to insure operators do not mix tools between right left or different jobs The rings are available in several different colors and fit on the nose of the tool Bosch suggests that BT EXACT cordless tools and batteries be stored in locked cabinets during times when the assembly line is not running Bosch suggests that all EXACT and BT EXACT tools be run until the tool stops and the battery indicator on the tool is RED This will insure top performance 43 Charge the tool battery using only a Bosch 15 minute charger Allow the charging cycle to complete Batteries can remain in Bosch chargers indefinitely without damage Bosch strongly suggests that chargers are placed very close to the location where the tools are being used It MUST be easy for the operators to obtain freshly charged batteries when needed Do not place the charger more than a few steps away from where the operator normally would rest the tool Bosch suggests that all stored tools have the battery REMOVED from the tool while in storage This preserves battery life by keeping the tool from maintaining a Bluetooth wireless connection to the EXAConnecT Since a cordless tool is somewhat different than an electric DC nutrunner you may notice different error or alarm messages in the
91. nd test the system for correct operation 23 Chrysler PFCS protocol configuration Version 9 2008 One page The PFCS protocol is used for all North American Chrysler assembly plants This protocol allows the EXAConnecT to communicate directly with the Chrysler network via the Ethernet connection PFCS is an abbreviation for the Chrysler network system that monitors tool data and screw count To configure the PFCS protocol you will need to go to the EXAConnecT setup menu and select the database tab Open the pull down menu and select DC PFCS from the list EXAConnecT Setup al x f Database l Automatic Save via FTP COM Port Devices l Barcode Table i Tightening Programs identification Screwdrivers Access Point Parameters WLAN Compatibility TCPAP Settings Mode Setup Load from XML File apy Caacel Print View You MUST click on apply to confirm that you have selected the correct protocol BEFORE moving to the next steps in the setup process Save to XML File Now Click on the setup button to configure the system for the desired Chrysler assembly plant You must then setup the protocol communication path 2 DC PFCS Protocol Setup 5 x IP Address PFCS Server 10 10 10 10 Server TCP Port 3 000 PFCS Operation Mode Batch Count in PFCS server 1 port v Single Tool Mod
92. needed All ground terminals are in one circuit so only one wire from the PLC is needed for all GND connections Output Connection Wiring up to 7 tools The output connections are also dry contacts Follow the same precautions as the inputs Think of the output as a relay you need to provide a path for current to flow through it When the output is enabled it allows current flow sending it back to the PLC GND back to PLC ground QO4444446 4 44 244644 aaya A H t O fal aje A a m BP aie be SSsizisislzisislzisisiz F SIE z S E O OloO OlO OlO O d 9lololS lo O Switched 24 volts DC from PLC input The following example shows output wiring If the PLC has fully isolated and polarized inputs multiple outputs from the I O module can be connected to multiple inputs from the PLC like this PLC a ANSIN P 7N pat e ea a A baw Bosch I O E B Connect the PLC 24V output to the positive terminal of each PLC input as shown Since the PLC inputs are isolated they must be connected back to the PLC GND terminal to complete the circuit This is done by wiring the PLC through the Bosch I O module The I O module switches the circuit via its output to GND connection which then closes the circuit back to GND of the PLC 25 14 O Module Software Configuration Version 9 2008 One page After completing all power RS422 and PLC connections you must configure the I O module in the software of the EXA
93. neously This allows up to V Fee Ft Only hard wring of a scanner is possible the Bosch V Most standard scanners use an RS 232 connection to talk with a host Since the EXAConnecT is fitted Specific wiring of the bar code scanner RS 422 with two RS 422 ports a converter must be obtained converter is shown above This connection is for the to make the connection The RS 422 ports allow for RS 422 side of the adapter to the RS 422 input of the much longer cable length as compared to RS 232 EXAConnecT The wiring of the RS 232 side of the which has a limit of about 5 meters RS 422 converter is not shown In most cases this will be a connections can use cables as long as one kilometer standard serial connection without data loss If the RS 422 converter has switch settings these RS 422 converters are commercially available Bosch must be as follows does not manufacture them Wiring is shown below we Jag Oo lt r rF E AAIE A AIA eA e Switch number 1 DTE l Switch number 2 TXON RxON Power for the RS 422 converter can come from an external source If the converter accepts 24 volts DC power this can be obtained from the PW terminals in the EXAConnecT These are located to the right on the terminal strip of the controller Note that if a second scanner is to be connected to the system just use the second RS 422 port Once the wiring is complete the software in the EXAConnecT must be configured to accept th
94. ner time 50 ms increments N 0 Min job time 250 ms increments o Max job time 250 ms increments lo Se aroraa NOTE Take values to edit fields by clicking on row in table No Name NumiD Count LockNoK Strategy Rot MinS MaxS MinT MaxT 1 DefauitEnty 0 11 0 Nocount Re 0 o b 2 _ No count 2 1 lo Nocount R L o 0 fo 0 3 B batch E E lo 4 oK R o o p Jo 4 CF mode i4 1 0 No count _ R LICF 0 O 0 0 5 crossthread__ 0 4 0 1 OK R L 500 1000 0 0 6 dummytool 0 1 0 Nocount R L O 0 0 0 Save to XML File Load from AML File Exit 18 If you do not have a program configured for do not count fasteners you MUST create one to proceed Make sure you UNLOCK the screwdriver prior to removing it from the controller or it will not run Overview EXAConnecT 029 EXACT 4 0 029 EXACT 4 Dee 0 0 Oy 14 51 31 REMOVE the tool from the connected list of tools in the controller EXAConnecT Setup 10l x Database Automatic Save via FTP COM Port Devices Barcode Table Tightening Programs identification Screwdrivers Access Point Parameters WLAN Compatibility TCPAP Settings unnecteq 029 EXACT 4 591000029 Connect le Manually Found Search Save to AML File Load from XML File OK Apply Cancel Pri
