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SPX Cooling Technologies CS4000 User's Manual

1. 002022221 22 4 3 Meeting the AC Input Power Requirements 4 4 GEOUDUIDO ot dice tii Va d ob cedi d ay eats 4 4 demum 4 5 Connector Pinout Definitions 4 11 TS SIN roues cada 4 11 eleva MN LU c T TT 4 11 Pee CONDECION om cesi AG 4 12 Tool Control Module TCM Network Connector 4 12 HS 292 CONUS Oa nei RO addu as AUD UU eL daa E S add 4 12 Priner Barcoge Connector 4 12 Interpusso IN Connecti cuin e eerie reb a Vesti eed de 4 12 Iite pusss OUT Connector sio ge erii ver v d veniri ecd 4 13 5 Seting Up hie pH etie icut 5 1 Programming the Ethernet Interface 5 1 Working with the IP Address Subnet Mask and Default Gateways 5 1 Updating Application SO TINS ise eroe ces inr ra ter 5 10 Setting Up Visual Supervisor for an Ethernet 5 13 Editing VSMain ini for an Ethernet 5 14 Using Ethernet Network 1
2. 2 2 2 4 44 4 4242 5 16 Testing he Ethernet IBIWOITK iiri 5 17 Testing Ethernet Network 5 24 6 Setting Up the 485 Network scienze ccixseueci renasci eL neck ars mnes 6 1 installing the SDLG Card uiii obti EE Pm sca bb oci Re rH ai 6 1 Setting Up Visual Supervisor for a 485 6 1 Editing VSMain ini for a 485 08 6 2 Assigning A Network iei M 6 4 Using 485 Network beso ba ae Eos nelle exse bod bp edd da 6 7 Page viii T 38324 A 39 30 38324 Contents Seting UP ihe H9 232 Kx EE n 7 1 Setting Up Visual SupervisOE t aaas 7 1 Using RS 232 CIDOS uarie Gene bu dou RH iO dM ga Mus 7 1 Maintenance Troubleshooting eee eene 8 1 LESE 8 1 Replacing Main Power 2 2 2 2 24 RS 8 2 Replacing Backplane FUSES eie tice aera lb ni aa b cate mi cada Ra 8 2 Cleaning the Enclosure Window sse nennen 8 2 DUl psdgmee 8 3 Eenet
3. 1 1 1 0 o 8 1 Ethernet Common Problems and Solutions esses 8 3 Programming the Ethernet Interface 5 2 Editing Applicaton ee docsters 5 10 Editing VSMain ini for an Ethernet Network 5 15 Testing the Network From A Laptop 5 17 Testing the Network From A Host 5 23 Editing VSMain ini for a 485 Network essent 6 3 Setting the Address for the 1 6 6 May 2002 T 38324 A Page xi CS4000 Mini Controller with Ethernet This page is left blank intentionally Page xii T 38324 A 39 30 38324 1 Overview The GSE tech motive tool CS4000 Mini Controller with Ethernet is the control component of one of the most powerful DC electric nutrunner fastening control systems available The system uses 100 digital technology to ensure accurate and reliable fastening and torque angle data acquisition Microprocessors in both the tool nutrunner and the controller enable the system to perform to levels of accuracy while providing easy setup and operation The system uses the industry s first truly Intelligent Tools With this technology you no longer need to key tool identification calibration angle counts
4. 8 GRN Not DO1 Not Dit Page 4 12 T 38324 A 39 30 38324 Chapter 4 Installing the CS4000 Mini Controller with Ethernet Interbus S Connector 1 vw May 2002 T 38324 A Page 4 13 CS4000 Mini Controller with Ethernet This page is left blank intentionally Page 4 14 T 38324 A 39 30 38324 5 Setting Up the Ethernet The CS4000 Mini Controller with Ethernet can be connected to an Ethernet Local Area Network LAN This chapter describes the steps you must take to set up the Ethernet LAN e Programming the Ethernet interface card e Setting up Visual Supervisor for networks e Using Ethernet cables e Testing the network Programming the Ethernet Interface Card The Ethernet interface card shown in Figure 3 10 on page 3 14 has its own firmware You must install this software on to the card before attempting to connect the controllers via the Ethernet To program the Ethernet interface card you require Pentium class laptop computer Microsoft Windows 95 98 2000 or Windows NT version 4 0 or above At least 64 MB RAM for Windows 95 98 2000 or 128 MB for Windows NT e Null modem cable with female to female connectors TINI Ethernet Interface Flash Utility Etherflash version 1 2 NOTE Before programming the Ethernet interface card it is recommended that you make a note of its IP address and subnet mask settings If you do not
