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m-Pro-400S-DGD-Intelligent-Spindle

1. 5 3 5 Size 3 1x transducer DGD IS B 1 2 1 2 1 2 1 2 1 2 1 2 1 2 SBTS 3B300A 3K2B 3ZB 947577 6 2 934302 378 927233 KMAG 961088 002 3BTS 3B300A 3VK2B 947579A4 3 4BT 935562 TS 961146 3VK2B 934342 KMAG 961088 004 3BTS 3B300A 3WK2B 947581A0 3WK2B 934382 KMAG 961088 003 3B300A 935590 3BUTS 3B300A 3K2B 3ZB 947583A8 2 934302 328 927233 3BUTS 3B300A 3VK2B 947585A6 3 4BUT 936323 TUS 961147 3VK2B 934342 KMAG 961088 004 3BUTS 3B300A 3WK2B 947587 4 3WK2B 934382 1 Code 2 Part no 5 3 6 Size 3 2x transducer DGD IS B 1 2 1 2 1 2 1 2 1 2 1 2 1 2 SBTS 3B300A 2 3K2B 37B 947578 5 3K2B 1 378 927233 961088 002 3BTS 3B300A 3K2B 3VK2B 947580 1 3 4 935562 TS 961146 2 984842 KMAG 961088 003 3BTS 3B300A 3K2B 3WK2B 947582 9 3WK2B 934382 en 934302 961088 005 3BUTS 3B300A 2 3K2B 3ZB 947584 7 2 5 328 927233 KMAG 551088006 3BUTS 3B300A 3K2B 3VK2B 947586A5 9 4BUT 936323 TUS 961147 3VK2B 934342 961088 005 2 934302 KMAG 5 3BUTS 3B300A 3K2B 3WK2B 947588A3 3WK2B 934382 2x 1 Code 2 Part no 5 3 7 Size 4 1x transducer DGD IS B 1 2 1 2 1 2 1 2 1 2 1 2 1
2. 7 1 Centric attachment 8 Illustration of 1ZB Ratio Permissible load Lateral force at wrench head i on output shaft TQ Pres Ten 25 mm 50 mm sure sion Extended Retracted Retracted Nm N N N N N 1ZB 927222 1 1 53 1900 1500 1150 1350 1600 27 927227 200 4500 3200 2450 2700 3250 3ZB 927233 300 6500 5000 3000 3500 4100 4ZA 927236 660 9000 8800 4300 4800 5400 421250A 5976950 3 7368 1250 9000 8800 4300 4800 5400 4Z1600A S976951 3 7368 1600 1 During continuous operation for long periods multiply the specified values by 0 3 17g_Komponenten en fm 01 06 2011 1917 2011 05 33 Attachment 7 2 Offset attachment Range Torque measurement Range Angle measurement telemetry system aa 2 Only with version VK J oL Helical spur gears ap nut 8 Crown gearing Code Order no Torque Ratio Permissible load Lateral force at wrench head Calibration i on output shaft TQ Pres Ten 25 50 sure sion Extended Retracted Retracted Nm N N N N N 1VK1B 935862 35 1VK2B 935861 60 1 0526 53 2300 2300 1510 1720 2000 1VK3B 935860 12 2VK1B 934334 170 TETTEN 200 1 0714 160 2500 2500 2300 2600 3100 3VK2B 934342 300 1 0769 260 3600 36
3. 5 2 7 Size 4 1x transducer Designation Order Torque Speed Spring travel min Length Weight Spring a axis Chuck Nm distance rpm mm mm mm kg flange 4BTS 4B500A 4K2B 4ZA 947589A2 500 100 254 3 4 916643 4BTS 4B660A 4K3B 4ZA 947601A5 660 130 174 1 916642 4BTS 4B360A 4K1B 4Z1250A 947617 7 1250 320 86 1 S976956 4BTS 4B500A 4K2B 4Z1600A 947621 1 1600 400 68 50 1 1 2 5308441 4BTS 4B500A 4VK2B 947591A8 500 100 238 3 4 912106 4BTS 4B660A 4VK3B 947603A3 660 130 163 1 76 684 22 5 5308440 4BTS 4B660A 4VK4B 947607A9 750 160 135 1 ind 4BTS 4B500A AWK2B 947593A6 500 100 245 3 4 358 T 929077 4BTS 4B660A 4WK3B 947605A1 660 130 167 1 929089 4BUTS 4B500A 4K2B 4ZA 947595A4 500 100 254 3 4 916643 4BUTS 4B660A 4K3B 4ZA 947609A7 660 130 174 17 916642 4BUTS 4B360A 4K1B 4Z1250A 947619 5 1250 320 86 i S976956 4BUTS 4B500A 4K2B 4Z1600A 947623A9 1600 400 68 50 1 1 2 E m S308441 4BUTS 4B500A 4VK2B 947597A2 500 100 238 3 4 912106 4BUTS 4B660A 4VK3B 947611A3 660 130 163 1 76 512 S308440 4BUTS 4B660A 4VK4B 947615A9 750 160 135 1 24 5 4BUTS 4B500A 4WK2B 947599A0 500 100 245 3 4 28 6 929077 4BUTS 4B660A 4WK3B 947613A1 660 130 167 E 1 s 28 7 929089 Smallest scribed circle diameter in mm Quantity Attachment DGD IS Centric Offset Angle head 2 91 76 11
4. cable for breaks especially the calibration signal wire The calibration signal is short circuiting with another signal Check the KMAG KMAW cable transducer TS TUS for short circuits gt Replace the cable Error in the transducer gt Replace the transducer Internal error gt Replace the TS TUS 171 Fehlersuche en fm 01 06 2011 P1917E EN 2011 05 81 Troubleshooting DGD Error Description Possible causes Measures and remedies Transducer 1 2 Offset value NOK The zero point voltage is outside the permissible range of 200 mV 200 mV The torque signal is interrupted Inspection of station controller in test mode value outside the permissible limits Check the KMAG KMAW cable transducer TS TUS for breaks gt Replace the cable The torque signal is short cir cuiting with another signal Check the KMAG KMAW cable transducer TS TUS for short circuits gt Replace the cable Error in the transducer gt Replace the transducer Internal error gt Replace the TS TUS Transducer 1 2 Angle encoder NOK The angle signals are disrupted One or both angle signals is are interrupted Check the KMAG KMAW cable transducer TS TUS for breaks especially the angle sig nal wires gt Replace the cable short circuiting with another signal Check the KMAG KMAW cable transducer
5. Wiring of robot area SuperhighFlex Quality Cable HighFlex Quality suitable for cable ducts Super Highflex suitable for Function description Torque 2 044 22122 Angle measurements Redundant design a sensor system according to VDI 2862 Troubleshooting Acknowledgment of BDGDAS cm Tightening module CPS3 in nutsetter control unit m Pro 400S CPM Tightening module TS TUS sies see Station controller 4005 Maintenance Service Disposal 57 57 62 65 65 Ben 66 69 69 70 71 ct 76 83 83 P1917E EN 2011 05 P1917E EN 2011 05 m Pro 400S DGD ISIVZ fm 01 06 2011 Safety 1 1 1 DANGER WARNING Safety Warnings and notes CAUTION NOTE 1 2 DANGER A WARNING A CAUTION symbol combined with the word DANGER warns of impending health risk or risk of fatal injury to personnel If this danger note is not adhered to severest injury that may lead to the death of people is the consequence A symbol combined with the word WARNING warns of a potentially dangerous situation for the health of personnel which
6. Power supply Generated Maximum voltage current V A Internal servo section logic 3 3 8 2 8 4 0 5 Internal servo section analog 5 0 4 9 5 1 0 5 Internal servo section analog 15 0 14 25 15 75 0 12 Internal measuring section logic 1 9 1 78 2 02 1 Internal measuring section analog 2 5 2 4 2 6 1 Internal measuring section analog 3 3 3 2 3 4 0 5 Internal measuring section analog 12 0 11 4 12 6 0 5 Transducer 12 0 11 8 12 2 0 6 ARCNET output stage 5 0 4 8 5 2 0 2 174 Schraubmodul en fm 01 06 2011 P1917E EN 2011 05 31 Tightening module TS TUS DGD 6 5 2 6 5 3 NOTE Motor end stage Short circuit proof Phase phase phase phase temperature monitor Minimum losses due to IGBT end stage Features Data Intermediate circuit voltage Uz VDC 380 10 Excess voltage shut off VDC gt 480 Low voltage shut off VDC lt 160 Rated output at 50 C VA 1000 Peak power momentary VA 8000 Peak current maximum A 65 Current controlled shut off short circuit A 100 Efficiency approx 98 Pulse frequency of the PWM 2 10 Measuring board The measuring board is a component of the tightening module and should not be replaced separately Separate processors for measuring and communication tasks Two separate measuring channels for torque and angle tracking 2 tracks each Measuring
7. 2a 21 6 Tightening module TS TUS 27 6 1 pee Nee 28 6 2 General technical tere a a 28 6 3 EON D cec 29 6 4 Service panel Mec o 29 6 5 Internal 5 5 31 7 Attachment 33 7 1 Centric attachments 33 7 2 Ollsel attachment eenn 34 7 3 Angle head attachment esses 35 7 4 Spring collet enn 36 8 Transducer 38 8 1 m sine 39 8 2 Pin configuration of 5 40 9 Gearing 40 P1917E EN 2011 05 m Pro 400S DGD ISIVZ fm 01 06 2011 P1917E EN 2011 05 3 10 10 1 10 2 10 3 10 4 11 11 1 11 2 11 3 11 5 12 12 1 12 2 12 3 12 4 12 5 13 13 1 13 2 14 14 1 14 2 14 3 15 15 1 15 2 15 3 15 4 15 5 16 17 Motor Technical data nn ae Electrical OSE OA eend Pin configuration motor connector Nutsetter control unit m Pro 400S CPM Brief function description nonnen General technical Electrical Data Supply module CP Ste AUG Instructions on laying cables T Strain relief clamp nr einlegen Laying High Flex Quality cables in cable ducts
8. 100 238 3 4 bs 912106 4BUTS 4B660A 4K3B 4VK3B 947612A2 660 130 163 i 76 639 5308440 4BUTS 4B660A 4K3B 4VK4B 947616A8 750 160 135 1 27 5 4BUTS 4B500A 4K2B 4WK2B 947600A6 500 100 245 3k 3 4 s 31 6 _ 929077 4BUTS 4B660A 4K3B 4WK3B 947614 0 660 130 167 1 31 7 929089 Smallest scribed circle diameter mm Quantity Attachment DGD IS Centric Offset Angle head 2 91 76 112 3 122 88 130 4 130 108 160 5 174 130 192 6 217 153 224 7 246 180 263 20 P1917E EN 2011 05 17e IntelligenteSpindel en fm 01 06 2011 DGD DGD intelligent spindles 5 3 Component overview B C H F G Ho KMAGIKMAW 5 3 1 Size 1 1x transducer DGD IS B J 1 2 1 2 1 2 1 2 1 2 1 2 1 2 2 1BTS 1B012A 1K3B 1ZB 947541 8 1B012A 927346 1K3B 934285 1BTS 1B035A 1K1B 1ZB 947553A4 1B035A 927344 1 1 934283 12 927222 961089 002 1BTS 1B060A 1K2B 1ZB 947565 0 1B060A 927345 1K2B 934284 1BTS 1B012A 1VK3B 947543A6 1 012 927346 1VK3B 935860 1BTS 1B035A 1VK1B 947555 2 1 93
9. 171 Fehlersuche en fm 01 06 2011 DGD Troubleshooting gt Error Possible causes Measures and 3 Description remedies o 2 2 3 24 supply gt Measure the voltage at XS3 terminals 1 and 6 24 supply is not within the 24 V power adapter in gt Replace the power range 21 5 27 3 V m Pro 400S CPM is defec adapter tive Power adapter T2 in gt Check the maximum load m Pro 400S CPM is over on the CPS3 loaded Voltage on power adapter in gt Set the voltage on the m Pro 400S CPM is incor power adapter to 26 0 V rect Fuse thermal 24 V in the gt Switch off the CPS3 is highly resistive m Pro 400S CPM and switch back on again after a minute gt Check the maximum load replace the CPS3 2 5 5 V supply internal Internal voltage external check not possible Power adapter inthe CPS3 is gt Replace the CPS3 Internal 5 V supply defective IS MOL WIN Power adapter inthe CPS3 is gt Replace the CPS3 4 5 V 5 5 V range overloaded 2 7 Error in 15 V driver supply The internal 15 V supply is Internal voltage can not be for the braking chopper 12 5 V checked externally Power adapter in the CPS3 is gt Replace the CPS3 defective Power adapter in the CPS3 is gt Replace the CPS3 overloaded 3 3 Initialization or Internal program error no external actions possible program error Error during program initializa tion gt Inform Sale
10. System handbook P1917E EN 2011 05 For additional product information visit our website at http www apextoolgroup com DGD m Pro 400S DGD Intelligent Spindle Series BTS About this system handbook This is the translation of the original system handbook and provides important information on safe correct and efficient operation of the system describes the function and operation of the components Serves as a lexicon for technical data It points out options Secondary information P1792E P1909E P1910E P1911E P1912E P1913E P1914E P1915E P1916E P1918E P1919E P1921E Symbols in text italics lt gt Courier Abbreviations m Pro 400S m Pro 400S CPM TS TUS CPS3 DGD IS Symbols in graphics Disclaimer Operator information Nutsetter control unit m Pro 400S Spare parts sheet Tightening module Spare parts sheet Attachment Spare parts sheet Gearing Spare parts sheet Motor Spare parts sheet Transducer Assembly instructions DGD IS built in nutsetter Assembly instructions TS TUS tightening module Assembly instructions Supply module CPS3 Service manual DGD intelligent spindle Identifies instructions to be followed Identifies lists Indicates menu items such as Diagnostics in software descriptions Identifies elements that have to be selected or deselected such as buttons or control boxes e g lt F5 gt Indicates the name of paths a
11. TS TUS for short circuits gt Replace the nutsetter cable temporarily unavailable Error in the transducer gt Replace the transducer Internal error gt Replace the TS TUS Transducer 1 2 CRC of service memory NOK Could not read in the data for self identification correctly The data cables are interrupted Check the KMAG KMAW cable transducer TS TUS for breaks especially the signal wires for data transfer RS422 gt Replace the cable short circuiting with another signal Check the KMAG KMAW cable transducer TS TUS for short circuits gt Replace the cable Error in the transducer gt Replace the transducer Communication was disrupted when the transducer was plugged in gt Unplug and plug in again Transducer 1 2 Tool identification NOK Station controller does not con firm the data for self identifica tion of the transducer Data communication failed Transfer the data from the sta tion controller see operator information m Pro 400S gt Acknowledge the TS TUS with lt Reset gt Data communication not com pleted yet Transfer the data from the sta tion controller see operator information m Pro 400S gt Acknowledge the TS TUS with lt Reset gt P1917E EN 2011 05 171 Fehlersuche en fm 01 06 2011 Maintenance Service 16 DANGER A WARNING A 17 CAUTION A Mainte