95. nnecT to verify a connection Sometimes it is necessary to verify that your PC can REALLY communicate with the controller and that the problem is isolated to your browser or other settings To do this you must PING the controller This means that you will send a signal via a DOS window to the EXAConnecT and the controller will reply with a clear message The following steps are needed Test the availability of the EXAConnecT via the TCP IP connection Select START then RUN from your windows start bar SS 2x p n Type the name of a program Folder document or Internet resource and Windows will open it For you Cancel Browse This will bring up the above screen Type CMD and select OK This will open a DOS window At the prompt type the command ping 10 10 10 10 This must be done exactly as shown with a space between the word ping and 10 10 10 10 oC WINNT system32 cmd exe Microsoft Windows 2608 Version 5 00 2195 CC Copyright 1985 2000 Microsoft Corp H 5 gt ping D The system will reply four times If the connection CANNOT be made you will get the reply of request timed out shown in the next picture to the upper right of the page 48 Microsoft Windows 2000 Version 5 00 2195 lt C gt Copyright 1985 20800 Microsoft Corp 16 18 18 18 with 32 bytes timed out timed out timed out timed out Ping statistics for 8 18 10 10 Packets Sent 4 Rece
96. nput one 10 1414 12 13 4 l ee Y YAZISIZ ae I EHETE L a H i eae l T Sale Tae i a A f maat im hb bp Sedat ieee eee to Esta dete aada is rome RS R4727 meat f pv ad 1 The red wires are connecting power from the EXAConnecT to the release push button AND to the positive side of OUTPUT ONE 2 Power flows through the release push button when pushed via the pink wire to release the tool on INPUT ONE 3 The signal of INPUT ONE is grounded back to the GND terminal in the controller via the green wire to form a complete circuit This unlocks screwdriver one when the push button is depressed 4 The signal from OUTPUT ONE is triggered via software when tool one finishes its job This OUTPUT signal is connected to INPUT TWO for tool two via the blue wire 5 INPUT TWO of tool two is grounded to the controller via another green wire to complete the circuit Screwdriver two is unlocked The system must be configured in the software to perform this function Refer to section 12 for details Just remember that you must mind which inputs and outputs are being activated You can configure any input or output to any number of tools as desired It is also important to watch how you set the trigger on times of each output A short time interval is better as described in section 12 19 Blocking Bluetooth from interfering with Wireless LAN communications Version 9 2008 Two pages
97. nt Setup You must remove the tool to insure it stays independent and runs without locking As an option you may decide to set the run time of each individual screw to monitor cross threads Remember that the tool has a clock in it and can monitor time independently of the controller You have now completed configuration of a BT EXACT to run as a standard EXACT tool 11 Basic 24 Volt PLC Connections Version 9 2008 Two pages The EXAConnecT has four 4 built in 24 volt input output I O connections These 4 I O s can be configured in various ways via the software The I O s are located on the terminal strip 9 inside the box The I O s are optically isolated polarized dry contacts that require external voltage to perform a switching function To connect the I O s remove the lower cover of the EXAConnecT and view the terminal strip inside The I O S are clearly labeled inside the EXAConnecT as input 13 and output 14 Note that the I O s are numbered from left to right with input one being on the left Note that the terminal strip has a 24 volt power Supply on the right it is marked PW 15 This power supply has a maximum output of 150 milliamps or LESS than 4 8 watts of power The EXAConnecT software can be programmed to configure the inputs and outputs in many ways We will list a few examples here for reference The inputs amp outputs can be used for OK NOK t
98. ock 12 data memory full Device BT EXACT 4 User Name 029 EXACT 4 Bluetooth Address 00 0C D3 01 03 45 User ID EXACT 4 Serial Number 591000029 User Information BOSCH Setup Exit BOSCH Click on the Unlock button or click on the picture of the locked tool to unlock the driver The system is now ready to use For more advanced configurations see sections 7 26 7 Creating Tightening Programs batch counting Version 9 2008 Three pages The EXAConnecT can store up to 99 custom tightening programs for use by up to seven tools simultaneously The system cannot change the torque of a specific screwdriver but can change count strategy rotation and other parameters If you will be using advanced features and tightening programs it is best to create your programs first and then connect the screwdrivers You do not need to have any screwdrivers connected to create or edit tightening programs Tightening programs can be linked to Bar code tables for use with bar code scanners This allows the system to change screw count and rework strategy for up to 7 tools based on a bar code scan input The EXAConnecT can be linked to two 2 bar code scanners simultaneously via the COM1 and COM2 ports Refer to creating bar code tables in section 8 for bar code setup details The system can create save and delete programs Tightening programs are created in the setup menu of the EXAConnecT Open the setup menu and click on the
99. of a system using one of these customer protocols Remember that you MUST change your IP settings of your computer BACK to Obtain an IP address automatically when you are done configuring an EXAConnecT or you will not be able to connect your PC back to your company network Please note that the system is NOT designed to interface with Microsoft Windows Vista OS and Bosch makes no guarantee that all functions can be programmed using MS Vista Note Do NOT use the steps below if you are only trying to connect to a stand alone system Move to section 3 for stand alone configuration These steps are only for use when the I P address must be changed to communicate to a network or customer specific protocol e g Ford Mercedes etc If you must change the I P Address of the EXAConnecT before connecting to a customer protocol or network click on the TCP IP tab Database Automatic Save via FTP COM Port Devices Barcode Table V Tigh eirg Identification Screwdrivers Access Point Parameters WLAN Comp amp bility Get network parameters automatically DHCP O Yes No Ethernet MAC Address 00 03 05 09 00 18 IP Address Netmask 10 10 10 10 Default Gateway Save to XML File Load from XML File C ox hy Cancel Print Setup You can change the IP address netmask and default gateway as needed The changes are not effective until after you restart the EXAConn