5. 3 5 RoO232 3 5 Ground Fault Circuit re Ead EUR dd s EU aaa 3 5 USOS asm disti rci erba uri 3 6 May 2002 T 38324 A Page vii CS4000 Mini Controller with Ethernet Enclosure ou ds eto bao e LE a rU qos M 3 6 TOS Conn ol MO auster sca etae MED o tud tera ere Ea 3 8 opio AMUNG cs Fai God Fus s EUM paid 3 10 Bue menester E ER 3 10 T 3 11 3 12 fava old s chore ja aig fe ana Sd 3 12 VE BO anecdotes ad D Md 3 13 BGs Lan a eR erty NR RR E TR US 3 13 Ethernet eM 3 14 nice ccc Module eC 3 16 Ground Fault Circuit InterP pter 2255 kd er eee dt pena 3 18 gil 3 18 4 Installing the CS4000 Mini Controller with Ethernet esses 4 1 Mounting the CS4000 Mini Controller with Ethernet 4 1 Power and Connection Requirements
6. 3V Lithium Battery side up J 2 Figure 3 7 Board Battery Location 3 10 T 38324 A 39 30 38324 Chapter 3 Identifying the Components Backplane The backplane part number 420890 35327 is a printed circuit board into which many of the internal component cables plug It also contains address switch SW 1 and the DCM fuse F4 See Figure 3 8 Device Control Module DCM Fuse F4 Jumpers JP1 to 8 Jumper JP9 Address Switch SW 1 m 24VDC Input Fuse 24VDC Fuse to Tool F2 24V Input 8 i Board J2 Figure 3 8 CS4000 Mini Controller with Ethernet Backplane May 2002 T 38324 A Page 3 11 CS4000 Mini Controller with Ethernet Backplane Fuses Fuse F4 is Littelfuse 239001 5x20 mm SLO BLO SB 250V part number 13 10 61001 Fuse F4 protects the DCM board inside the TCM Fuses F2 and F3 are Littelfuse 255 500 subminiature 0 5A part number 13 10 4050 Fuse F2 protects the 24VDC to the tool and Fuse protects the 24VDC used with the discrete I O circuits Address Switches Each TCM has a unique serial address The first six DIP switches on the address switch SW 1 allow you to set up the communication address 1 to 32 for the TCM Switch 7 assigns the baud rate at which the TCM sends data to an a
7. The Hyperterminal session ends and returns you to the Windows desktop When the ping command is successfully applied to the IP addresses you are testing you know the physical network connections are working correctly If you still have a network problem it is likely to be the result of a software malfunction NOTE As well as the ping command described in Procedure 5 4 there are a number of other commands available such as ipconfig and tcm These commands can also be used to diagnose problems with an Ethernet network Consult a GSE tech motive tool engineer for details Page 5 22 T 38324 A 39 30 38324 Chapter 5 Setting Up the Ethernet Use Procedure 5 5 to test the Ethernet network from the host computer NOTE There is an alternative to the method described in Procedure 5 5 You can use the Telnet application if it is installed on the Windows operating system of the host computer Telnet establishes a connection across the Ethernet network to the Ethernet interface card in any controller Telnet logs on to the network using the IP adaress of the controller Once logged in you can use the ping command to test the network connection refer to Procedure 5 4 from Step 6 onward To find out more about using Telnet see your System Administrator Procedure 5 5 Testing the Network From A Host Computer 1 Open Windows Explorer on the Windows desktop NOTE Different versions of the Windows operating system may have a diffe
8. Limit Set Select BO input When Set Defaults is clicked VS sets these three inputs to select which Red wire internal of the eight internal limit or parameter sets are used for a fastening Orange wire external cycle as follows Limit Set Select B1 input Limit Set B2 Input B1 Input BO Input Green wire internal inactive inactive inactive Blue wire external inactive inactive active inactive active inactive inactive active active active inactive inactive active inactive active active active inactive active active active Limit Set Select B2 input After a fastening cycle has started changing the state of these inputs Orange wire internal does not change which limit set the CS4000 Controller uses until the White Black wire external cycle on command from either the nutrunner or the cycle on input or both is de activated This means these inputs must be in the desired state BEFORE activation of the cycle start input CS4000 24 VDC This pin and pin T is connected to the positive 4 terminal of the Blue wire internal internal 24VDC I O power supply and is normally used as the common Red Black wire external connection for the input signals Discrete output 1 Pins J K L M N P and Uare the programmable discrete outputs White Black wire internal Green Black wire external Discrete output 2 Any one of these outputs will become active when its programmed White Red wire internal Red