12. 0 6 Inductance 2 mH 6 5 3 1 2 4 Voltage constants mV RPM 34 34 44 Torque constant 3 Nm A 0 28 0 28 0 36 Current at peak torque 1 11 44 59 Max peak current 1 4 A 20 54 73 Electrical time constants ms 0 59 1 7 4 1 Sine peak value 2 Measured between two phases 3 10 4 The values specified apply to operation within the temperature range of 0 40 C They may not be exceeded even for a short period of time since this would lead to the risk of a magnetic weakening 10 3 Thermal data Features Data 1BT 1BUT 2 2 0 3 4BT 3 4BUT Insulation class according to VDE 0530 Thermal time constants min 17 5 25 35 Temperature rise K W 1 30 1 05 0 75 without cooling 42 P1917E EN 2011 05 17g_Komponenten en fm 01 06 2011 DGD Motor 10 4 Pin configuration motor connector Pin Signal designation Wire colors in motor Motor type BT Motor type BUT Motor 1 4 PE Green yellow 1 Phase S Green Green 2 Phase R Black Red 3 Phase T Red Resolver 2 1 Resolver R1 Red white 2 Resolver R2 Yellow white 3 Resolver S1 Red 4 Resolver S3 Black 5 Resolver 52 Yellow Blue 6 Resolver S4 Blue Yellow Temperature sensor 3 1 OV Black 2 Signal Red 17g_Komponenten en fm 01 06 2011 P1917E EN 2011 05 43 Motor 44 P1917E EN 2011 05 17 en fm 01 06 2011 DGD Nutsetter control unit m Pro 400S CPM 11 N
13. 2 DIN EN 61000 3 3 DIN EN 61000 6 2 DIN EN 61000 6 4 The filters required to fulfill the EMC standards are integrated in the system components Shielded cables offer protection against irradiating and radiating interference All cable shields are connected to the shield terminals on the nutsetter control unit and the plug casing on the DGD IS NOTE Equipment from EMC limit class value A DIN EN 550081 2 This equipment may cause radio interference in residential areas Should this occur you may request that the operator pay for and implement relevant EMC measures 1 8 Noise DGD IS dB A 1B U TS 1B012A 72 1B U TS 1B035A 72 1B U TS 1BO60A 67 2B U TS 2B110A 71 2B U TS 2B200A 67 3B U TS 3B300A 66 4B U TS 4B500A 66 4B U TS 4B660A 66 Measured sound pressure level at idling speed no load clockwise rotation in accordance with ISO 3744 2 Transport Storage Transport only in the original packing Ifthe package is damaged check the part for visible damage Inform the carrier or Sales amp Service Center if necessary WARNING Sharp cooling fins on the m Pro 400S CPM may cause cutting injuries gt Wear gloves when transporting and assembling the machine System components Storage temperature Relative humidity DGD IS 20 to 70 0 to 90 no condensation m Pro 400S CPM 20 to 70 0 to 90 no condensation TS TUS
14. 2 4BTS 4B500A 4K2B 4ZA 947589A2 48500 935780 4K2B 934315 4BTS 4B660A 4K3B 4ZA 947601A5 4B660A 935781 4K3B 934316 KMAG 961088 002 4 5 4 360 4 1 421250 947617 7 4B360A 929541 4K1B 934314 421250 5976950 4BTS 4B500A 4K2B 4Z1600A 947621A1 4B500A 935780 4K2B1 934317 4Z1600A 5976951 4BTS 4B500A 4VK2B 947591 8 3 4BT 935562 TS 961146 4B500A 935780 4VK2B 934353 4BTS 4B660A 4VK3B 947603A3 4B660A 935781 4VK3B 934354 961088 004 4BTS 4B660A 4VK4B 947607A9 4B660A 935781 4VK4B 934355 4BTS 4B500A 4WK2B 947593A6 4B500A 935780 4WK2B 934393 KMAG 961088 003 4BTS 4B660A 4WK3B 947605A1 4B660A 935781 4WK3B 934394 24 P1917E EN 2011 05 17e IntelligenteSpindel en fm 01 06 2011 DGD DGD intelligent spindles DGD IS B 1 2 1 2 1 2 1 2 1 2 1 2 1 2 4BUTS 4B500A 4K2B 4ZA 947595 4 4B500A 935780 4K2B 934315 4BUTS 4B660A 4K3B 4ZA 947609 7 4 660 935781 4 934316 4BUTS 4B360A 4K1B 4Z1250A 947619A5 4B360A 929541 4K1B 934314 471250 8976950 4BUTS 4B500A 4K2B 4Z1600A 947623A9 4B500A 935780 4K2B1 934317 421600 5976951 4BUTS 4B500A 4VK2B 947597A2 3 4BU
15. 2000 0 33 1 27 910609 1 2 110 4500 3200 2300 2600 3100 0 45 2V 935553 3 4 200 0 48 3Z 910613 3 4 300 6500 5000 2850 3250 3750 0 67 3V 912106 3 4 500 9000 8800 4300 4800 5400 0 87 912147 1 750 9000 8800 4300 4800 5400 0 90 including flange housing 12i 5308434 3 8 53 2300 1500 1510 1720 2000 0 65 27 5308435 1 2 110 4500 3200 2300 2600 3100 1 05 5308436 3 4 300 6500 5000 2850 3250 3750 1 80 1 Under continuous operation for long periods multiply the specified values by 0 3 Size 47 For Order Permissible load no a on output shaft Lateral force at wrench head Ten Weight TQ Pres sion 25 50 mm 1 sure 1 Extended Retracted Retracted Nm N N N N N kg iz 916643 3 4 460 9000 8800 4300 4800 5400 1 21 916642 1 630 1 24 1 Under continuous operation for long periods multiply the specified values by 0 3 P1917E EN 2011 05 17 en fm 01 06 2011 DGD Attachment 7 4 2 For angle head including flange housing Stroke of spring 25 mm 00335 t eps For Order Permissible load Lateral force at wrench head no on output shaft TQ Pres Ten 25 mm sure 1 sion Extended Retracted Nm N N N N 1W 929041 3 8 53 1700 6800 1800 2100 929053 1 2 110 1850 6800 2500 3000 is 929061 3 4 200 3800 7800 3000 3450 3W 929065 3 4 300 3800 7800
16. Wer Excessive number of DGD IS m Pro 400S CPM DGD IS is powered externally 5 Check the mechanics of the fastening station 72 P1917E EN 2011 05 171 Fehlersuche en fm 01 06 2011 DGD Troubleshooting play Error Description Possible causes Measures and remedies Dis A Excessive voltage between artificial neutral point of the power supply and PE or the center of the intermediate circuit approx 190 VDC and PE Voltage gt 100 V Short circuit between gt Check connection of inter IC and PE mediate circuit voltage 380 VDC and 0 to PE CPS3 gt Check CPS3 replace if necessary System cable gt Replace the system cable TS TUS gt Replace the TS TUS Motor gt Replace the motor or DGD IS 1 2 Excessive current or short circuit in the intermediate circuit Current 2250 A Check the system cable between the 380 VDC and 0 V wires for short circuiting System cable short circuit gt Replace the cable Short circuit TS TUS gt Replace the TS TUS 1 3 Temperature of the cooling element is too high CPS3 temperature cooling element is gt 90 Constant overload CPS3 Excessive number of DGD IS gt Reduce the number of m Pro 400S CPM Ambient temperature m Pro 400S CPM gt 40 gt Improve the ambient con ditions m Pro 400S CPM is expos
17. and short circuits gt Replace motor Measuring current is not mea sured Internal error gt Replace the TS TUS Motor is not connected gt Connect the motor Motor 121 monitor The Pt monitor has measured excessive power on the DGD IS Motor power required is too high Check the motor temperature if gt 80 C gt Shorten the fastening time by increasing the speed DGD IS is defective e g gear ing bearings Check the ease of movement of the gearing and motor on the DGD IS gt Replace the DGD IS or motor Motor Resolver NOK No resolver signals measured Signals are not present Check whether the motor is con nected gt Connect the motor Signal interruption Check the resolver wires in the DGD IS gt Replace motor Short circuit of signals Check the resolver wires in the DGD IS for short circuits gt Replace motor Supply to the resolver is defec tive Internal defect gt Replace the TS TUS Measurement card Task monitoring NOK Error at the program execution end of the measuring board Internal error gt Replace the TS TUS gt Inform Sales amp Service Cen ter 171 Fehlersuche en fm 01 06 2011 P1917E EN 2011 05 79 Troubleshooting DGD Error Description Possible causes Measures and remedies Measurement card RAM Insufficient RAM available in the measuring board Int
18. on the sense of rotation The angle signals are read by query of the 360 magnetic poles of the pole wheel and are then transferred to the measuring electronics at amplified output voltage voltage increase of 12 V wi Wi gt t 90 30 360 i 17k Funktionsbeschreibung en fm 01 06 2011 P1917E EN 2011 05 65 Function description DGD 14 3 NOTE 14 3 1 14 3 2 Redundant design of a sensor system according to VDI 2862 If the transducer is used in conjunction with an offset or angle head attachment the calibration data must be taken into consideration accordingly Torque measurement calibration The dispersion of efficiency linked to manufacturing requires the inclusion of a calibration factor This can only be determined by additional measuring systems and is defined as a calibration factor mk Example DGD IS with transducer 1K3B Offset attachment 1VK3B Specified calibration factor mk 1 0351 Rated torque 12 Nm at 5 Corrected calibration value Rated torque x mk gt 12 Nm x 1 035 12 42 Nm Angle measurement calibration The transmission ratio also causes the angle measurement to change it is corrected with the angle calibra tion factor W The angle calibration factor corresponds to the transmission ratio 8 Transducer Seite 38 Example of a DGD IS standard 200721 eps Centric version 1BTS
19. remedies Output signal is not linear Measuring hub was over stretched Offset voltage is too high Measuring hub was over stretched No output signal Pre amplifier is defective Torque output is set to an out put value gt 6 5 V Error bit is set in the operating data memory CPU NOK internal transmission to D A converter fails HF section NOK HF telemetry transmission fails no measuring shaft rotor present rotor electronics defective gap between rotor and stator antenna too large gt Send the transducer to Sales amp Service Center for repair recalibration Supply voltage NOK voltage under low supply volt age limit After an operation error the transducer remains in the operation error state until one of the fol lowing events occurs the operating voltage of the transducer is disconnected the transducer receives a calibration signal via the CAL input pin K the error bit in the operating memory is reset via the RS422 interface 70 P1917E EN 2011 05 171 Fehlersuche en fm 01 06 2011 DGD Troubleshooting 15 3 Tightening module CPS3 in nutsetter control unit m Pro 400S CPM 15 3 1 Ready LED Error Description Possible causes Measures and remedies Ready LED does not light up nected from the power supply 24 V supply is unavailable gt Check the 26 V voltage at XS3 terminals 1 and 4 m Pro 400S
20. spindle may rotate come loose and cause injury Avoid speed increases of over 3 m s on all axes 17b Sicherheit bedingt en fm 01 06 2011 P1917E EN 2011 05 5 Safety DGD CAUTION Work area 1 3 gt Close all safety devices gt Ensure that there is enough space in the work area gt Keep the work area clean Electrical safety gt Do not operate the fastening system outdoors gt Observe the safety notes on the DGD IS Safe working with and around fastening tools gt Inspect screw bits and retaining ring for visible damage and cracks Replace damaged parts immediately gt Always disconnect the power supply to the DGD IS before changing screw bits gt Only use screw bits for machine controlled fastening tools Make sure that the screw bits are retained securely We do not claim that these safety notes are complete Read and observe all applicable general and local safety and accident prevention rules Follow a safety conscious maintenance program which takes into account the local regulations for main tenance and servicing in all phases of operation of the fastening electronics Operator training The fastening system may only be operated by personnel that have been trained and instructed corre spondingly and authorized by the operator The fastening system may only be maintained and serviced by personnel instructed by qualified staff from DGD The operator must make sure that all new operating a
21. 00 2850 3250 3750 4VK2B 934353 500 4VK3B 934354 660 6300 2100 4300 4800 5400 4VK4B 934355 900 1 2857 750 1 Under continuous operation for long periods multiply the specified values by 0 3 7 2 1 Pin configuration of offset attachment Type 12 pin circular connector Lumberg SGR 120 Binder series 680 no 09 0331 90 12 with locking connector in accordance with DIN 45 321 Pin Color Signal Description A nc B Brown ANGA Angle output A Green TQ Torque output JEVEO E D Yellow 0 VA 0 V torque reference connection D F E gray 0v 0 V supply G F Pink 12 V Supply L M G Blue ANGB Angle output B B H H Red RxD Interface A K J J Black RxD Interface K Violet CAL Input calibration voltage L Gray pink TxD Interface M Red blue TxD Interface Housing PE Shield connection 34 P1917E EN 2011 05 17g_Komponenten en fm 06 06 2011 DGD Attachment 7 3 Angle head attachment Helix toothed Cap nut Bevel wheels Crown gearing N H 2 Only with version WK B Angle measurement Torque measurement range 2 telemetry system range 2 i Code Order no Torque Ratio Permissible load Lateral force Calibration i on output shaft on square TQ Pressure Tension Nm N N N 1WK1B
22. 10 2011 DGD Instructions on laying cables For this use the following shield clamps Cables Shield clamp DGD Phoenix Phoenix Order No Name Item number DGD IS cable BTS series 961062 SK14 30 25 17 6 tool cable S961062 SK14 30 25 176 The shielding in the transducer line is connected to the connector housing The front panel of the measuring board is grounded via the STM housing and ensures good shielding connection gt Maximum unshielded area of the motor line between shield end and plug connection on tightening mod ule 50 mm gt On the Built in nutrunner or hand tool extensively connect the shield to the metal housing of the plug connection 5 System cable a a S Fig 12 2 12 4 Laying High Flex Quality cables in cable ducts The laying of lines and protection hoses in cable ducts must be carried out with the greatest possible care Generally the following points must be observed gt gt The cables should lie free of twists in the cable duct Prior to assembly lay the cables on an even surface so that they can be inserted while stretched out Lay the cables in the cable duct individually lying loosely adjacent to each other whenever possible Lay a maximum of 2 cables per partition Separate cables lying adjacent to each other using cut off bridges whenever possible Don t bundle cables or fasten them