100. ograms 4 Identification Screwdrivers q Access Point Parameters WLAN Compatibility TCPAP Settings Mode FORD OPEN Ford Open Protocol Setup Controller Name max 25 chars Server TCP Listen Port Timeout on Ack s Save Load settings to from File 4 Save to XML File Load from XML File OK Save Cancel Print View Save to XML File Load from XML File OK Apply Cancel Print View As shown above assign a name to the EXAConnecT and verify the TCP listen port is set to 4545 Time out is 5 sec Click on OK to accept the setup If the Ford protocol is enabled and the EXAConnecT is NOT connected to a working AIS box an error message of U1 will show on the LED display of the EXAConnecT and also in the software program This will clear itself once the EXAConnecT recognizes a good connection to the AIS box EXAConnecT 029 EXACT 4 0 Screwdriver Date Time 11 55 42 ExAConnecT 029 EXAC 18 06 2007 S Mode FORD OPEN 029 EXAC 18 06 2007 18 06 COM1 not used COM2 not used 18 06 2007 Status Code U1 029 EXAC 18 06 2007 4a Aatcannacied 029 EXAC 18 06 2007 029 EXAC 18 06 2007 11 56 22 18 06 2007 11 56 22 Total Lock all screwdrivers missing shut off si
101. ondition three The yellow LED is blinking This indicates that data is being sent back and forth from the EXAConnecT to the PC or network You will see this light blinking when you are either programming or monitoring the EXAConnecT Refer to Why can t connect to the EXAConnecT in section 29 for possible causes and corrections when having problems connecting with the system 29 Why can t connect to the EXAConnecT Version 9 2008 Two pages One of the best features of the Bosch Bluetooth EXACT system is that unlike most assembly tool systems that use software there is NO specific communication software to buy or load onto a laptop or desktop PC The system uses a common internet browser like Microsoft Internet Explorer or Mozilla Firefox to connect to a default IP address in the EXAConnecT The browser needs to have Java runtime version 1 4 2 or higher loaded to talk with the EXAConnecT controller This is free software that is available from Sun Microsystems at http www java com That said there are times when connecting to the EXAConnecT can be a challenge Conflicts due to incorrect PC settings or restrictions based on user rights can block you from making a connection to the controller This section will try to give you possible causes and corrections for connection problems You must have several minimum requirements to connect to the EXAConnecT e You must be the administrator of your PC e You must have
102. one properly zicz Database Automatic Save via FTP i COM Port Devices Barcode Table j Tightening Programs identification Screwdrivers Access Point Parameters WLAN Compatibility TCPAP Settings Found gt Connected Search 029 EXACT 4 591000029 Connect ls Remove L Manually Save to XML File Load from XML File Cancel Print Setup After all the desired tools are connected click OK Now move to the Screwdriver Setup stand alone in section 6 to configure the strategy screw count and other tool parameters 5 Screwdriver Manual Connection Version 9 2008 One page Sometimes a tool must be connected to the controller manually This is done when a tool needs a specific index position e g an EXACT 6 on index position 3 Another example of specific index positions is when using customer specific protocols Note The desired tools MUST be in range with fully charged batteries to connect to the system Attempting to connect a tool with a dead or low battery will result in failure and frustration Working range of a tool is 30 ft with no obstructions The manual connection process starts on the same screwdrivers programming tab as the automatic connection but is slightly different Database Be Pewee COM Port Devices Barcode Table Tightening Programs Identificafion Screwdrivers Acces Point Param
103. ool release signal Bluetooth tool manual reconnect etc Output wiring configuration for two tools reporting OK NOK Let s assume you want to have 2 tools with each tool reporting the OK signal from one output and the NOK not ok signal from another output Group the wires for the output of tool number zero 0 to outputs one and two Group the wires of tool number one 1 to outputs 3 and 4 Since the software is flexible it does not matter how you group wiring however it s best to group things in a logical sequence to keep you from being confused during setup and configuration 19 The wiring to amp from a PLC could look like this 24 volts DC positive from PLC jumped across all contacts Baie H Harroa IO DNIA RSAT Output 1 tool zero OK Output 2 tool zero NOK Output 3 tool one OK Output 4 tool one NOK The negative side of the EXAConnecT output must go to a positive voltage input in the PLC Another version of output wiring 24 volts DC positive from PLC positive feed is independent for each contact 1 52 LC i Alea ONO Pee FP a el IDA RSa77 Output 1 tool zero OK Output 2 tool zero NOK Output 3 tool one OK Output 4 tool one NOK The negative side of the EXAConnecT output must go to a positive voltage input in the PLC Output wiring configuration for four tools reporting OK only Another possible configuration could be where four tools are r
104. oot the controller The flash update is complete The following instructions are to be used for an EXAConnecT that has a specific IP address assigned in a network This means that you are trying to update an EXAConnecT from a networked PC to a networked controller There are three files needed to flash a controller filesys bin formdisk bat hyflash exe The initial setup and use of the three files is the same as described in the default IP address configuration on this page left column The major difference is that the IP address in the formdisk bat file MUST be changed to point to an EXAConnecT with a specific IP address This file must be edited to point to the correct IP address Right click on the formdisk bat file and select edit The file will look like this File Edit Format Help petas 10 10 10 10 4000 formatdisk filesys bin Now edit the file to point to the desired IP address of the EXAConnecT you want to flash E formdisk bat Notepad File Edit Format Help far tasn 192 168 0 1e5 4000 formatdisk filesys bin Our example above shows an EXAConnecT IP address of 192 168 0 185 You would edit this line of code to show the actual IP address you wish to flash Save this file with a new name and then continue To START the process just double click on the formdisk bat file This starts both the hyflash file and the filesys file The firmware is then loaded erasing ALL data s
