AFC-1200 Manual
Chapter 8.3
Replacements

8.3.1 ISA Main Controller unit Replacement (No Partial Replacement)
8.3.2 Processor PCB (CMOS Real Time Clock) Battery Replacement
8.3.3 Axis Controller Unit Replacement (No Partial Replacement)
8.3.4 nutrunner (tool) replacement (NO partial replacement)
8.3.5 Replace homerun cables

The ISA Main Unit controls overall operations of the AFC1200 Fastening System. The values for System configuration and operational programs/presets are stored on the components of this System. Values are stored on a combination of EPROM, EEPROM, CMOS, and magnetic disk as indicated in the following chart:

The ISA Main Unit is not user-serviceable, and no attempt should be made to replace any component of the Unit except for the Real Time Clock battery, as described in Section 8.3.2.

In the event of failure, the ISA Main Controller should be replaced as a complete assembly. Do not remove the Controller cover (except as directed in Section 8.3.2) or attempt to repair or modify the Unit. The circuit boards in the ISA Main Controller Unit should be handled by FEC INC. personnel, only.

ISA Main Controller Units must be replaced with identical equipment. Ensure that the hardware and software configuration of the replacement Unit is identical to that of the failed Unit.

To replace the ISA Main Controller, proceed as follows:

• Ensure that there is no power to the System, then disconnect all power cables and communication cables connected to the ISA Main Unit.
• Carefully remove the Main Unit from the enclosure. (Sections 4.2.2 and 4.3)
• Verify that the replacement Unit's hardware and software configuration is identical to the configuration of the failed Unit. Secure the replacement Unit in the enclosure.
• Verify that the power source is within specifications (Section 2.3), then connect all power cables and communication cables to the replacement ISA Main Unit.
• Prepare the System for operation by following the procedures in Chapter 5.

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CAUTION: When the cover is removed from the ISA Main Controller Unit, the circuit boards are exposed. Take precautions to ensure that the boards are not subjected to any electrical shocks. The boards support many surface-mounted devices for System operation, and rough handling of the boards could result in damage requiring replacement of the ISA Main Unit.

• Ensure that there is no power to the System. Disconnect all cables (communication and power) from the ISA Main Unit. Remove the Unit from the enclosure.
• Remove the six (6) screws securing the top cover of the ISA Main Unit, and lift off the cover. Locate the lithium battery on the left face of the Processor PCB (the first full-size board on the right).
• Exercise extreme care to avoid damage to the circuit board, and use a non-conductive, blunt tool to gently pry the battery from the holder.
• Place a new battery (3-Volt Panasonic BH32) in the battery holder, and reinstall the cover on the ISA Main Unit.
• Secure the ISA Main Unit in the enclosure. Verify that the power source is within specifications (Section 2.3), then connect all cables (communication and power) in the reverse order of removal. The System may require the date/time to be reset to the current date and time. Refer to 7.9.4 Screen Operation [System Configuration (2)]

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Axis Controller Units are not user-serviceable, and no attempt should be made to replace any component of the Unit. In the event of failure, the Axis Unit should be replaced as a complete assembly. Ensure that the hardware and software configuration of the replacement Unit is identical to that of the failed Unit.

Note: Although "A" type Axis Units (AXIS-203A, for example) accommodate the same nutrunners as their older style counterparts, they are not fully interchangeable. REPLACE OLDER STYLE AXIS UNITS WITH THE SAME, AND REPLACE THE "A" TYPE UNIT WITH OTHER "A" TYPE UNIT. If it is necessary to intermix older style Units with "A" type Units, contact FEC INC. for guidance.

TOOL TYPE	AXIS UNIT
DFT-101M1-S1/O1	AXIS-203 / 203A
DFT-201M1-S/O	AXIS-203 / 203A
DFT-401M1-S/O	AXIS-203 / 203A
DFT-401M2-S/O	AXIS-203 / 203A
DFT-601M3-S/O	AXIS-205 / 205A
DFT-801M3-S/O	AXIS-205 / 205A
DFT-132M3-S/O	AXIS-205 / 205A
DFT-152M3-S/O	AXIS-205 / 205A
DFT-202M3-S/O	AXIS-205 / 205A
DFT-302M3-S/O	AXIS-205 / 205A
DFT-502M4-S/O	AXIS-210 / 210A

WARNING: DO NOT CONNECT OR DISCONNECT CABLES OR OTHER SYSTEM COMPONENTS WITH POWER APPLIED. FOLLOW LOCKOUT/TAGOUT AND OTHER APPLICABLE SAFETY PRECAUTIONS WHEN CONNECTING OR DISCONNECTING CABLING, WIRING, AND EQUIPMENT.

To replace an Axis Unit, proceed as follows:

• Ensure that there is no power to the System, then disconnect all power cables and communication cables connected to the Axis Unit.
• Carefully remove the Axis Unit from the enclosure (Sections 4.2.3 and 4.3).
• Verify that the replacement Axis Unit's hardware and software configuration is identical to the configuration of the failed Unit.
• Verify that the Axis Unit dip switches are set to the appropriate spindle number and ramp-up time. Refer to Section 4.9.
• Secure the replacement Unit in the enclosure.
• Verify that the power source is within specifications (Section 2.4), then connect all power cables and communication cables to the replacement Axis Unit.
• Prepare the System for operation by following the procedures in Chapter 5.

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Nutrunners are not user-serviceable, and the tool should not be disassembled except to perform the Transmission Inspection procedure described in Section 8.2.4. In the event of failure, the nutrunner should be totally replaced with an identical tool. The tool type identification can be found on both the identification tag affixed to the tool, and on the System [PREAMP EEPROM DATA] screen.

• Ensure that there is no power to the System, then disconnect the three (3) homerun cables from the tool.
• 2. Ensure that the spindle assembly is supported, and remove the two (2) bolts securing it to the mounting plate. WARNING: These two (2) bolts also secure the nutrunner, with the two (2) bolts removed in the next step. Some tool models are very heavy. Use precautions when disconnecting, removing, and installing these components.
• 3. The preamplifier is secured to the powerhead frame with two (2) screws. When possible, it is more convenient to disconnect the preamp from the powerhead frame prior to removing the nutrunner. CAUTION: The preamp is also connected to the nutrunner, and this connection must not be subject to stress or shock which could cause damage and result in inaccurate System output. Do not allow any pull on the preamp cable.
• 4. To remove the nutrunner, first verify the preamplifier removal status (Step 4, above). Ensure the nutrunner is supported, and remove the two (2) remaining bolts (two of the four were removed in Step 3).
• 5. Follow all safety precautions to install an identical nutrunner/preamp assembly by performing the removal procedure in reverse order.
• 6. Prepare the System for operation by following the procedures in Chapter 5.

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FEC INC. provides a spare set of homerun cables with each System.

Verify all System power is off.

Disconnect the damaged cable(s) from the nutrunner and the Axis Unit, and replace with the spare cable(s). Bypass all other Axis Units, and verify that the new cables function.

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