23. 1B 1ZB 947553 4 35 5 727 43 486 4 8 5308434 1BTS 1B060A 1K2B 1ZB 947565 0 53 15 427 1BTS 1B012A 1VK3B 947543A6 12 1825 TESTS 1BTS 1B035A 1VK1B 947555A2 35 5 690 35 474 5 3 5308437 1BTS 1B060A 1VK2B 947567A8 53 15 405 1BTS 1B012A 1WK3B 947545A4 12 1801 1BTS 1B035A 1WK1B 947557A0 35 681 25 52 542 5 7 929041 1BTS 1B060A 1WK2B 947569A6 53 15 400 1BUTS 1B012A 1K3B 1ZB 947547 2 12 1921 m 1BUTS 1B035A 1K1B 1ZB 947559 8 35 727 43 393 5 3 5308434 1BUTS 1B060A 1K2B 1ZB 947571 2 53 15 427 50 922325 1BUTS 1B012A 1VK3B 947549A0 12 1825 1BUTS 1B035A 1VK1B 947561A4 35 690 35 382 5 8 S308437 1BUTS 1B060A 1VK2B 947573A0 53 15 405 1BUTS 1B012A 1WK3B 947551 6 12 1801 1BUTS 1B035A 1WK1B 947563 2 35 681 25 52 370 6 2 929041 1BUTS 1B060A 1WK2B 947575 8 53 15 400 Smallest scribed circle diameter in mm Quantity Attachment DGD IS Centric Offset Angle head 2 43 35 52 3 54 40 60 4 61 50 74 5 81 58 89 6 99 70 105 7 116 85 120 14 P1917E EN 2011 05 17e IntelligenteSpindel en fm 01 06 2011 DGD DGD intelligent spindles 5 2 2 Size 1 2x transducer Designation Order Torque Speed Spring min Lengt Weight Spring No travel a h Chuck Nm dis tance max min rpm mm mm mm kg flange 1BTS 1B012A 2 1K3B 1ZB 947542 7 12
24. 1B012A 2 1K3B 1ZB Order no 947542A7 Serial no 0550815 Speed 1921 RPM Torque max 12 Nm Cal TQ1 12 Nm 5V DC Cal TQ2 12 Nm 5V DC Angle calibration A 1 000 1 degrees Angle calibration A 1 000 1 degrees Voltage 380 V DC 1 is calculated using attachment transducer and test case MPK see system description 3 1 Components Seite 9 66 P1917E EN 2011 05 17k Funktionsbeschreibung en fm 01 06 2011 Function description 200721 eps Offset version 1BTS 1B012A 1K3B 1VK3B Order no 947544A5 Serial no 0550816 Speed 1824 RPM Torque max 12 Nm Cal TQ1 12 Nm 5V Cal TQ2 12 Nm x mk 5V DC Angle calibration 1 000 1 degrees Angle calibration A 1 053 1 degrees Voltage 380 V DC 17k_Funktionsbeschreibung en fm 01 06 2011 P1917E EN 2011 05 67 Function description Blank side 68 P1917E EN 2011 05 17k_Funktionsbeschreibung en fm 01 06 2011 DGD Troubleshooting 15 Troubleshooting The following displays will help you to troubleshoot Nutsetter control unit m Pro 400S CPM Supply module CPS3 m Pro 400S CPM Tightening module TS TUS on DGD IS DANGER High leakage current Fatal electric shock could occur Always disconnect the system cable motor or motor cable from the m Pro 400S CPM or DGD IS before making throughput resistance and short circuit meas
25. 2 3 122 88 130 4 130 108 160 5 174 130 192 6 217 153 224 7 246 180 263 17e_IntelligenteSpindel en fm 01 06 2011 P1917E EN 2011 05 19 DGD intelligent spindles DGD 5 2 8 Size 4 2x transducer Designation Order No Torque Speed Spring travel min Length Weight Spring distance max min rpm mm mm mm kg flange 4BTS 4B500A 2 4K2B 4ZA 94759049 500 100 254 3 4 916643 4BTS 4B660A 2 4K3B 4ZA 947602A4 660 130 174 1 916642 4 5 4 60 2 4 1 421250 947618 6 1250 320 86 n 5976956 4 5 4 500 2 4 2 421600 947622 0 1600 400 68 50 1 1 2 m po S308441 4BTS 4B500A 4K2B 4VK2B 947592A7 500 100 238 3 4 912106 4BTS 4B660A 4K3B 4VK3B 947604A2 660 130 163 1 76 812 25 5 aise 5308440 4BTS 4B660A 4K3B 4VK4B 947608A8 750 160 135 1 4BTS 4B500A 4K2B 4WK2B 947594A5 500 100 245 3 4 929077 4BTS 4B660A 4K3B 4WK3B 947606 0 660 130 167 1 vr p 929089 4BUTS 4B500A 2 4K2B 4ZA 947596A3 500 100 254 3 4 916643 4BUTS 4B660A 2 4K3B 4ZA 947610A4 660 130 174 T 2 ER 916642 4 0 5 4 60 2 4 1 421250 947620 2 1250 320 86 1 5976956 4BUTS 4B500A 2 4K2B 4Z1600A 947624 8 1600 400 68 50 1 1 2 5308441 4BUTS 4B500A 4K2B 4VK2B 947598A1 500
26. 2 1921 1BTS 1B035A 2 1K1B 1ZB 947554A3 35 5 727 43 566 5 4 S308434 1BTS 1B060A 2 1K2B 1ZB 947566 9 53 15 427 1BTS 1B012A 1K3B 1VK3B 947544 5 12 2 1825 a 1BTS 1B035A 1K1B 1VK1B 947556 1 35 5 690 35 554 5 9 5308437 1BTS 1B060A 1K2B 1VK2B 947568A7 53 15 405 1BTS 1B012A 1K3B 1WK3B 947546 12 2 1801 1BTS 1B035A 1K1B 1WK1B 947558A9 35 5 681 25 52 622 6 3 929041 1BTS 1B060A 1K2B 1WK2B 947570 53 15 400 1BUTS 1B012A 2 1K3B 1ZB 947548 1 12 2 1921 ae 1BUTS 1B035A 2 1K1B 1ZB 947560A5 35 5 727 43 393 5 9 5308434 1BUTS 1B060A 2 1K2B 1ZB 947572 1 53 15 427 1BUTS 1B012A 1K3B 1VK3B 947550 7 12 2 1825 x nn 1BUTS 1B035A 1K1B 1VK1B 947562A3 35 5 690 35 382 6 4 S308437 1BUTS 1B060A 1K2B 1VK2B 947574 9 53 15 405 1BUTS 1B012A 1K3B 1WK3B 947552A5 12 2 1801 1BUTS 1B035A 1K1B 1WK1B 947564 1 35 5 681 25 52 450 6 8 929041 1BUTS 1B060A 1K2B 1WK2B 947576 7 53 15 400 Smallest scribed circle diameter Quantity Attachment DGD IS Centric Offset Angle head 2 43 35 52 3 54 40 60 4 61 50 74 5 81 58 89 6 99 70 105 7 116 85 120 17e IntelligenteSpindel en fm 01 06 2011 P1917E EN 2011 05 15 DGD intelligent spindles DGD 5 2 3 Size 2 1x transducer Designation Order Torque Speed Spring min Lengt Weight Spring No travel axis h Chuc
27. 20 to 70 C 0 to 90 96 no condensation Motor 20 to 70 0 to 90 no condensation CPS3 25 to 70 0 to 90 no condensation 8 P1917E EN 2011 05 17b Sicherheit bedingt en fm 01 06 2011 DGD System description 3 System description The system design is determined by the size and quantity of DGD IS used and always varies depending on the individual situation These components can be combined with one another in various sizes This chapter includes a brief description of the components Each respective chapter contains separate technical details Special features of the fastening system m Pro 400S DGD Intelligent Spindle In the m Pro 400S DGD Intelligent Spindle fastening system the tightening modules are no longer installed in acontrol cabinet but directly on the built in nutsetter see system m Pro 400 tm with single cable solu tion The intermediate circuit voltage was increased from 320 VDC to 380 VDC compared to the TM tightening modules This increased the maximum speed of the built in nutsetter by 20 3 1 Components Item Designation 1 Nutsetter control unit m Pro 400S CPM Cable machine control Mains cable 3x400 VAC Operator panel with emergency stop button DGD IS ARCNET terminator Optional test case MPK INIo AJ OIN System cable type A System cable type Station controller m Pro 400S touch screen a00588_c
28. 2011 P1917E EN 2011 05 Cable 13 2 Super Highflex suitable for robots Thermal properties Ambient temperature C 20 90 Flammability Flame retardant and self extinguishing in accordance with EN 50265 2 1 IEC 60332 1 and UL1581 Chemical properties of the coating Coating material PUR low adhesion resistant to hydrolysis and microbes UV resistant abrasion resistant tear resistant cut resistant notch resistant Oil resistance Oil resistant in accordance with DIN VDE 0472 part 803 ASTM oil 1 to 3 and HD 505 2 1 Resistance to hydrolysis In accordance with VDE 0283 part 10 Color Orange RAL 2003 matt Mechanical properties Diameter mm approx 14 Bending radii mm Single bends 30 min Multiple bends 60 mm flexing action 43 min alternate bending Torsional length mm 500 min 180 separate acceleration m s 100 13 2 1 System cable type A Use Intermediate plug position DGD IS Order No 961103 cable length in dm aa TEES e Boose FS KS An 1 1 IF EE SSL 954 H H SY 99 13 2 2 Jumper cable type F Use DGD IS DGD IS Order No 961395 xxx xxx cable length in dm 62 1917 2011 05 17i_Kabel en fm 01 06 2011 DGD Cable 13 2 3 Jumper cable type H U
29. 3000 3450 929077 3 4 500 12000 13000 4300 5050 S 929089 1 660 1 Under continuous operation for long periods multiply the specified values by 0 3 17g Komponenten en fm 01 06 2011 P1917E EN 2011 05 37 Transducer DGD 8 Transducer Evaluation electronics Range Range Torque measurement Angle measurement Transducer K E Code Order no Capacity calibration value Nm 1K1KB 934283 35 1 1K2KB 934284 60 1K3KB 934285 12 2K1KB 934293 110 2K3KB 934292 200 3 3K2KB 934302 300 4 934314 400 4 2 934315 500 4K2KB1 934317 500 for 1600 Nm 4K3KB 934316 660 38 P1917E EN 2011 05 17g_Komponenten en fm 01 06 2011 DGD Transducer 8 1 Electrical Data Torque measurement features Data Nominal supply voltage V 12 Supply voltage limits V 10 75 12 5 Supply current mA 80 Measured output voltage nominal voltage V 5 5 Measured output voltage limits Uy 5 000 0 5 Up Permitted measuring range of rated torque 10 125 Zero voltage limit value Ug mV 100 Nonlinearity Torque measurement of Un 0 25 Measuring of Un 0 5 Output current maximum mA 5 Internal resistance Ri torque output Q lt 10 Limit frequency of the torque measurement 3dB KHz 2 Measured output voltage calibration ON Ux V Uy 0 25 Calibrati
30. 443 Apex Tool Group GmbH amp OHG IndustriestraBe 1 73463 Westhausen Germany Phone 49 7363 81 0 Fax 49 7363 81 222 www apexpowertools eu
31. 5560 TS 961146 1B035A 927344 1VK1B 935862 961088 004 1BTS 1B060A 1VK2B 947567A8 1 060 927345 1VK2B 935861 T 1BTS 1B012A 1WK3B 947545A4 1B012A 927346 1WK3B 934366 1BTS 1B035A 1WK1B 947557A0 1B035A 927344 1WK1B 934364 961088 003 1BTS 1B060A 1WK2B 947569A6 1B060A 927345 1WK2B 934365 1BUTS 1B012A 1K3B 1ZB 947547 2 1B012A 927346 1K3B 934285 1BUTS 1B035A 1K1B 1ZB 947559 8 1 035 927344 1 934283 1ZB 927222 961088 004 1BUTS 1B060A 1K2B 1ZB 947571 2 1B060A 927345 1K2B 934284 1BUTS 1B012A 1VK3B 947549 0 1B012A 927346 1VK3B 935860 1BUTS 1B035A 1VK1B 947561 4 1BUT 936321 TUS 961147 1 927344 1VK1B 935862 1BUTS 1B060A 1VK2B 947573 0 1 060 927345 1VK2B 935861 961088 003 1BUTS 1B012A 1WK3B 947551 6 1B012A 927346 1WK3B 934366 1BUTS 1B035A 1WK1B 947563 2 1B035A 927344 1WK1B 934364 1BUTS 1BO60A 1WK2B 947575 8 1B060A 927345 1WK2B 934365 1 Code 2 Part no assembled as spacer 17e IntelligenteSpindel en fm 01 06 2011 P1917E EN 2011 05 21 DGD intelligent spindles 5 3 2 Size 1 2x transducer DGD IS B 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1BTS 1B012A 2 1K3B 1ZB 947542 7 1B012A 927346 1K3B 1BTS 1B035A 2 1
32. 7581A0 i 437 25 T di 678 17 8 929065 3BUTS 3B300A 3K2B 3ZB 947583A8 453 Es 417 16 1 5308436 3BUTS 3B300A 3VK2B 947585A6 421 59 412 17 2 5308439 3BUTS 3B300A 3WK2B 947587 4 437 25 81 506 19 8 929065 Smallest scribed circle diameter Quantity Attachment DGD IS Centric Offset Angle head 2 81 59 81 3 94 69 94 4 116 84 116 5 139 102 139 6 164 122 164 7 189 138 189 5 2 6 Size 3 2x transducer Designation Order Torque Speed Spring min Lengt Weight Spring No travel axis h Chuck Nm dis tance min rpm mm mm mm kg flange 3BTS 3B300A 2 3K2B 3ZB 947578 5 453 81 701 16 2 S308436 3BTS 3B300A 3K2B 3VK2B 947580A1 421 59 696 17 3 nn S308439 SBTS 3B300A 3K2B 3WK2B 947582 9 437 25 790 19 9 929065 3BUTS 3B300A 2 3K2B 3ZB 947584 7 er 453 528 18 2 5308436 3BUTS 3B300A 3K2B 3VK2B 947586A5 421 59 523 19 3 5308439 3BUTS 3B300A 3K2B 3WK2B 947588 437 25 81 617 21 9 929065 Smallest scribed circle diameter in mm Quantity Attachment DGD IS Centric Offset Angle head 2 81 59 81 3 94 69 94 4 116 84 116 5 139 102 139 6 164 122 164 7 189 138 189 18 P1917E EN 2011 05 17e IntelligenteSpindel en fm 01 06 2011 DGD DGD intelligent spindles
33. 934364 35 1 0667 53 1700 3400 3100 1WK2B 934365 60 1WK3B 934366 12 2WK1B 934372 110 1 0625 200 1850 3900 4200 2WK3B 934373 200 3WK2B 934382 300 1 0385 300 3800 4800 5100 4WK2B 934393 500 1 0370 660 1200 6500 5900 4WK3B 934394 660 1 Under continuous operation for long periods multiply the specified values by 0 3 7 3 1 Pin configuration angle head attachment Type 12 pin circular connector Lumberg SGR 120 Binder series 680 no 09 0331 90 12 with locking connector in accordance with DIN 45 321 Pin Color Signal Description A nc B Brown ANGA Angle output A C Green TQ Torque output D Yellow 0 VA 0 V torque reference connection D F E gray OV 0 V supply Pink 12 V Supply L M G Blue ANGB Angle output B B H H Red RxD Interface J J Black RxD Interface K Violet CAL Input calibration voltage L Gray pink TxD Interface M Red blue TxD Interface Housing PE Shield connection 17g Komponenten en fm 01 06 2011 1917 2011 05 35 Attachment DGD 7 4 Spring collet Optional 7 4 1 For centric offset attachment Size 1 4 For Order Permissible load Do eT on output shaft Lateral force at wrench head Ten Weight TQ pas e 26 50mm sure Extended Retracted Retracted Nm N N N N N kg 12 4 922325 3 8 53 2300 1500 1510 1720