105. or dummy no communication to EXAConnecT tool can be done with a few simple programming steps The advantage of this function is that it lets you keep one type of Bosch tool for both standard and error proofing applications You need to insure that the tool is properly configured before disconnecting it from an EXAConnecT Disable the communication and theft protection by clicking Off in the screwdriver settings tab ms xox Service and Calibration Cog Serer Urrier creer Identification Screwdriver Settings Job Setting f Output Settings On Off Communication and i protection Theft protection delav 5 s increments Set the tool job definition program to static in the job settings tab Identification Job Definition Program Program Number if static noo dynamic via Barcode Table dynamic via Protocol Job Release Rework Release 1 x left rotation nde Bore I Set the tool to a tightening program of do not count fasteners The program number must be set in the screwdriver setup menu under job settings above aix Program Number 1 Name Default Entry Numeric ID lo Number of fasteners per job 1 Lock after number of fasteners NOK 0 coun Sate z I Rotation RITTO AE v Min fastener time 50 ms increments 0 Max faste
106. ove the bar code mask defines how many characters are in the bar code and which characters are to be used or ignored By using the sign we can tell the system how many total characters we see But the key Is to define the exact character or set of characters that we are looking for which will choose the related tightening programs So in the example above we do not care about any other characters except the last one which is the letter A This means that when the EXAConnecT sees A in the last character of the set It will tell the screwdrivers to run as follows driver 0 to run program 3 driver 1 to run program 42 driver 2 to run program 60 driver 3 to run program 8 driver 4 to run program 1 driver 5 to run program 29 and driver 6 to run program 15 all at the same time from a single scan Be sure to SAVE the program before exiting Another example of a possible use for a bar code is shown as follows The bar code needs to have unique characters to determine the model variant of a vehicle In this configuration the car is built with either left hand or right hand drive the steering wheel is on the right or left depending on in which country it is sold We need to tell the right and left screwdrivers to change count as they have different jobs to perform depending on where the steering column will be We need to check the bar code length and define the key characters that will trig
107. ow This message will usually only be displayed if you had the system firmware open in another browser window Just click on ok to acknowledge the prompt SS t I Connection to Access Point lost Please restart the Applet The service tool is a convenient way to perform various tasks Contact Bosch if you cannot resolve your situation by using the service tool 35 Digital O Module Diagnosis Version 9 2008 One page There are several conditions that can cause problems when using the I O module These conditions are usually due to human error but are easily corrected The I O module has an Ethernet jack two LED s for status a restart push button and two dip switches Ethernet jack Green amp Red LED s Dip switches Restart button The Ethernet jack is not normally needed in the field but can be used to change or update I O module firmware in the same manner as EXAConnecT updates are performed A crossover cable from a PC is needed to make a connection Contact Bosch for details if you wish to connect to the Ethernet jack for any reason Green LED function The Green LED indicates that the I O module has booted properly and is functioning normally Red LED function The red LED indicates a communication failure between the I O module and the EXAConnecT There are three possible causes 1 Incorrect wiring from I O module to EXAConnecT 2 Incorrect baud rate setting in the EXAConnecT
108. r error codes are present they will roll over in order every 2 seconds Customer specific protocols may be configured to interface with these messages The status and error codes represent four groups Warnings Non critical errors Critical errors Protocol specific errors 1 Warnings Warnings are non critical errors that are displayed for information only and signal that there could be a failure in the near future The operation of the controller is not interrupted at this time A lt gt Screwdriver lt gt N OFF lt 1000 Screwdriver lt gt tools 0 to 6 will be locked after 1 000 more OK screws are finished Corrective action You MUST reset the screw count in the tool setup menu under service and calibration or the tool will lock after it completes 1 000 screws EXAConnecT memory full 50 The memory of the controller is half full of completed screw data not active if ring buffer is enabled Corrective action You should backup the data to an external source amp delete the files to prevent the controller from locking the screwdriver Corrective action You should backup the data to an external source amp delete the files to prevent the controller from locking the screwdriver EXAConnecT memory full 90 The memory of the controller is 90 full of completed screw data not active if ring buffer is enabled Corrective action You should backup the data to an external source amp delete the files to prev
109. rch Connect CT x Searching for Bosch BT Exact screwdrivers Save to XML File Load from XML File OK Apply Cancel Print Setup The system will display all tools found Our example shows only one tool the maximum displayed is 7 Do NOT attempt to find more than 7 tools The system will find 100 tools in the area but will only display the first SEVEN tools it locates NOTE The system sequences tools based on the order found when connecting to the EXAConnecT If you require specific tools to get a certain sequence number you must either search amp connect the tools one at a time OR you can connect the tools manually refer to section five You must now connect the tools to the controller Highlight a single tool and then click Connect You must WAIT until the tool is shown in the Connectea list before moving to the next tool c Database Automatic Save via FTP COM Port Devices l Barcode Table Tightening Programs Identification Screwdrivers Access Point Parameters WLAN Compatibility TCPAP Settings 029 EXACT 4 591000029 a Connected Search Remove Manually Saveto XML File Load from XML File OK Apply Cancel Print Setup The tools will be in the connected list when the sequence is d
110. reely in both directions If the setting is right only the tool will NOT rotate left to remove a screw The CF mode refers to the crow foot or tube nut function of a BT EXACT tool to run with limited power in reverse when needed Select this mode ONLY if you are using a tube nut attachment on a tool This mode allows full power to the tool motor in the right or forward direction but LIMITS the left rotation to a maximum run time of 5 seconds at about 25 of normal power This action prevents damage to the return stop normally incorporated into custom made tube nut heads The minimum and maximum fastener run time can be programmed in their respective boxes You must set the time in 50 ms increments This function allows you to monitor time as a function of angle of rotation to determine cross threads or missing parts during the tightening process While this function is not a direct substitute for true angle measurement it can be very helpful to detect problems in your manufacturing process 13 Edit Tightening Programs Program Number Name icross thread Numeric ID io Number of fasteners per job 4 Lock after number of fasteners NOK lo Count Strategy Plus 1 if OK v eft Rotation Min fastener time 50 ms increments boo a 1 000 Max fastener time 50 ms increments Min job time 250 ms increments Max job ti
111. ring the connection between the two devices is shown below CRAII Olas au The connections between the I O module and EXAConnecT are listed below I O Module EXAConnecT 1 OY to IA 1 OZ to IB 1 IA to OY 1 IB to OZ gnd to gnd 9 30v to 24v gnd to gnd The input power can be from 9 30 volts If the I O module is to be installed more than 20 meters away from the EXAConnecT it is recommended that power be supplied from a different dedicated source Be sure that any external power source can be switched if a restart is needed see section 35 for details Follow the diagrams below for wiring two I O modules to an EXAConnecT Remember that the two modules CANNOT be connected in parallel via COM1 and COM2 they must be wired in series from either COM1 or COM2 The wiring from I O one to the EXAConnecT is shown on the previous page The wiring from I O one to I O two is shown below I O ONE G PG AT 7 A O TWO b PG A AA AR A WOOK The connections between I O module one and I O module two are listed below I O Module One I O Module Two 2 OY to 1 IA 2 OZ to 1 IB 2 A to 1 OY 2 B to 1 OZ gnd to gnd 9 30v to 9 30v gnd to gnd Input connections to the I O Module are similar to the inputs of the EXAConnecT controller The O s are located on the terminal strip inside the I O module 24 The I O s are optically isolated polarized dry contacts that requir
112. roller contains a Bluetooth antenna that can be set to a relative range of operation The maximum working distance of the system is about 30 40 feet from EXAConnecT to a BT EXACT tool To limit the working range of ALL screwdrivers connected to a controller perform these simple steps as listed here Note that these settings should have been configured by your distributor you may not need to perform these steps Remove the lower cover of the Bosch EXAConnecT controller Connect a null modem serial cable to the serial port inside the controller 19 Connect the other end of the cable to a PC serial port i eit rooaoaa Ss Q 0 0 Select the HyperTerminal program from your Windows menu 4 ff Accessibility gt Fn Communications gt Entertainment gt En Games gt A System Tools A Address Book gt i Calculator gt E command Prompt J Fax gt T HyperTerminal d iw Internet Connection Wizard gt NetMeeting Network and Dial up Connections HA Phone Dialer A HyperTerminal Fn Business Explorer 5 EXTRA Personal Client 32 Bit it_sec Fn Microsoft Office A Neue Rechtschreibung 3 Peacy SAP Front End fF Startup gt Imaging A Toshiba Internal Modem gt Eaz Notepad fF Trend Micro OfficeScan Client gt w Paint Fn Winzip Ay Acrobat Reader 5 0 g Internet Explorer Security Check Internet Explorer
113. rs to a preset index number If you must assign the index number of the tool manually click on the pull down menu after entering the 6 digit Bluetooth address lOl x Database Automatic Save viaFTP COM Port Devices Barcode Table Tightening Programs Identification Screwdrivers Access Point Parameters WLAN Compatibility TCPAP Settings Found __ Connected i ia laan rss BT Address Entry x Enter BT address manually LP phy Cancel Print View Now select the desired index number from the list Seven screwdriver numbers are available from 0 6 Click OK and the tool will be connected and given the correct index number Repeat the process for additional screwdrivers Click OK in the lower left of the screen to save your settings and exit Manual configuration is complete Move to the Screwdriver Setup and Creating tightening Programs sections 6 amp 7 to finish setting the strategy screw count and other tool parameters Note Use the manual connection process when you have problems connecting automatically If the EXAConnecT searches for tools in an area where many non communicating or dummy BT EXACT tools are located it will find hundreds of tools but only display the first SEVEN This means that the desired tool may never connect automatically even if it is closest to the EXAConnecT Use the manual pro
114. rting the controller gives you a default IP address regardless of software setting See hardware buttons and switches in section 33 for details e Make sure you have any pop up or security blocks removed Sometimes a browser will treat the Java script poorly and prevent it from running correctly Symptom connected my PC to one controller and everything worked properly then disconnected the PC from that EXAConnecT and went to another EXAConnecT in my facility and now cannot connect to the new controller The browser runs or just times out after a while Corrections e You need to close your browser and reopen it again Sometimes depending on your network card hardware and your operating system the Java script that talks to the EXAConnecT is not reset The best thing to do is to close your browser every time you finish programming one controller and Opening it when you start programming a new one e Sometimes different network cards take longer to react to a disconnection and reconnection to a network In this case go into your local area connection right click on it and select disable Wait for at least one minute then go back to the connection and right click again this time select enable Note if the yellow LED on the EXAConnecT starts to blink If it does open your browser again and connect If you still cannot connect try to ping the controller see next page Pinging the EXACo