34. A 935780 33 4219 4B660A 935781 48 9345 40 P1917E EN 2011 05 17 en fm 01 06 2011 DGD Motor 10 Motor 10 1 Technical data Features Data Code 1BT 1BUT 2BT 2BUT 3 4BT 3 4BUT Order no 935560 935563 935561 935564 935562 935565 Speed maximum RPM 11000 11000 8500 Operating mode according to 1 1 1 VDE 0530 Enclosure type according to IP54 IP54 IP54 DIN 40050 Sense of rotation Reversible Reversible Reversible Design B 14 B 14 B 14 Connection type Plug connector Plug connector Plug connector Mass moment of inertia x 10 0 017 0 06 0 25 Rated torque Nm 0 55 1 60 3 Permanent torque maximum Nm 0 61 1 8 4 at a stop Peak torque Nm 2 8 10 5 18 3 Speed change per torque RPM 12 2 1 9 0 34 Nem Mechanical time constants ms 2 1 1 3 1 1 torque Nm 0 03 0 07 0 15 Rotor weight kg 0 36 0 79 1 54 Motor weight kg 1 6 3 1 6 5 Ball bearing A B side 6000 608 6200 6200 6202 6201 17g_Komponenten en fm 01 06 2011 P1917E EN 2011 05 41 Motor DGD 10 2 Electrical Data Features Data 1BT 1BUT 2 2BUT 3 4 3 4 0 Intermediate circuit voltage V 380 380 380 Rated current 1 A 2 1 6 8 7 Rated output 260 500 940 Number of phases 3 3 3 Terminating resistance 2 Ohms 11 1 8
35. B 2ZB 947530 1 200 40 502 3 4 50 910609 2BTS 2B110A 2K1B 2VK1B 947522A1 110 25 831 1 2 44 648 10 3 308438 2BTS 2B200A 2K3B 2VK3B 947534A7 200 40 468 3 4 2BTS 2B110A 2K1B 2WK1B 947526 7 110 25 838 1 2 25 59 678 9 8 929053 2BTS 2B200A 2K3B 2WK3B 947538 200 40 472 3 4 2BUTS 2B110A 2 2K1B 2ZB 947520 3 110 25 890 1 2 56 464 9 7 308435 2BUTS 2B200A 2 2K3B 2ZB 947532 9 200 40 502 3 4 2BUTS 2B110A 2K1B 2VK1B 947524A9 110 25 831 1 2 44 487 11 3 5308438 2BUTS 2B200A 2K3B 2VK3B 947536A5 200 40 468 3 4 2BUTS 2B110A 2K1B 2WK1B 947528A5 110 25 838 1 2 25 59 518 10 8 929053 2BUTS 2B200A 2K3B 2WK3B 947540 9 200 40 472 3 4 Smallest scribed circle diameter in mm Quantity Attachment DGD IS Centric Offset Angle head 2 56 44 59 3 75 50 68 4 80 62 86 5 106 74 101 6 130 89 118 7 151 102 137 17e IntelligenteSpindel en fm 01 06 2011 P1917E EN 2011 05 17 DGD intelligent spindles DGD 5 2 5 Size 3 1x transducer Designation Order Torque Speed Spring min Length Weight Spring No travel axis Chuck Nm rr dis tance max min rpm mm mm mm kg flange 3BTS 3B300A 3K2B 3ZB 947577 6 453 T 81 589 14 1 sidus 5308436 3BTS 3B300A 3VK2B 947579A4 421 59 584 15 2 5308439 3BTS 3B300A 3WK2B 94
36. CPM is discon gt Check the mains supply tance 24 V power adapter is discon gt Check the fuse nected from the power supply Fuse in the 83 is high resis gt Check the 26 V voltage at XS4 terminals 1 and 4 Switch off the m Pro 400S CPM and switch back on again after a minute Replace the CPS3 15 3 2 stop LED emergency stop Error Description Possible causes Measures and remedies stop lights up CPS3 is in Emergency stop status Intermediate power circuit 380 VDO is deactivated No signals at the emergency stop inputs XS4 terminal 2 or Control on XS5 terminals 3 and 4 5 Check the 24 V voltage the CPS3 Plug connector XS4 terminals 2 and 4 Plug connector XS5 terminals 3 and 4 Check the 24 V voltage on PM Plug connector XS3 terminals 2 and 6 Plug connector XS2 terminals 5 and 6 Fact the signals are not gener ated by external controls 171 Fehlersuche en fm 01 06 2011 P1917E EN 2011 05 71 Troubleshooting 15 3 3 7 segment Status display Encoded errors are displayed a 7 segment display on the CPS3 The display alternates between the first and second digit at brief intervals Display Duration Pause tst digit 0 55 0 2s 2nd digit 0 5s 1s istdigit 0 55 0 2 s etc A period in the display means NO error If several errors occur the error with the
37. K1B 1ZB 947554A3 1 927344 1 1 A 12 927222 ES 1BTS 1B060A 2 1K2B 1ZB 947566 9 1B060A 927345 1K2B 4 1BTS 1B012A 1K3B 1VK3B 947544A5 1 935560 TS 961146 1B012A 927346 1K3B 934285 1VK3B 935860 KMAG 961088 004 1BTS 1B035A 1K1B 1VK1B 947556 1 1B035A 927344 1K1B 934283 1VK1B 935862 Maw 91088 02 1BTS 1BO60A 1K2B 1VK2B 947568 7 1B060A 927345 1K2B 934284 1VK2B 935861 1BTS 1B012A 1K3B 1WK3B 947546 1 012 927346 1K3B 934285 1WK3B 934366 961088 003 1BTS 1B035A 1K1B 1WK1B 947558 9 1 927344 1K1B 934283 1WK1B 934364 KMAG 961088 003 1BTS 1B060A 1K2B 1WK2B 947570A3 1B060A 927345 1K2B 934284 1WK2B 934365 1BUTS 1B012A 2 1K3B 1ZB 947548A1 1B012A 927346 1K3B ae 1BUTS 1B035A 2 1K1B 1ZB 947560 5 1B035A 927344 1K1B ice 178 927222 KMAW a 1BUTS 1B060A 2 1K2B 1ZB 947572 1 1 060 927345 1K2B eee 1BUTS 1B012A 1K3B 1VK3B 947550 7 1BUT 936321 TUS 961147 1B012A 927346 1K3B 934285 1VK3B 935860 KMAG 961088 003 1BUTS 1B035A 1K1B 1VK1B 947562A3 1 927344 1K1B 934283 1 935862 KMAG 961088 003 1BUTS 1B060A 1K2B 1VK2B 947574A9 1B060A 927345 1K2B 934284 1VK2B 935861 1BUTS 1B012A 1K3B 1WK3B 947552 5 1B012A 927346 1K3B 934285 1 934366 1BUTS 1B035A 1K1B 1WK1B 947564A1 1B035A 927344 1 934283 1WK1B 934364 KMAG m 1BU
38. No 961104 cable length in dm 58 P1917E EN 2011 05 17i_Kabel en fm 01 06 2011 Cable 13 1 5 Jumper cable type E Use DGD IS DGD IS Order No 961299 xxx cable length in dm 13 1 6 Jumper cable type F Use DGD IS DGD IS Order No 961295 xxx cable length in dm 13 1 7 Jumper cable type G Use DGD IS DGD IS Order No 961298 xxx xxx cable length in dm 17i Kabel en fm 01 06 2011 P1917E EN 2011 05 59 13 1 8 Jumper cable type Use DGD IS DGD IS Order No 961297 xxx cable length in dm 13 1 9 Jumper cable type K Use DGD IS DGD IS Order No 961292 xxx cable length in 13 1 10 Jumper cable type L Use DGD IS DGD IS Order No 961293 cable length in dm 60 P1917E EN 2011 05 17i_Kabel en fm 01 06 2011 Cable 1 3 13 1 11 Jumper cable type Use DGD IS DGD IS Order No 961296 xxx cable length in dm PE 380VDC 24VDC Enable DATAA DATAB Eee MES on E 24VDC 0 0 24 17i_Kabel en fm 01 06
39. T 936323 TUS 961147 4B500A 935780 934353 KMAG 961088 005 4BUTS 4B660A 4VK3B 947611 4B660A 935781 4VK3B 934354 4BUTS 4B660A 4VK4B 947615A9 4B660A 935781 AVK4B 934355 4BUTS 4B500A 4WK2B 947599A0 4B500A 935780 4WK2B 934393 4BUTS 4B660A 4WK3B 947613A1 4B660A 935781 4WK3B 934394 1 Code 2 Part no 5 3 8 Size 4 2x transducer DGD IS B G 1 2 1 2 1 2 1 2 1 2 1 2 1 2 934315 4BTS 4B500A 2 4K2B 4ZA 947590A9 4B500A 935780 4K2B 9237 42 927236 4BTS 4B660A 2 4K3B 4ZA 947602A4 4B660A 935781 4K3B 4BTS 4B360A 2 4K1B 4Z1250A 947618A6 4B360A 929541 4K1B 2 421250 5976950 934317 961088 002 7 4B500A 935780 4K2B1 4Z1600A 5976951 4BTS 4B500A 2 4K2B 4Z1600A 947622A0 3 4 935562 TS 961146 4B500A 935780 e 600A 5976951 KMAG 961088002 4BTS 4B500A 4K2B 4VK2B 947592A7 4B500A 935780 4K2B 934315 4VK2B 934353 4BTS 4B660A 4K3B 4VK3B 947604A2 4B660A 935781 4K3B 934316 4 934354 4BTS 4B660A 4K3B 4VK4B 947608A8 4B660A 935781 4 934316 4VK4B 934355 4BTS 4B500A 4K2B 4WK2B 947594A5 4B500A 935780 4K2B 934315 4WK2B 934393 4BTS 4B660A 4K3B 4WK3B 947606A0 4B660A 935781 4K3B 934316 AWK3B 934394 4BUTS 4B500A 2 4K2B 4ZA 947596A3 4B500A 935780 4 2 m KMAG nn 42 927236 4BUTS 4B660A 2 4K3B 4ZA 947610A4 4B660A 935781 4K3B 2 4BUTS 4B360A 2 4K1B 4Z1250A 947620A2 4B360A 929541 4K1B 2 421250 5976950 4BUTS 4B500A 2 4K2B 4Z1600A 947624 8 3 4B
40. TS 1B060A 1K2B 1WK2B 947576 7 1B060A 927345 1K2B 934284 1WK2B 934365 1 Code 2 Part no included in B 22 P1917E EN 2011 05 17e IntelligenteSpindel en fm 01 06 2011 DGD DGD intelligent spindles 5 3 3 Size 2 1x transducer DGD IS B 1 2 1 2 1 2 1 2 1 2 1 2 1 2 2BTS 2B110A 2K1B 2ZB 947517 8 2B110A 935548 2K1B 934293 278 927227 KMAW 961089 002 2BTS 2B200A 2K3B 2ZB 947529 4 2B200A 935549 2K3B 934292 2BTS 2B110A 2VK1B 947521 A2 2B110A 935548 2VK1B 934334 2 935561 TS 961146 KMAG 961088 004 2BTS 2B200A 2VK3B 947533A8 2B200A 935549 2VK3B 934333 2BTS 2B110A 2WK1B 947525A8 2B110A 935548 2WK1B 934372 KMAG 961088 003 2BTS 2B200A 2WK3B 947537A4 2B200A 935549 2WK3B 934373 2BUTS 2B110A 2K1B 2ZB 947519 6 2B110A 935548 2K1B 934293 22 927227 KMAG 961088 004 2BUTS 2B200A 2K3B 2ZB 947531A0 2B200A 935549 2K3B 934292 2BUTS 2B110A 2VK1B 947523A0 2B110A 935548 2VK1B 934334 2BUT 936322 TUS 961147 KMAG 961088 003 2BUTS 2B200A 2VK3B 947535A6 2B200A 935549 2VK3B 934333 2BUTS 2B110A 2WK1B 947527A6 2B110A 935548 2WK1B 934372 KMAG 961088 004 2BUTS 2B200A 2WK3B 947539A2 2B200A 935549 2WK3B 934373 1 Code 2 Part no 5 3 4 Size 2 2x tr
41. UT 936323 TUS 961147 4B500A 1935780 4 2 1 471600 5976951 KMAG 961088 005 4BUTS 4B500A 4K2B 4VK2B 947598A1 4B500A 935780 4 2 934315 4VK2B 934353 961088 006 4BUTS 4B660A 4K3B 4VK3B 947612A2 4 660 935781 4 934316 AVK3B 934354 4BUTS 4B660A 4K3B 4VK4B 947616 8 4B660A 935781 4K3B 934316 4VK4B 934355 4BUTS 4B500A 4K2B 4WK2B 947600 6 4B500A 935780 4K2B 934315 AWK2B 934393 4BUTS 4B660A AK3B AWK3B 947614A0 4B660A 935781 4K3B 934316 AWK3B 934394 1 Code 2 Part no 17e IntelligenteSpindel en fm 01 06 2011 P1917E EN 2011 05 25 DGD intelligent spindles Blank page 26 P1917E EN 2011 05 17e IntelligenteSpindel en fm 01 06 2011 DGD Tightening module TS TUS 6 Tightening module TS TUS TS Order No 961146 TUS Order No 961147 Item Designation XS1A supply input XS1B supply output Service panel XS3 transducer plug connector XS4 plug connector for second redundant transducer XS2 plug connector crosscheck with measuring case AJOI Pp Ready LED ready for operation green or fault red 17f_Schraubmodul en fm 01 06 2011 P1917E EN 2011 05 27 Tightening module TS TUS DGD 6 1 Description The TS TUS tightening module controls the DGD IS The servo amplifier output section and the measuring section measurin
42. Z1600A If higher settings are chosen the number channels should be reduced If different spindle types are used at the controller the number of channels will be individually defined Please contact your Sales amp Service Center 3 1 3 Cables Maximum length 164 ft 50 m From m Pro 400S CPM to the last DGD IS 3 1 4 ARCNET Communication to the m Pro 400S CPM is achieved via the ARCNET serial high performance field bus based on RS485 e ARCNET lines are integrated in the system cable between m Pro 400S CPM DGD IS and from DGD IS to DGD IS e Several system cable harnesses converge at the nutsetter control units m Pro 400S CPM6 and 400 9 An ARCNET bus amplifier module ARCNET HUB 1E3A order no 961237 is installed for this purpose The module allows a star shaped bus topology 10 P1917E EN 2011 05 17c_Systembeschreibung en fm 01 06 2011 Initial operation CAUTION gt NOTE 2 DANGER gt 2 4 ouo Initial operation When operating the machine for the first time read and observe the system manual or the operator informa tion for the m Pro 400S E 1 Position the DGD IS components together via flat toothed interfaces see Service manual Turn size 1 in 15 increments Turn sizes 4 to 2 in 10 increments 2 all components see 3 1 Components Seite 9 Risk of tripping or falling over loose cables on the ground Lay all connected ca
43. able IP FLT FMK FHW KAL1 KAL2 OFF1 OFF2 VLP AN1F AN2F WG1D WG2D see also operator information Nutsetter control unit m Pro 400S The Error log window opens with a description of the error that has occurred The System information window appears in the ARCNET Map window see operator information m Pro 400S All current errors are displayed here descriptive text and listed in the following table All errors are logged in the Logbook see operator information m Pro 400S for the m Pro 400S and be viewed at a later time 76 P1917E EN 2011 05 171 Fehlersuche en fm 01 06 2011 DGD Troubleshooting Error Possible causes Measures and Description remedies Servo Error in Check the resolver wires in the IP monitoring NOK also displayed in the rundown data table Overload If a current higher than the maxi mum permissible current is required for fastening the servo amplifier switches off automati cally motor position tracing e g resolver cable nutsetter cable gt Replace the nutsetter cable and check the resolver wires in the nutsetter cable for breaks gt Replace the DGD IS or the motor Error in the motor circuit e g motor does not attain the required torque gt Check the motor against PE and phase impedances for short circuits 1BT approx 11 O 2BT approx 2 O 3 4 approx 0 6 W gt Replace motor Incorrect programming C
44. al properties Ambient temperature 20 80 Flammability Flame retardant and self extinguishing in accordance with EN 50265 2 1 IEC 60332 1 and UL1581 Chemical properties of the coating Coating material PUR low adhesion resistant to hydrolysis and microbes UV resistant abrasion resistant tear resistant cut resistant notch resistant Oil resistance Oil resistant in accordance with DIN VDE 0472 part 803 ASTM oil 1 to 3 and HD 505 2 1 Resistance to hydrolysis In accordance with VDE 0283 part 10 Color RAL 2003 matt Mechanical properties Diameter mm approx 13 8 Bending radii mm 6 Single bends 30 min Multiple bends 95 mm flexing action 130 min alternate bending Torsional length mm 500 min amp 180 around separate central axis Max acceleration m s 100 13 1 1 System cable type C Use Nutrunner control unit DGD IS Order No 961109 cable length in dm 17i_Kabel en fm 01 06 2011 P1917E EN 2011 05 57 4 7 Cable 2 13 1 2 System cable type Use Nutrunner control unit DGD IS Order No 961294 xxx cable length in 13 1 3 System cable type J Use Nutrunner control unit DGD IS Order No 961289 xxx cable length in 13 1 4 System cable type A Use Intermediate plug position DGD IS Order
45. ansducer DGD IS B 1 2 1 2 1 2 1 2 1 2 1 2 1 2 2BTS 2B110A 2 2K1B 2ZB 947518A7 2B110A 935548 2K1B re 2x 2zB 927227 961088 003 934292 961089 002 2BTS 2B200A 2 2K3B 2ZB 947530A1 2B200A 935549 2K3B 74 2BTS 2B110A 2K1B 2VK1B 947522 1 2BT 935561 TS 961146 2B110A 935548 2K1B 934293 2VK1B 934334 2BTS 2B200A 2K3B 2VK3B 947534 7 2B200A 935549 2 934292 2 934333 kMAG 961088 003 2BTS 2B110A 2K1B 2WK1B 947526 7 2B110A 935548 2K1B 934293 2WK1B 934372 KMAW 961089 002 2BTS 2B200A 2K3B 2WK3B 947538A3 2B200A 935549 2K3B 934292 2WK3B 934373 2BUTS 2B110A 2 2K1B 22B 947520 3 2B110A 935548 2k1B 998208 2 278 927227 KMAG 961088 004 934292 961088 005 2BUTS 2B200A 2 2K3B 2ZB 947532 9 2B200A 935549 2 2BUTS 2B110A 2K1B 2VK1B 947524 9 2BUT 936322 TUS 961147 2 110 935548 2K1B 934293 2VK1B 934334 2BUTS 2B200A 2K3B 2VK3B 947536 5 2 200 935549 2K3B 934292 2 934333 KMAG 961088 004 2BUTS 2B110A 2K1B 2WK1B 947528 5 2B110A 935548 2K1B 934293 2WK1B 934372 KMAG 961088 005 2BUTS 2B200A 2K3B 2WK3B 947540A9 2B200A 935549 2K3B 934292 2WK3B 934373 1 Code 2 Part no 17e IntelligenteSpindel en fm 01 06 2011 P1917E EN 2011 05 23 DGD intelligent spindles DGD
46. ategory 4 Electrical Data Features Datam Pro 400S CPM CPM3 CPM6 CPM9 Supply voltage VAC x 400 10 Frequency Hz 50 60 Rated current A 3x5 3x10 3x15 Peak current momentary A 3x25 3 x 50 3x75 Rated output VA 3000 6000 9000 Peak power momentary VA 30 000 60 000 90 000 Output voltage of intermediate power circuit VDC 380 10 Nominal output current 380 VDC A 8 16 24 Output current maximum 5 s A 80 160 240 Circuit breaker 3 pin A 32 32 50 Tripping characteristic C D D Control voltage Output voltage VDC 24 10 Output current maximum 24 VDC A 5 10 20 Intermediate power circuit 380 VDC The intermediate power circuit supplies the DGD IS with 380 VDC A safety isolating transformer converts the supply voltage to 270 VAC which is then supplied to the CPS3 The processor controls two integrated relays that limit the switch on current The main relay switches on after the system initializes The intermediate circuit capacitors are charged via a resistor until the inter mediate circuit voltage reaches approx 380 VDC The resistor is then bridged via a start up relay Energy is generated when the motor brakes which causes the voltage to increase The braking chopper with braking resistor integrated in the CPS3converts the excess energy into heat When the circuit is switched off the intermediate circuit capacitors is discharged via the braking resistor Unpiugging the system cable while still
47. auxiliary materials oils greases when drained and dispose of them properly gt Separate the components of the packing and dispose of them by segregating them clearly gt Follow the locally applicable regulations Observe generally valid disposal guidelines such as in Germany the Electrical and Electronic Equipment Act ElektroG gt Hand in the DGD IS at your company collection point or return to Sales amp Service Center 17m_Wartung_Entsorgung_bedingt en fm 01 06 2011 P1 91 7E EN 201 1 05 83 Sales amp Service Centers Note All locations may not service all products Please contact the nearest Sales amp Service Center for the appropriate facility to handle your service requirements Dallas TX Detroit MI Houston TX Lexington SC Apex Tool Group Apex Tool Group Apex Tool Group Apex Tool Group Sales amp Service Center Sales amp Service Center Sales amp Service Center 670 Industrial Drive 1470 Post amp Paddock 2630 Superior Court 6550 West Sam Houston Lexington SC 29072 Grand Prairie TX 75050 Auburn Hills MI 48326 Parkway North Suite 200 USA USA USA Houston TX 77041 Phone 1 800 845 5629 Phone 1 972 641 9563 Phone 1 248 391 3700 USA Phone 1 803 359 1200 Fax 1 972 641 9674 Fax 1 248 391 7824 Phone 1 713 849 2364 Fax 1 803 358 7681 Fax 1 713 849 2047 Los Angeles CA Seattle WA York PA Canada Apex Tool Group Apex Tool Group Apex Tool Group Apex Tool Group Sales amp Service Ce
48. bles safely 3 Close all plug connectors and lock The red ring around the outer diameter of plug connectors with a slide lock should not be visible Always terminate the ARCNET with an ARCNET terminator at the bus end i e at the last DGD IS order no 961127 This terminator is installed permanently in the nutsetter control unit m Pro 400S CPM bus start 4 Connect the mains cable to the nutsetter control unit High leakage current Fatal electric shock could occur Establish a grounding connection PE to the nutsetter control unit before taking into operation 5 Preset the ARCNET address on each DGD IS under the service panel see 6 4 1 ARCNET address preset Seite 30 Each address can be used only once in the system Close the service panel Close the protective devices e g safety grilles Switch on the machine control unit PLC SPS Switch on the nutsetter control unit If there are no faults pending after switching on the unit the Ready LED on the DGD IS lights up green Otherwise see 15 Troubleshooting Seite 69 Troubleshoot ing Ready LED 10 Enter the parameters for the torque angle setting via the 400 specialist staff are responsible for programming the m Pro 400S CPM prior to initial operation The first time the nutsetter control unit is switched on the parameters for controlling fastening sequences must be read in via the keyboard or a valid parame
49. cooling Servicelife operating h 40 000 On Off switching cycles 5 000 000 Usability period if stored h 100 000 approx 11 years 11 4 3 Electrical DataCPS3 Features Data Supply voltage power 3x 270 10 Frequency Hz 50 60 Rated current A 3x7 Peak current momentary in RMS mode A 3x25 Rated output VA 3000 Peak power momentary in RMS mode VA 30 000 Output voltage of intermediate power circuit VDC 380 10 Nominal output current 380 VDC A 8 Output current maximum 5 s A 80 Control supply voltage VDC 24 10 Input current without external load A 0 5 Control voltage Output voltage VDC 24 10 Output current maximum 24 VDC A 8 48 P1917E EN 2011 05 17h_Schraubersteuerung en fm 01 06 2011 DGD Nutsetter control unit m Pro 400S CPM 11 4 4 Size 260 280 Retaining holes NS S 11 4 5 Indicators LED Signal LED CPS3 Green Ready Ready for operation Red EM stop Emergency stop or Control on signal unavail able The intermediate power circuit 380 VDC is deactivated 7 segment Status display Error indicators see 15 3 3 7 segment Status display Seite 72 11 4 6 lt Reset gt button Press the lt Reset gt button to acknowledge faults You will require a pointed object such as a ball point pen Pressing this button resets the processor and reconfigures all functions 17h_Schraubersteuerun
50. could result in death or serious injury if not avoided A symbol combined with the word CAUTION warns of a potentially harmful situation for the health of personnel or damage to property or the environment If this warning is not observed injuries property or environmental damage may occur This symbol indicates a general instruction General instructions include application tips and special useful information but no warnings against dangers Basic requirements for safe working practices Take the fastening system into service only after you have read and completely understood the following safety instructions and this document Failure to observe the instructions below may result in electric shock fire and serious injuries High leakage current Fatal electric shock could occur gt gt gt Always disconnect the power supply before performing maintenance work on the DGD IS and the m Pro 400S CPM Always disconnect the system cable motor or motor cable from the m Pro 400S CPM or DGD IS before making throughput resistance and short circuit measurements Do not attempt to repair possible faults on the fastening system by yourself if you do not have the required knowledge Inform the local repair center or your Sales amp Service Center High temperature the motor on the DGD IS may heat up and cause burns during removal max engine temperature 90 C Wear gloves Risk of flying parts Components of the
51. d signal lines separately For this use cable ducts in the control cabinet that are physically separated from each other Hot signal lines System cable mains nutrunner control power supply cooling unit Cold signal lines 24 VDC PE ARCNet cable bus cable separate cables from transducers There is a risk of tripping or falling over loose cables on the ground gt NOTE gt gt Lay all connected cables safely Only cable types approved by DGD may be used Remember that the maximum total cable length is 50 m Take appropriate measures to limit cable bending radii and torsion Obverse the respective allowed bending radii and torsional lengths All plug connections must be closed The locks must be tightened The red ring around the outer diam eter of plug connectors with a slide lock should not be visible 17i_Kabel en fm 01 06 2011 P1917E EN 2011 05 53 Instructions on laying cables DGD 12 2 NOTE 12 3 Strain relief clamp gt Generally all cable and hose components must be provided with traction reliefs at the beginning and end of the sections so that no tensile stresses can occur at connectors plugs and rundowns Strain relief clamp Strain relief clamp ET gt Fig 12 1 Use with robot example other installations possible gt Position the strain relief clamps so that the cables have maximum freedom of movement Lay cables slight loops such that the cables neve
52. eady output relay contact 2 max 26 V Relay contact 2 max 100 mA on Control on Control or Emergency stop input 24 V 10mA 0 VDC Ext 0 VDC Ext 0 V from input XS6 ARCNET The CPS3 is not equipped with ARCNET 11 5 Installation Secure the m Pro 400S CPM to the machine using 4 x M8 8 8 screws Tq 25 Nm 17h_Schraubersteuerung en fm 01 06 2011 P1917E EN 2011 05 51 Nutsetter control unit 400 DGD 11 5 1 Guidelines The m Pro 400S CPM is ventilated by a natural convection system an active fan is not required NOTE Warm air must not enter below the cooling element Q No objects are allowed to obstruct the air flow below and above the cooling element see hatching in the graphic 11 5 2 Dimensions Seite 52 The m Pro 400S CPM should not be exposed to direct sunlight 11 5 2 Dimensions A B mm mm CPM3 380 340 CPM6 600 560 CPM9 760 720 77 hod Li dE 52 1917 2011 05 17h_Schraubersteuerung en fm 01 06 2011 DGD Instructions on laying cables 12 Instructions on laying cables 12 1 General gt gt CAUTION Don t bend cables while unrolling them Don t create any loops or twists Remember that a strain relief clamp and compression set must be incorporated within the bending radius Don t use extra long cables and wires reserve Avoid mutual interference Lay so called hot and col
53. eck the motor wires for breaks and short circuits gt the nutsetter cable Motor phases interrupted gt Check the motor against PE and phase impedances for short circuits 1 approx 11 2 approx 20 3 4 approx 0 6 W gt Replace motor Test current for cable monitoring is misdirected gt Replace motor Internal error gt Replace the TS TUS P1917E EN 2011 05 171 Fehlersuche en fm 01 06 2011 DGD Troubleshooting Error Possible causes Measures and Description remedies Motor In the cable Check the motor wires in the Short circuit surveillance nutsetter cable for short circuits NOK m gt Replace the cable Motor short circuit monitoring the motor Check the motor for short cir There is a short circuit in the motor circuit on the DGD IS cuits for phase impedances see above gt Replace motor In the TS TUS Internal error gt Replace the TS TUS Motor Temperature NOK The motor temperature is gt 90 C temperature sensor in the motor measures a temperature gt 90 C Check the motor temperature if gt 90 C gt ensure adequate ventilation of the motor Measuring cable in the motor is interrupted Check the thermosensor for breaks The resistance should be approx 1 KO at 20 C gt Replace motor Measuring current is misdi rected Check the wires in the DGD IS for breaks
54. ed to other heat sources e g sunlight gt Improve the ambient con ditions attach covers if necessary Heat dissipation from the m Pro 400S CPM is inade quate due to external condi tions gt Ensure that air can circu late through the cooling fins Pt Error in intermediate circuit The intermediate circuit is overloaded Excessive number of DGD IS gt Reduce the number of m Pro 400S CPM 1 6 The intermediate circuit voltage is too high Intermediate circuit voltage 480 VDC May also occur momen tarily Braking chopper is defective Replace the CPS3 Excessive number of DGD IS is causing the braking chop per to overload gt Reduce the number of m Pro 400S CPM Intermediate circuit capaci tors no longer have sufficient capacity Life span exceeded gt Replace CPS3 171 Fehlersuche en fm 01 06 2011 P1917E EN 2011 05 73 Troubleshooting DGD gt Error Possible causes Measures and Description remedies o 2 1 7 Intermediate circuit voltage Mains supply is not powerful Check the mains supply is 100 low enough gt More powerful mains m supply required ntermediate circuit volt Relay to the switch on current gt Replace the CPS3 age lt 250 VDC limiter is defective perma nently open Excessive number of DGD IS gt Reduce the number of The voltage drops during fas