115. ry contacts that require external voltage to perform a switching function To connect the I O s remove the lower cover of the EXAConnecT and view the terminal strip inside The I O S are clearly labeled inside the EXAConnecT as input 13 and output 14 Note that the I O s are numbered from left to right with input one being on the left Note that the terminal strip has a 24 volt power supply on the right it is marked PW 15 This power supply has a maximum output of 150 milliamps or LESS than 4 8 watts of power The EXAConnecT software can be programmed to configure the inputs outputs to operate a stack light The stack light trigger connections are wired to the EXAConnecT as shown on the right Note that the dry contacts of the controller are polarity sensitive and may not trigger the lights if wired backwards The diagram above shows wiring for lights that are using the outputs as a switch See section 12 for software configuration 31 The diagram below shows wiring for lights that are using the outputs as a switch Yellow Blue Green You can use 24 volt power to trigger LED stack lights directly from the EXAConnecT as shown below 24 volts DC positive from EXAConnecT jumped across all positive contacts Output 1 Green LED stack Output 2 Red LED stack Output 3 Yellow LED stack Output 4 Blue LED stack Stack
116. s WLAN Compatibility TCPAP Settings Save Mode off x Save Period daily x Number of Events 1 Backup of Single and Total Results Automatic balote after Backup O Yes No FTP Server Setup FTP Server IP address 10 10 10 10 FTP server user name anonymous liro ot FTP server password File path on ftp server Cancel Save to XML File Load from XML File OK Apply Cancel Print Setup Click on the FTP server setup button to access the server setup window You must point the EXAConnecT to the FTP server you are running on your PC or network Your IT department can provide assistance for this setup if needed Configure the external server IP address the user name password and path Click on save to finish You must select WHEN you want data to transfer to the FTP server If by number of events screws open the save mode box and select by number of events Be sure to set the actual number too Database Automatic Save via FTP COM Port Devices i Barcode Table l Tightening Programs Identification Screwdrivers access Point Parameters WLAN Compatibility TCPAP Settings Automatic Delete after Backup FTP Server Setup Save to XML File Load from XML File OK Apply Cancel Print View 44 If yo
117. setting for each tool used in the EXAConnecT You can do this in the screwdriver setup menu of each individual tool Save your settings and test the system for correct operation 21 Bosch open protocol configuration Version 9 2008 One page The Bosch protocol is not customer specific or even Bosch specific It is simply an open protocol that can be interpreted and used freely by any customer that decides to write a few commands from their network systems to control the EXAConnecT and BT EXACT tools The protocol allows mid sized companies that have an IT department to connect to our system without the expense of creating a large network system or purchasing a control system The parameters for defining the communication via this protocol are NOT INCLUDED with this manual they will only make sense to at IT person or programmer These instructions can be obtained from Bosch or your distributor The instructions contain specific programming code and telegram information needed to write command codes to control the EXAConnecT and BT EXACT tools Contact Bosch for assistance when using the Bosch open protocol interface To configure the Bosch protocol you will need to go to the EXAConnecT setup menu and select the database tab Now open the pull down menu and select Bosch from the list EXAConnecT Setup f Database Automatic Save via FTP COM Port Devices Barcode Table Tightening Programs Identificat
118. sition the EXAConnecT defaults to an IP address of 10 10 10 10 regardless of what the programmed IP address configuration is Example the IP address of a controller is set to 192 168 5 10 You need to service the controller without changing the IP address Flip the switch down and RESTART the controller The IP address is now 10 10 10 10 and you can connect to the controller without changing the IP address When you have finished using the bypass IP address flip the switch up restart the controller and the IP address will be returned to its pre defined setting 34 Using the service tool software Version 9 2008 Three pages The service tool software is a separate program that runs on your PC It is a small Java application that is free of charge from Bosch Contact your distributor or Bosch to get a copy The service tool can perform various functions to diagnose change settings delete files and control the EXAConnecT The software runs a Java script like the EXAConnecT software Files needed are listed below General Tech safety Cordless Bluetoo sneraliTech safety Cordless Bluetoothi USA BT System Files 05_BT Softwaret0a_Service Tool Files To Send _ Received Files d accesspoints xml 1 KE a deutsch lang 2 KB Aarah lang zZ K Z EXACO 03_Service Tool start bat M5 DO5 Batch File nine TService Tool jar ol KB 1 KB Modified 7 4 2006 8 55 AM To start the service tool double click
119. t Setup In this example we still have more than twenty 20 Bluetooth channels remaining which is all we need to insure solid data transfer for the Bosch system By using the Wide mode the marked Wireless LAN channels will be completely hidden By using the Narrow setting there is a very small chance that one or two Bluetooth frequencies are in the Wireless LAN reserved areas but only at the very end of the spectrum The second condition is when a tool either leaves an area and returns or when the tool battery is changed and the tool must reconnect to the controller This condition is the page scan for the tool and can be limited or avoided depending on what the IT department of a facility wants to do EXAConnecT Setup loj x Database Automatic Save via FTP COM Port Devices Barcode Table Tightening Programs Identification Screwdrivers Access Point Parameters I WLAN Compatibility TCPAP Settings WLAN Channel Number 1 2 Ss 4 ee Go Ves eS AE NA A2 13 Exclude WLAN Channels i aa dal laal i a d Dal l a a laa im O Wide Narrow Exclusion window size Remaining BT Channels shall be gt 20 Automatic Bluetooth reconnect Bluetooth reconnect trigger Bluetooth reconnect Bluetooth auto reconnect OFF warnini Save to XML File aa trom XML File OK Apply Cancel Print View There are three settings The first