55. eps 17c_Systembeschreibung en fm 01 06 2011 P1917E EN 2011 05 9 System description 3 1 1 DGD IS DGD IS is available sizes 1B U TS 2B U TS 3B U TS and 4B U TS for a torque range of 2 to 1600 Nm 3 1 2 Nutsetter control unit Power and logic power supplied via the nutsetter control unit m Pro 400S CPM Depending on the size and number a maximum of 16 DGD IS can be connected to a system cable m Pro 400S CPM to the last DGD IS If the number of channels is greater the m Pro 400S CPM is set up as a control cabinet maximum of 32 DGD IS can be connected to one nutsetter control unit Available channel numbers Code Maximum number of DGD IS Number of 1B U TS 2B U TS 3B U TS 4B U TS system cables m Pro 400S CPM3 16 6 6 6 1 m Pro 400S CPM6 32 12 12 12 m Pro 400S CPM9 18 18 18 Control cabinet 32 32 32 depending on version The maximal numbers of DGD Intelligent Spindles per Controller depends on load When calculating the maximum number of spindles please consider the following conditions Maximum speed at 20 of maximum torque at 1BTS 2BTS 3BTS and 4BTS Final tightening stage up to 500 Nm Maximal Speed 50 rpm at maximum torque at 1BTS 2BTS 3BTS and 4BTS 4B500A Finaltightening stage over 500 Nm Maximal Speed 20 rpm at maximum torque at 4BTS 4B660A 4BTS 4B660A 4VK4MS 4BTS 4B360A 4Z1250A and 4BTS 4B460A 4
56. ernal error gt Replace the TS TUS gt Inform Sales amp Service Cen ter Measurement card Sampling clock from servo NOK The system clock from the servo amplifier is missing Internal error gt Replace the TS TUS Measurement card Servo type correct NOK The selected servo amplifier type is incorrect Error in programming gt Check the system programming Self identification of transducer is not OK Check the transducer gt Replace the transducer Internal error gt Replace the TS TUS Measurement card Servo par matching servo NOK The parameter set selected from the measuring board is not pres ent in the TS TUS Error in programming gt Check the system programming Self identification of transducer is not OK Check the transducer gt Replace the transducer Internal error gt Replace the TS TUS Measurement card ARCNET communication Dup ID The same ARCNET addresses are preset Several TS TUS are preset to the same ARCNET address Check the preset ARCNET addresses gt Set different addresses Measurement card ARCNET communication Recon The ARCNET is temporarily dis rupted ARCNET terminator missing gt Plug in the ARCNET terminator No power supply to the ARCNET terminator gt Switch on the power supply for the last device Error in cabling gt Plug in all cables and lock Error in potential equali
57. g board are integrated in the tightening module Both circuit boards are linked to the connections via cables and plug connectors 6 2 General technical data Features Data Weight TS 52 2 oz 1480 g TUS 52 9 oz 1500 g Protection category is attained IP54 when all connectors are plugged in and the service panel is closed Cooling type Convection self cooling Servicelife operating 40 000 h Usability period if stored 100 000 h approx 11 years Acceleration of each axis max 100 m s 6 2 1 Power loss Low loss components generate minimal heat Extremely good heat dissipation Overall housing serves as a cooling element Standby 9A Operation max 40 W WARNING High temperature the tightening module TS TUS may heat and cause burns during removal max temperature 70 C Wear gloves 6 2 2 Power supply 380 VDC Intermediate power circuit 380 VDC and logic power 24 VDC are supplied separately by the nutsetter control unit The intermediate power circuit is switched off separately by the nutsetter control unit after an emergency stop The logic section remains connected to the power Performance data various DGD IS Features Data 1B U TS 2B U TS 3B U TS 4B U TS Supply voltage VDC 380 510 Rated supply current A 0 5 1 Peak supply current A 6 15 15 15 28 P1917E EN 2011 05 17f_Schraubmodul en fm 01 06 2011 DGD Tighteni
58. g en fm 01 06 2011 P1917E EN 2011 05 49 Nutsetter control unit 400 DGD 11 4 7 Plug connectors and configuration WARNING Unplugging the system cable while still live may generate an electric arc and cause serious burns N The contacts may become damaged Switch off the power supply to the m Pro 400S CPM before unplugging or inserting the system cable 1 Power In Required connector type Phoenix Power Combicon 6 4 5 10 16 Order No 961175 Contact Signal Description L1 L1 L2 L2 Supply voltage 3 x 270 VAC L3 L3 PE PE Earth conductor connection to housing XS21 Power Out Power supply DGD IS 380 VDC Required connector type Phoenix Power Combicon IPC6 3 ST 10 16 Order No 961188 Contact Signal Description ZK 380 VDC Intermediate circuit voltage 380 VDC 10 IC 0 VDC Intermediate circuit voltage 0 V PE PE Earth conductor connection to housing 522 TS TUS 24 V supply and Enable servo signal end stage release signal to DGD IS Required connector type Phoenix Combicon MSTB2 5 3 STF 5 08 Order No 5959935 Contact Signal Description 24V 24 V Out Supply TS TUS 24 V 10 max 4A 8 DGD IS Enab SV Enable servo Enable servo output End stage release Active when no errors or Emergency stop pending 24 VDC 0 3 OVDC Ov Supply TS TUS 0 V XS3 logic supply and contro
59. heck programming in the station controller Spindle constants Calibration values Fastening process sequence Parameter set Targets Servo Intermediate circuit voltage too high The voltage in the intermediate power circuit is gt 440 VDC Constant error See CPS3 troubleshooting no error on CPS3 gt Replace the TS TUS The error is triggered during braking i e when the DGD IS stops See CPS3 troubleshooting no error on CPS3 gt Replace the TS TUS Sporadically the voltage is tem porarily too high See CPS3 troubleshooting no error on CPS3 gt Replace the TS TUS Servo Intermediate circuit voltage too low The voltage in the intermediate power circuit is lt 190 VDC Constant error See CPS3 troubleshooting no error on CPS3 gt Check the system cable for interruptions gt Replace the system cable System cable OK gt Replace the TS TUS During fastening error is trig gered during the fastening pro cess See CPS3 troubleshooting no error on CPS3 gt Replace the TS TUS Sporadically the voltage is tem porarily too low See CPS3 troubleshooting no error on CPS3 gt Check the mains power sup ply for voltage drops 171 Fehlersuche en fm 01 06 2011 P1917E EN 2011 05 77 Troubleshooting DGD Error Possible causes Measures and Description remedies Servo The temperature sensor
60. highest priority is displayed i e with the lowest number The errors or faults that the CPS3 detects are NOT communicated to the station controller via ARCNET and then displayed on the screen z Error Possible causes Measures and Description remedies o 2 0 0 Error loading the intermedi Short circuit in the inter gt Replace the CPS3 ate circuit capacitors after mediate circuit CPS3 Switching on Cables gt Check the cables for short circuiting between con tacts 1 and 2 on the plug connectors and replace if necessary TS TUS gt Replace the TS TUS Main relay Q4 or Q5 in gt Check the main relay PM does not switch replace if necessary 0 1 Faulty supply 3 x 270 VAC Phases missing gt Check phases Check mains supply Safety relay PNOZ 2 in the gt Check the emergency power module has triggered stop circuit an emergency stop 2 Read the operating instructions for the PNOZ type X3P Relay Q2 or Q3 has not gt Check the relay switched replace if necessary Supply voltage gt Check the supply voltage is too high U phase phase gt ZOT VAC Check mains supply too low U phase phase lt 240 VAC 0 2 Excess current or short cir Braking current gt 200 gt Replace the CPS3 cuit on braking chopper Short circuit in the braking resistor 0 4 Braking chopper overload Braking resistor is overloaded gt Reduce the number of The braking power is gt 100
61. in the Check temperature if gt 80 C Temperature output section TS TUS measures a tempera gt ensure adequate ventilation too high ture gt 80 C of the DGD IS The temperature in the TS TUS output section is gt 80 DGD IS is ventilated sufficiently gt Replace the TS TUS Servo Driver supply outp section NOK The power adapter for the inter nal supply to the output section is overloaded or defective Internal error gt Replace the TS TUS Servo Offset of current measure ment NOK The zero point of the integrated motor current measurement has moved Internal error gt Replace the TS TUS Servo SSIO communication NOK The communication interface between the servo amplifier and the measuring board is faulty Internal error gt Replace the TS TUS Servo Node guarding NOK The servo amplifier monitors the function of the measuring board watchdog Sporadic malfunction of the measuring board Internal error gt Replace the TS TUS Servo Flash NOK The flash memory in the servo amplifier indicates an error Internal error gt Replace the TS TUS Servo Program NOK Error in the program execution for the servo amplifier Internal error gt Replace the TS TUS gt Inform Sales amp Service Cen ter Motor Motor cable NOK The motor cable is defective motor wire in DGD IS is broken Broken motor wire in the nutsetter cable Ch
62. k Nm dis tance max min rpm mm mm mm kg flange 2BTS 2B110A 2K1B 2ZB 947517A8 110 25 890 1 2 56 528 7 6 308435 2BTS 2B200A 2K3B 2ZB 947529 4 200 40 502 3 4 50 910609 2BTS 2B110A 2VK1B 947521A2 110 25 831 1 2 44 551 9 2 308438 2BTS 2B200A 2VK3B 947533A8 200 40 468 3 4 2BTS 2B110A 2WK1B 947525A8 110 25 838 1 2 25 59 581 8 7 929053 2BTS 2B200A 2WK3B 947537A4 200 40 472 3 4 2BUTS 2B110A 2K1B 2ZB 947519 6 110 25 890 1 2 56 367 8 6 308435 2BUTS 2B200A 2K3B 2ZB 947531 0 200 40 502 3 4 50 910609 2BUTS 2B110A 2VK1B 947523A0 110 25 831 1 2 44 390 10 2 308438 2BUTS 2B200A 2VK3B 947535A6 200 40 468 3 4 2BUTS 2B110A 2WK1B 947527A6 110 25 838 1 2 25 59 421 9 7 929053 2BUTS 2B200A 2WK3B 947539 2 200 40 472 3 4 Smallest scribed circle diameter mm Quantity Attachment DGD IS Centric Offset Angle head 2 56 44 59 3 75 50 68 4 80 62 86 5 106 74 101 6 130 89 118 7 151 102 137 16 P1917E EN 2011 05 17e IntelligenteSpindel en fm 01 06 2011 DGD DGD intelligent spindles 5 2 4 Size 2 2x transducer Designation Order Torque Speed Spring min Lengt Weight Spring No travel Chuck Nm dis tance max min rpm mm mm mm kg flange 2BTS 2B110A 2 2K1B 2ZB 947518A7 110 25 890 1 2 56 625 8 7 308435 2BTS 2B200A 2 2K3
63. l on relay output 24 V supply for the CPS3 and control on relay connection for the power supply Required connector type 50 1 91 201 1 05 17h_Schraubersteuerung en fm 01 06 2011 DGD Nutsetter control unit m Pro 400S CPM Phoenix Combicon MSTB2 5 6 STF 5 08 Order No 961177 Contact Signal Description 24 V IN 1 24 V IN Supply of the logic in the CPS3 24 V 10 CTR on CTR on Control on output relay relay for external relay 24 VDC max 0 3 A PWR on PWR on Power on output 24 VDC max 0 3 A 0 VDC 0 VDC 0 V of 24 V 0 VDC 0 VDC 0 VDC 0 VDC XS4 m Pro 400S 24 supply for m Pro 400S Emergency stop signal from the m Pro 400S and Ready signal to the m Pro 400S Required connector type Phoenix Combicon IC2 5 4 STF 5 08 Order No 961178 Contact Signal Description 24 VDC 24 VDC Supply output 24 V max 2A EM stop Emergency stop Emergency stop input from m Pro 400S Ready Ready for operation Ready output to the 4005 24 VDC max 0 3A 0 VDC 0 VDC OV XS5 machine control Emergency stop signal from the machine control and Ready signal to the machine control Required connector type Phoenix Combicon MSTB2 5 4 STF 5 08 Order No 961179 Contact Signal Description Ready 1 Ready for operation Ready output relay contact 1 max 26 V Relay contact 1 max 100 mA Ready 2 Ready for operation R
64. lights up Data transfer to the ARCNET LED flashes ARCNET reconfiguration transfer is disrupted LED off Internal fault no power available lt Reset gt button Press the lt Reset gt button to acknowledge faults You will require a pointed object such as a ball point pen Pressing this button resets the processor and reconfigures all functions service interface RS232 for measuring board Only for DGD Service e Connection to PC via special cable Plug connector type PS2 Pin Signal Description 1 RxD 10 V 2 TxD 10 V 3 VCC 3 3 V 2 20 mA 4 5 6 Housing GND OV 30 P1917E EN 2011 05 17f_Schraubmodul en fm 01 06 2011 DGD Tightening module TS TUS 6 4 5 DGD service interface RS232 for servo NOTE Q Only for DGD Service Connection to PC via special cable Plug connector type PS2 Pin Signal Description 1 RxD 10 V 2 TxD 10 V 3 VCC 3 3 V 2 20 mA 4 AMON Analog monitor 0 V 3 3 V 5 AIN Analog preset 0 V 3 3 V 6 START Start signal to servo 0 V start 3 3 V Housing GND OV 6 5 Internal assemblies 6 5 1 Power adapters The internal power adapters supply power to all electronic assemblies in the tightening module All generated voltages are short circuit proof Galvanic isolation of ARCNET output stage from all other power supplies Pulse frequency of the converter is 80 kHz
65. live may generate an electric arc and cause serious burns The contacts may become damaged gt Switch off the power supply to the m Pro 400S CPM before unplugging or inserting the system cable 46 P1917E EN 2011 05 17h Schraubersteuerung en fm 01 06 2011 DGD Nutsetter control unit m Pro 400S CPM 11 4 Supply module CPS3 11 4 1 Description The supply module CPS3 Central Power Supply 3 KVA is integrated in the nutsetter control unit 1x in m Pro 400S CPM3 2x in m Pro 400S CPM6 3x in m Pro 400S CPM9 The CPS3 has the following functions Rectification and smoothing of the intermediate circuit voltage to 380 VDC for the tightening module TS TUS Switch on current limiting Braking chopper Excess and low voltage monitoring with intermediate circuit shut off Short circuit and overcurrent monitoring Generation of Ready signal on the m Pro 400S and machine control Evaluation of Emergency stop signal Enab SV a00639 wmt 17h_Schraubersteuerung en fm 01 06 2011 P1917E EN 2011 05 47 Nutsetter control unit 400 DGD 11 4 2 General technical data CPS3 Features Data Order No 961112 Weight G 3650 Protection category IP20 Cooling type Convection self
66. lterations repairs and modifications are prohibited for reasons of safety and product lia bility Do not operate the fastening system outdoors Always remove the complete DGD IS from a unit gt Do not open the transducer offset attachment or angle head attachment as this will void the war ranty A repair is only permitted by DGD authorized personnel If repair is required send the com plete component to Sales amp Service Center gt Do not open the TS TUS or CPS3 as this will void the warranty This does not include the service panel A repair is only permitted by DGD authorized personnel If repair is required send the complete component to Sales amp Service Center gt Read the following documents when replacing the DGD IS this system manual see 16 Maintenance Service Seite 83 the DGD intelligent spindle assembly instructions Service manual DGD IS Spare part sheets 1 6 Ambient conditions Do not operate the fastening system in an explosive atmosphere System components Ambient temperature Relative humidity Working height DGD IS 400 32 to 113 TS TUS 0 to 45 C 0 to 90 no condensa upto 3000 m above Motor tion sea level CPS3 32 to 158 F 0 to 70 17b Sicherheit bedingt en fm 01 06 2011 P1917E EN 2011 05 7 Transport Storage DGD 1 7 EMC The tool complies with the following applicable EMC standards DIN EN 61000 3
67. m Pro 400S CPM tening 2 0 Temperature in CPS3 is too Excessive number of DGD IS gt Reduce the number of high or too low Constant overload of the m Pro 400S CPM CPS3 Temperature is Ambient temperature gt Improve the ambient con outside of the 40 C to 4005 gt 40 C ditions 85 C range 400 is gt Improve the ambient con exposed to other heat ditions attach covers if sources e g sunlight necessary Heat dissipation from the gt Ensure that air can circu m Pro 400S CPM is inade late through the cooling quate due to external condi fins tions Housing openings on the gt Clear the housing open CPS3 are covered ings 2 1 Switch on relay contact Subsequent error a differ gt Replace the CPS3 does not open ent fault destroyed the relay Maximum number of switch gt Replace the CPS3 Relay for switch on on cycles exceeded current limitation in the CPS3 is stuck Detection only occurs when switching on The relay contact is closed during operation 2 2 Intermediate circuit Subsequent error a different 380 VDC discharge not fault destroyed the relay possible Main relay Q4 or Q5 in PM Replace the main relay Q4 The intermediate circuit cannot be discharged does not open or Q5 Braking chopper in the CPS3 Replace the CPS3 is defective Braking resistor is highly Replace the CPS3 resistive or burnt through 74 P1917E EN 2011 05
68. nance Service Only trained personnel are permitted to perform maintenance See service manual DGD IS High leakage current Fatal electric shock could occur gt Always disconnect the power supply before performing maintenance work on the DGD IS and the m Pro 400S CPM gt Always disconnect the system cable motor or motor cable from the m Pro 400S CPM or DGD IS before making throughput resistance and short circuit measurements gt Do not attempt to repair possible faults on the fastening system by yourself if you do not have the required knowledge Inform the local repair center or your Sales amp Service Center gt Establish a grounding connection PE to the nutsetter control unit m Pro 400S CPM before taking into operation High temperature the motor on the DGD IS may heat up and cause burns during removal max engine temperature 90 C Wear gloves Regular maintenance reduces operating faults repair costs and downtime Implement a safety related maintenance program that takes the local regulations for repair and maintenance for all operating phases of the tool into account Disposal Injuries and environmental damage from improper disposal Components of the DGD IS pose risks to the health and the environment gt The DGD IS contains components that can be reused as well as components that require special disposal Separate the components and dispose of them by segregating them clearly gt Catch
69. nd files e g setup exe A backslash between two names indicates the selection of an item from the menu e g file print Station controller Nutsetter control unit Tightening module Supply module DGD intelligent spindles Identifies movement in a direction Identifies function and force DGD reserves the right to modify supplement or improve this document or the product without prior notice This document may not be reproduced in whole or in part in any way shape or form or copied to another natural or machine readable language or to a data carrier whether electronic mechanical optical or other wise without the express permission of DGD DGD and Cleco are trademarks and plant names of the Apex Tool Group Division P1917E EN 2011 05 17a_Deckblatt en_A fm 01 06 2011 Contents 1 Safety 5 1 1 Warnings and notes Hair ee 5 1 2 Basic requirements for safe working practices 5 1 3 Operator training MORE ee 6 1 4 Personal protective 2 2 4 00000000 6 1 5 Intended USE a 7 1 6 Ambient conditions ernennen 7 1 7 EMG A E A 8 1 8 NOS 8 2 Transport Storage 8 3 System description 9 3 1 Components 9 4 Initial operation 11 5 DGD intelligent spindles 13 5 1 General technical OA 13 5 2 Catalogue 14 5 3 Component
70. nd maintenance personnel are instructed in the operation and maintenance of the fastening system to the same extent and with the same care and attention Personnel who are being trained may work on the fastening system only under the supervision of an experienced operator Personal protective equipment When working Wear the protective goggles to protect against spurting metal splinters Danger of injury by being wrapped up in and caught by machinery Wear close fitting clothing Do not wear jewelry P1917E EN 2011 05 17b_Sicherheit_bedingt en fm 01 06 2011 Safety 1 5 Intended use The owner is responsible for using the machine according to its designated use The fastening system may be used only under the following conditions NOTE Do not operate the fastening system outdoors Industrial environment EMC limit class value A DIN EN 550081 2 The DGD IS is designed for stationary operation only and is intended exclusively for fastening and loos ening thread connections Do not use as a hand held tool Always use the DGD IS in combination with the nutsetter control unit m Pro 400S CPM The DGD IS must be fully assembled Insert and lock all connecting cables Secure the DGD IS to an electroconductive grounded mounting plate Always use the DGD IS in combination with the control unit m Pro 400S CPM Only cable types approved by DGD may be used Only accessory parts approved by DGD may be used Unauthorized a
71. ng module TS TUS 6 2 3 Logic power supply The logic power control unit supply in the tightening module generates all supply voltages 24 V from the nutsetter Features Data Supply voltage V 24 410 96 Rated supply current A approx 0 35 Power loss standby 9 6 3 Ready LED The Ready LED indicates that the system is ready for operation Signal Tightening module Green Ready for operation Red Not ready for operation an error is pending see 15 Troubleshooting Seite 69 6 4 Service panel 2 4 3 4 5 Item Designation 1 ARCNET address preset 2 Active LED 3 lt gt button E 4 DGD service interface RS232 for measuring board 8 5 DGD service interface RS232 for servo E 174 Schraubmodul en fm 01 06 2011 P1917E EN 2011 05 29 Tightening module TS TUS DGD 6 4 1 NOTES 6 4 2 6 4 3 6 4 4 NOTE ARCNET address preset The ARCNET address is preset via the two 10 stage decode switch Permitted settings 01 to 32 e Switch x1 for units 00 09 e Switch x10 for tens 00 30 Always switch off the nutsetter control unit before making adjustments Each address be used only once in the system Otherwise an error is triggered on the 400 Active LED The Active LED indicates which activities the ARCNET is performing Signal Activity LED
72. nter Sales amp Service Center Sales amp Service Center Sales amp Service Center 15503 Blackburn Avenue 2865 152nd Avenue N E 3990 East Market Street 5925 McLaughlin Road Norwalk CA 90650 Redmond WA 98052 York PA 17402 Mississauga Ont L5R 1B8 USA USA USA Canada Phone 41 562 926 0810 Phone 1 425 497 0476 Phone 1 717 755 2933 Phone 41 905 501 4785 Fax 1 562 802 1718 Fax 1 425 497 0496 Fax 1 717 757 5063 Fax 1 905 501 4786 Germany England France China Apex Tool Group Apex Tool Group LLC Apex Tool Group SAS Apex Power Tools Tra GmbH amp Co OHG Pit Hill Zone Industrielle ding Shanghai Co Ltd Industriestra e 1 Piccadilly BP 28 A company of 73463 Westhausen Tamworth 25 Avenue Maurice Chevalier Apex Tool Group LLC Germany Staffordshire 77831 Ozoir la Ferri re Cedex A8 No 38 Dongsheng Phone 49 73 63 81 0 B78 2ER Road Shanghai Fax 49 73 63 81 222 U K Phone 33 1 64432200 China 201201 Phone 44 191 4197700 Fax 33 1 64401717 86 21 60880320 44 182 7874128 86 21 60880298 Brazil Cooper Tools Cooper Tools Industrial Ltda de Mexico S A de C V company of a company of Apex Tool Group LLC Apex Tool Group LLC Av Liberdade 4055 Vialidad El Pueblito 103 Zona Industrial Iporanga Parque Industrial Quer taro 18087 170 Sorocaba SP Brazil Quer taro 76220 Phone 55 15 3238 3929 Phone 52 442 211 3800 Fax 55 15 3228 3260 Fax 52 442 103 0
73. on voltage input ON V gt 3 5 Calibration voltage input OFF V 2 0 Calibration voltage maximum V 35 Calibration input impedance KO 5 Angle measurement features Data Angle resolution Pulse Degree 1 Pulses Rotation 360 Angle signals 2 Direction dependent phase shifting Degrees 90 30 angle signals Output shut off angle outputs Open collector with 10 kO to 12 V supply Output current maximum angle outputs mA 50 Electric strength angle outputs V 420 17g Komponenten en fm 01 06 2011 P1917E EN 2011 05 39 Gearing DGD 8 2 Pin configuration of transducer Type 12 pin circular connector Lumberg SGR 120 Binder series 680 no 09 0331 90 12 with locking connector in accordance with DIN 45 321 Pin Color Signal Description A nc B Brown ANGA Angle output A Green TQ Torque output dd E D Yellow 0 VA 0 V torque reference connec D F tion C G E gray OV 0 V supply L Pink 12 V Supply B H G Blue ANGB Angle output B J H Red RxD Interface J Black RxD Interface K Violet CAL Input calibration voltage L Gray pink TxD Interface M Red blue TxD Interface Housing PE Shield connection Gearing Gearin 8 o Code Order no Ratio 1 1 012 927346 5 7273 1B035A 927344 15 1364 1B060A 927345 25 7727 2 2B110A 935548 12 3595 2B200A 935549 21 9231 3 3B300A 935590 18 7500 4 4B360A 929541 26 3118 4B500
74. r become strained when the cable drag chain is pulled out Cable pulls between the carriages or end stops on the rail can be of assistance We recommend Run a few motion cycles after the initial installation of cables Afterwards check the cable installation once more and optimize it if possible gt Only secure cables with strain relief clamps designed for the corresponding cable diameter Use screw on cable clips if possible The clamping surface should be adjusted to the occurring tensile load Too narrow of a clamping surface may cause the cable to fail prematurely gt Avoid crushing individual wires or subcomponents We recommend applying a clamping force around the entire circumference of the cable Only secure the cables at the strain relief clamp gt secure strain relief clamp prevents the cable from shifting inside the flexible cable duct Shielding The shielding in the lines limits the expansion of perturbation energy into the surroundings and shields the System against disturbances The cables between tightening module and Built in nutrunner or hand tool are shielded against exterior dis turbances However this measure also counteracts interference emissions gt Generally connect it to both ends gt Extensively connect the shielding of the nutrunner cables skin effect to the lower edge of the tightening module housing with the aid of shield connecting elements 54 P1917E EN 2011 05 17i Kabel en fm 25