120. t View Cal Transfer Heip Diel alz elil a authentication successful BOSCH BT Exact Recess Point fitara Honi tor iHelp type command number and parameter in one line separated by a blank and terminated with lt RETURN gt jExample 2 192 168 0 1 to change the IP address Command menu ne Lip show current settings set IP address set IP netmask set IP gerar use DHCP y or n a set Ethernet speed 18 hari 18 full 100 half 100 full set system date DD HH Y YY set system time HH HH activate UPS y or n set bluetooth transmit power 0 20 Boone owes Your choice Conpected 00 00 40 Auto detect S600 de ae ca Menu items 2 6 can be set either here or in the actual software of the EXAConnecT 28 Items 7 8 9 amp B are only set in HyperTerminal To set the time date or Bluetooth transmit power just type the desired digit followed by a space followed by the desired value Example To change the time to 6 30 pm type the following in one line 8 18 35 00 You must use military time in hours minutes amp seconds bt HyperTerminal File Edit View Call Transfer Help Dias alz a 4 E 8 18 35 19 Current time is 09 44 14 29 May 2005 Updated time is 18 35 15 29 May 2005 Your choice ommand menu help show current settings set IP address set IP netmask set IP gateway use DHCP y or n set Ethernet speed 10 half 10 f
121. the Click on the Job Settings tab to continue tool give it an ID and put in user information Soreni o Ex Piel es State ad Seen are N oe thes sores EE Identification Screwdriver Settings aiia Copy settings from other screwdriver Identification q ewdriver Settings Job Settings Output Settings Job Definition Program Device BT EXACT 4 Program Number if static Bluetooth Address 00 00 D3 01 03 45 Job Release Manually v Serial Number 591000029 Rework Release 1 x left rotation Manually v User Name 029 EXACT 4 Job Cancelation Manually v User ID EXACT 4 Fi User Information BOSCH Save to XML File Load from XML File Save to XML File Load from XML File OK Apply Cancel Print Setup Back to Defaults OK Apply cancer Print View Back to Defaults Click on the Job Definition box and a pull down menu will be displayed Be sure that Dynamic via protocol is selected This tells the tool to take commands from the AIS box Be sure to check that the tool is set to Program Number 1 one to insure that the tool runs without counting screws or locking The Ford Open Protocol selected earlier will count screws in the EXAConnecT and report to the AIS box 4 All other fields in this tab can be left at their defaults There is no need to configure
122. tightening programs tab to begin EXAConnecT Setup Database Automatic Save via FTP Identification Screwdrivers Access Point Parameters WLAN Co No Name NumiD Count LockNOK Strategy Rot MinS MaxS MinT MaxT 1 Default Entry 0 5 0 1 0K R L 0 jo 0 0 2 No count 2 1 0 Nocount Re 0 0 0 0 3 J8 batch 13 8 j 1 OK Re o fo fo 10 4 CF mode 4 1 0 Nocount R UCF O jo jo o 3 jerossthread 0 z p J 1 OK ReL 500 1000 o 0 6 dummy tool 0 1 0 No count R L 0 0 Jo ft Edit Tightening Programs X Save to XML File Load from XML File OK Apply Cancel Print View Your EXAConnecT may have more or less programs stored than pictured in this example If your configuration only requires that the tools be unlocked all the time and they do NOT count screws you only need to insure that the default program in the system is correctly programmed You do not need to create any new programs To edit or create new programs click on edit tightening programs 11 The system will load the edit tightening programs window Edit Tightening Programs Program Number Name Numeric ID Number of fasteners per job Lock after number of fasteners NOK Count Strategy Rotation N Min fastener time 50 ms increments Max fastener time 50 ms increm
123. tool will keep running for that time even when out of range of the EXAConnecT controller 5 x Service and Calibration Copy settings from other screwdriver Identification l Screwdriver Settings Job Settings Output Settings Communication and theft protection On Off E nts ly 00 z700 Theft protection delay 5 s increments Double hit detection time 50 ms incre Repeat protection 100 ms increments Save to XML File Load from XML File OK Apply Cancel Print View Back to Defaults The default for the double hit detection time is 100 ms You can adjust this as needed to detect and report a double hit error in the system This value is reported as error code number four 4 in the system and will allow the screwdriver to keep working but report that screw as being double hit This field can be used to detect double hits and look for a minimum angle of rotation of a fastener Repeat protection is different and independent from a double hit This field controls the time that the trigger does NOT work after the last screw was run If you set the repeat protection to 700 ms that means the trigger will not run the tool even when depressed until at least 700 ms has passed from the time the trigger was last released This is adjustable down to a minimum of 300 ms Note that if you disable the communic
124. u decide that it has lost firmware If all else fails you must flash the firmware onto the controller Go to section 32 for details 31 Tools will not unlock Version 9 2008 one page There may be times when it appears that a tool or all tools will not unlock despite your best efforts There are a few settings to check to insure that you can isolate and find the problem In most cases tools unlock whenever they are manually unlocked via the Java software a PLC signals them to unlock or a protocol commands them to unlock If it appears that tools are no longer unlocked or are not responding to unlock commands check the following settings Database Automatic Save via FTP COM Port Devices Barcode Table Tightening Programs Identification Screwdrivers SEEEN EES Parameters WLAN Compatibility TCPAP Settings Language English x New Password Confirm Password Allow manual lock unlock Operate Data Buffer as Ring Buffer Size of Data Buffer no of Events Save to XML File Load from XML File OK Apply Cancel Print Setup In the EXAConnecT setup under the access point parameters tab check to see that manual locking and unlocking is allowed If NO is selected the only way to unlock tools is via a 24 volt input or a customer specific protocol It is usually best to leave this setting at YES It is also CRITICA