75. ransducer or DGD IS Internal power adapter defective gt Replace the TS TUS Measurement card Voltage 24 V The 24 V supply of the TS TUS is outside the limits of 20 4 V 27 6 V Supply is overloaded Inspection of station controller in test mode value outside the permissible limits gt Check the load Voltage on power adapter in m Pro 400S CPM is incorrect gt Set the power adapter to 26 0 V Measurement card Temperature NOK The temperature of the measur ing board is gt 80 C The temperature sensor in the TS TUS measures a tempera ture gt 80 C gt ensure adequate ventilation of the DGD IS Internal error DGD IS is ventilated sufficiently gt Replace the DGD IS Transducer 1 2 Connected NOK The signals from the transducer are not OK The connection to the trans ducer is interrupted Check the KMAG KMAW cable transducer TS TUS for breaks gt Replace the cable gt Replace the transducer short circuited Check the KMAG KMAW cable for short circuits Replace the cable Replace the transducer unavailable Connect the transducer Replace the cable Internal error Replace the TS TUS Transducer 1 2 Calibration voltage NOK The calibration voltage is outside the permissible range of 4 85 V 45 15 V The calibration signal is inter rupted MEE
76. s amp Service Center gt Switch the m Pro 400S CPM off and on again Communication error with a service PC gt Reconnect PC to CPS3 Checksum error gt Inform Sales amp Service Center gt Switch the m Pro 400S CPM off and on again 171 Fehlersuche en fm 01 06 2011 P1917E EN 2011 05 75 Troubleshooting DGD 15 4 15 4 1 15 5 15 5 1 Tightening module TS TUS Ready LED Error Description Possible causes Measures and remedies Ready LED lights up red Error in the TS TUS Error description on the station controller display see 15 5 Station controller m Pro 400S 5 76 Ready LED does not light up 24 V supply is unavailable the TS TUS is not connected to the power supply Measure the voltage 24 26 V at 1 Sockets A and B gt Check the error display on the CPS3 of m Pro 400S CPM gt f error present go to 15 3 Tightening module CPS3 in nutsetter control unit m Pro 400S CPM Seite 71 gt Replace the system cable TS TUS is defective gt Replace TS TUS Station controller m Pro 400S Display on the Control Unit The errors or faults that the TS TUS fastening electronics detect are communicated to the station controller via ARCNET and then displayed on the screen If an error occurs in the TS TUS or DGD IS during fastening the error reported by the TS TUS appears in the rundown data t
77. se DGD IS DGD IS Order No 961397 xxx xxx cable length in dm 13 2 4 Wiring diagram jemen 11 1 71 plugs HIT lain mage PE 80100 15 18 Ya 1 3006 AT ovoc 2 gt 2 Li m Hak 2 OVOC avoe As bn Le 24100 AUT Mis B CQ Enable gt bl k G Enable DATAA ts whtelgreen DATAA DATAB x whieked D DATAB 17i_Kabel en fm 01 06 2011 P1917E EN 2011 05 63 Cable Blank page 64 P1917E EN 2011 05 17i_Kabel en fm 01 06 2011 DGD Function description 14 14 1 NOTE 14 2 Function description Torque measurement The transducer is equipped with a telemetry system and therefore has no slip rings The transducer is either installed in the DGD IS as a component or integrated in an offset attachment or angle head attachment All components of the transducer measuring shaft antenna system rotor electronics and stator electronics belong together as one unit i e individual assemblies cannot be replaced The rotor electronics are attached to the measuring shaft and are connected to the full strain gage bridge and the rotor antenna system The stator electronics are located in the transducer housing They incorporate the evaluation circuit the sta tor antenna system and the 12 pin sy
78. software in FLASH memory The station controller m Pro 400S updates the software via the ARCNET Press the button under the service panel to reset see 6 4 3 lt Reset gt button Seite 30 Torque measuring accuracy 0 2 Resolution 12 bits at 6 6 V therefore approx 6 5 mV Measurement sampling rate 3300 measurements per second Analog filter for torque signals 1 KHz Maximum angle frequency 12 KHz corresponds to 2000 revolutions per minute of the DGD IS attachment with a resolution of 1 pulse per degree Angle redundancy only available for one transducer Current redundancy possible by measuring the motor current transferred by the servo amplifier Measuring the motor angle signals transferred by the servo amplifier via the synchronous serial interface SSIO These are generated from the resolver signals Communication between measuring board and servo amplifier A synchronous serial interface SSIO provides a means of communication between the servo amplifier and the measuring board For safety reasons the start signal is transferred from the measuring board to the servo amplifier both via a separate input output and via the SSIO Communication between tightening module and station controller The two units communicate via the ARCNET high performance field bus The transfer rate is 2 5 32 P1917E EN 2011 05 17f_Schraubmodul en fm 01 06 2011 DGD Attachment Attachment
79. stem connector The torque and the angle are measured directly at the attachment Exception the angle of the angle head attachment is measured at the drive wheel Torque measurement is made symmetrically for right and left rotating torques tightening and loosening direction The measured torque values are transferred from the transducer to the measuring electronics via an amplified analog voltage 0 5 V Always use measuring devices that are galvanically isolated from the protective earth conductor for mea suring the torque angle encoder signals directly on the transducer e g oscilloscope with isolation trans former When measuring ensure that both 0 V reference connections of the transducer 0 V torque Pin D and 0 V supply Pin E cannot be short circuited Ignoring this may result in failures or measuring errors from potential equalization currents between PE 0 V TQ and 0 V supply in the torque measurement circuit Calibration takes places in the rotor unit by means of a switched shunt resistor parallel to a strain gage mea suring bridge section The calibration signal has the following time behavior Input pulse duration pin K Output signal delay pin C 0 1 5 ms No output signal 1 5 ms random Max rise delay lt 3 ms Max drop delay lt 16 ms Angle measurement The integrated incremental angle encoder traces the angle with two angle tracks WI The phase shift between these depends
80. ter file See m Pro 400S operator information for details of nutsetter control unit process programming 17d_Inbetriebnahme_bedingt en fm 01 06 2011 P1917E EN 2011 05 11 Initial operation DGD Blank page 12 P1917E EN 2011 05 17d Inbetriebnahme bedingt en fm 01 06 2011 DGD DGD intelligent spindles 5 DGD intelligent spindles 5 1 General technical data torque measurement with integrated pre amplifier resulting in greater signal noise spacing e fault resistant magnetic field sensor angle measuring system reverse voltage protected supply Short circuit proof outputs low voltage monitor e watchdog for processor e noise protected input and output circuit Features Data Protection category IP54 Service life operating 40 000 h Load cycles min at maximum torque 1 000 000 then recalibration Mechanical overload capacity of the measuring shaft 100 17e IntelligenteSpindel en fm 01 06 2011 P1917E EN 2011 05 13 DGD intelligent spindles DGD 5 2 Catalogue data 5 2 1 Size 1 1x transducer Designation Order Torque Speed Spring Min Length Weight Spring No travel a dis tance max min rpm mm mm mm kg flange 1BTS 1B012A 1K3B 1ZB 947541 8 12 1921 1BTS 1B035A 1K
81. urements NOTE Always replace CPS3 and TS TUS completely Opening the CPS3 or TS TUS will void the warranty This does not include the service panel Observe the conditions for operation see 4 Initial operation Seite 11 15 1 Acknowledgment of Errors The system is ready for operation again once the fault is rectified and the Reset button on the CPS3 or TS TUS is pressed The measuring board acknowledges faults pending in the TS TUS each time a spindle starts If the failure is brief e g undervoltage the TS TUS becomes ready to operate automatically after the next acknowledgment signal All faults on the DGD IS not from CPS3 are archived in the station controller The error information is dis played here during troubleshooting The error is permanent if the error mode cannot be acknowledged 171 Fehlersuche en fm 01 06 2011 P1917E EN 2011 05 69 Troubleshooting DGD 15 2 15 2 1 DGD IS Error Description Possible causes Measures and remedies DGD IS does not turn Motor defective Gearing defective Tightening module TS TUS defective gt Replace the DGD IS Cable defective gt Replace the cable Loud noises Gearing wear gt Replace the DGD IS Transducer When an operating failure occurs the torque output is set to an output value of gt 6 5 V and an error bit is set in the operating data memory Error Description Possible causes Measures and
82. utsetter control unit m Pro 400S CPM 6 7 5 J 4 f TU a d 3 2 Designation 1 Cooling element aluminum 2 Front door lockable 3 Cable outlet 4 Ready indicator 5 Main switch 6 Station controller m Pro 400S touch screen 7 Supply module CPS3 integrated i 11 1 Brief function description The nutsetter control unit m Pro 400S CPM controls the fastening sequence 4005 Supplies the tightening module TS TUS with 380 VDC CPS3 and 24 VDC The machine control and the station controller 400 transmit the signals Control on and Emergency stop which activate and deactivate the intermediate circuit voltage to the DGD IS The integrated emergency stop safety relay PNOZ X3P activates and monitors two relays The relays activate the supply voltage 17h Schraubersteuerung en fm 01 06 2011 P1 91 201 1 05 45 Nutsetter control unit 400 DGD 11 2 11 3 11 3 1 WARNING AN General technical data Features Data CPM6 CPM9 Weight kg 75 130 180 Protection category IP54 Cooling type Convection self cooling Servicelife operating h 40 000 Usability period if stored h 100 000 approx 11 years On Off switching cycles 5 000 000 Safety requirements in accordance with EN 964 1 C
83. with cable ties Never lay cables with different diameters gt 3 mm together in the same parti tion Cables must be able to follow the radius of curvature without being forced around it Vertical installation gt Leave about 20 clearance within the partition height The lines hang out downward due to the cable weight including the chain This lengthening due to ER sagging must be monitored at regular intervals and adjusted if necessary 17i_Kabel en fm 01 06 2011 P1917E EN 2011 05 55 Instructions on laying cables DGD 12 5 Wiring of robot area SuperhighFlex Quality In order to achieve an optimal service life of cables in robotics applications comply with the following points when laying the cables gt Avoid using cable binders to fasten cables gt Lay the cable duct so that the cables have maximum freedom of movement gt Lay the cables so that the sleeves do not rub during operation Cables should not knock against static parts or hang loose gt Cables should not shift during operation gt Do not exceed the minimum specified bending radii The size of the bending radius is proportional to length of the service life gt Make sure that the length of the cable compensates for torsional loads 56 P1917E EN 2011 05 17i_Kabel en fm 01 06 2011 DGD Cable 13 Cable 13 1 HighFlex Quality suitable for cable ducts Therm
84. zation gt Connect potential equalization cable Internal error gt Replace the TS TUS Measurement card Initialization NOK Initialization error in measuring board Internal error gt Replace the TS TUS gt Inform Sales amp Service ter Measurement card Flash image NOK Flash image in the measuring board is not OK Station controller transferred the incorrect program gt Check the program version The program transfer was interrupted gt Repeat the program transfer Internal error gt Replace the TS TUS P1917E EN 2011 05 171 Fehlersuche en fm 01 06 2011 DGD Troubleshooting Error Description Possible causes Measures and remedies Measurement card Voltage 3 3 V NOK The 3 3 V supply to the mea suring board is outside the limits of 3 24 V 3 53 V The power adapter for the inter nal supply to the measuring board is overloaded or has an internal error gt Replace the TS TUS Measurement card Voltage 12 NOK The 12 V supply to the measur ing board and the transducer is outside the limits of 11 4 V 12 6 V 12 V short circuiting in the nut setter cable or DGD IS Inspection of station controller in test mode value outside the permissible limits Check the KMAG KMAW cable transducer TS TUS espe cially the 12 V and 0 V wires gt Replace the cable gt Replace the t

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