125. u want data saved by TIME select a choice under save period EXAConnecT Setup loj xj Database Automatic Sawe via FTP COM Port Devices Barcode Table Tightening Programs Identification Screwdrivers d Access Point Parameters WLAN Compatibility TCPAP Settings Save Mode Save Period Number of Events Backup of every 12 hours Automatic Delete after Backup daily 1 FTP Server Setup Save to XML File Load from XML File OK Apply Cancel Print View In either case you MUST set what you want to save each single screw count batch counts only or single screws and batch counts together EXAConnecT Setup E loj xj Database Automatic Save via FTP COM Port Devices Barcode Table Tightening Programs Identification Screwdrivers Access Point Parameters WLAN Compatibility TCPAP Settings Save Mode off v Save Period daily x Number of Events Backup of I ingle and Total Results v Automatic Delete after Backup Single Results otal Results R FTP Server Setup Single and Total Results we to XML File Load from XML File Once you have completed configuration test the system for connectivity Note that the EXAConnecT WILL report an error message of L1 if it sees that there is NO connection to an FTP server This error code will
126. ull 100 half set system date DD HMH YYYY set system time HH MM SS activate UPS y or n set bluetooth transmit power 0 20 Your choice Antenna power is set the same way Type in one line B 10 to set the antenna power to 50 range Input a lower number to set to a lesser range Antenna power cannot be defined in an exact distance Your value entered here will be a percentage from full power You must test the system to determine what range works for your application Remember that the system needs more power to MAKE a connection to a tool than to keep it Remember that you need to set the theft protection delay to 5 seconds in screwdriver setup to insure that the tool works for a minimum amount of time after going out of range You MUST restart the EXAConnecT controller after making a change to ANY item in this menu Failure to do so will result in no change being made Close the session and do NOT save it when finished You have finished reprogramming the EXAConnecT antenna time amp date 16 Bar Code Scanner Wiring amp Setup EXAConnecT Designator RS422 Version 9 2008 Two pages Pin Name Adapter Pin number The EXAConnecT can communicate with up to two A Transmitter 1 7 tools to be controlled locked released and reprogrammed via bar code input from a scanner Bluetooth system will not allow other standard Bluetooth device to communicate with it l bar code scanners simulta
127. ur browser running to flash a controller but you do need to verify that you can connect to it The following instructions are to be used for an EXAConnecT that has a default IP address of 10 10 10 10 There are three files needed to flash a controller filesys bin formdisk bat hyflash exe The file named filesys bin is the key file that actually contains the controller firmware It has the file known as project hen embedded in it There is a version of filesys bin for each version of project hen firmware that runs the EXAConnecT this file is only identified by date Be sure to verify you have the latest dated version of the file or you may wind up installing an old firmware The file named hyflash exe is the executable file that launches the program To START the process just double click on the formdisk bat file This starts both the hyflash file and the filesys file The firmware is then loaded erasing ALL data screwdrivers firmware and settings stored in the EXAConnecT During the loading process a DOS window will open and remain open for about a minute If this window does NOT remain open and closes immediately after double clicking on formdisk bat this indicates that you are not properly connected to the EXAConnecT Check your settings and IP addresses and try again When finished open your browser check the EXAConnecT 5I settings make changes if needed and reb
128. ver Settings Output Settings Device BT EXACT 4 Bluetooth Address 00 00 D3 01 03 A5 Serial Number 59100002 User Name 029 EXACT 4 User ID EXACT 4 User Information BOSCH Save to XML File Load from XML File OK Apply Cancel Print View Back to Defaults You can name the tool give it an ID and put in user information Each field holds 19 characters 16 Click on the Screwdriver settings tab next Screwdriver Setup N o x Service and Calibration Japa rewdriver Screwdriver Settings Identification Job Settings Output Settings Communication and theft protection On Off Theft protection delay 5 s increments 5 Double hit detection time 50 ms increments Repeat protection 100 ms increments li Set the repeat protection of the tool to 300 ms This will allow the operators to work quickly Now configure the theft protection setting We suggest a minimum time of 5 seconds the tool will now lock within 5 seconds after it is out of range If you input a longer time here the tool will keep running for that time even when out of range of the EXAConnecT controller ioj x Service and Calibration Copy settings from other screwdriver Identification y Screwdriver Settings Job Settings Output Settings Communication and theft protection
129. ystem will ask if you want to update the controller Click on OK and the firmware will begin loading When you are DONE you will need to restart the EXAConnecT The new firmware version will NOT begin running until the controller is restarted Restart EXAConnecT via service tool There are three ways to restart the controller 1 unplug it and plug it back in 2 Press the reset button in the controller section 33 3 Use the service tool software to reset the controller which is the easiest method while you are in the service tool software To reset the controller right click on the default controller icon or the icon of the named controller if that is the one you are connected to Select EXAConnecT reset from the menu 55 ExAConnecT Service Tool Program Options Help Dault nnectec Connect f Disconnect Query Status Query Configuration b Firmware Update Administrate Files P Administrate Password Esa onnecT Res The system will ask you if you are sure Confirm by clicking on yes _ExAConnecT Service Tool Program Options Help E ga Ex4ConnecT Hia m autt Connecting Default Default is connected Reset Default Are you sure Now the software will reset the controller The system will display the message below Info Default J a AP is resetting please wait while reconnecting Sometimes you may see an additional message as shown bel

Bosch Bluetooth Operating Instructions 9/2008

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