9. e Visual Supervisor installed on the computer in permanent mode e RS 485 cable and connector In this configuration the computer permanently connected to the network runs Visual Supervisor which now takes on the role of supervising all of the controllers on the LAN for both data and parameter set information as well as being the connection point for the LAN To set up a 485 network refer to Chapter 6 Setting Up the 485 Network Page 1 4 T 38324 A 39 30 38324 Chapter 1 Overview Example of a Permanent Embedded 485 Network Using CS4000 KDM and Mini Controllers with SDLC based CS4000 Compact Controller CS4000 Mini Controller each contains in read only mode contains one or two Pentium Class Computer running one Tool Control Module TCM TCMs Windows NT version 4 0 or above with an u SDLC card and RS 485 port on each d OW controller i 5 N SDLC Card S 2 5 s 1 iF 8 LAN CS4000 mini 54000 mini a SYSTEM SYSTEM 54000 mini L CONTROLLER CONTROLLER SYSTEM n amp 3 amp 3 CONTROLLER CN gt es OUT um J _ a RS 485 TCM termination A maximum of 32 TCMs can be daisy chained or wired together point NOTE The computer is attached to the first controller the first cont
10. 9600 e Click 3964R Byte Timeout ms and enter the timeout in milliseconds for the barcode scanner attached to the RS 422 port 7 save your changes click OK The new settings are flashed to the Ethernet interface card NOTE To flash the new application settings to the Ethernet interface card make sure you click OK before Cancel If you do not click OK first the changes are not flashed to the Ethernet interface card 8 Toexit the Application Settings window click Cancel Setting Up Visual Supervisor for an Ethernet Network Install Visual Supervisor on the computer that will be permanently attached to the Ethernet network During installation of Visual Supervisor on the computer the installation program will give you the choice to install Visual Supervisor in permanent or portable mode You must select permanent mode To find out how to install Visual Supervisor in more detail refer to the Visual Supervisor User s Guide part number 39 30 34823 May 2002 T 38324 A Page 5 13 CS4000 Mini Controller with Ethernet Editing VSMain ini for an Ethernet Network When you are using the Ethernet link you must also change VSMain ini manually In the following example shown in Figure 5 16 VSMain ini is configured to talk to four Tool Control Modules TCMs at IP addresses 10 1 100 167 through 10 1 100 170 Communications Detachable 0 Ports 4 CommOcx1 Ethernet CommOcx2 Ethernet CommOcx3 Ethernet CommOcx4 Ether
11. Page 2 2 T 38324 A 39 30 38324 Chapter 2 Think Safety First MAINTAIN TOOLS IN TOP CONDITION Keep tools properly lubricated and clean If any wires become frayed or exposed replace them immediately Prevent dirt grease or contaminants from getting into the tool REDUCE THE RISK OF UNINTENTIONAL STARTING Be careful how the tool is left unattended Avoid resting it on its throttle lever to prevent false starts CONTROL THE DIRECTION OF ROTATION The reaction torque changes direction when going from forward to reverse Always be aware in which direction the tool will rotate prior to using it If the tool is not fixtured this will allow you to brace for the proper direction of torque reaction CHECK DAMAGED PARTS Before further use of a tool any part of the tool that is damaged should be carefully checked to ensure that it will operate properly and perform its intended function Check for alignment of moving parts breakage of parts mounting and any other conditions that may affect its operation Never operate a tool that has damaged or exposed wires Never operate a tool that has any part of the powertrain other than the output spindle exposed Electrical Safety Only qualified and properly trained personnel should perform electrical electronic troubleshooting and repair Consider the following electrical system safety guidelines Before you troubleshoot or service a fastening system station be sure you have an up to date an
12. Warranty of peripheral equipment such as printers recorders plotters etc included with a GSE tech motive tool or GSE torque product or SPX GSE tech motive tool fastening system shall be extended to the Buyer on the original manufacturer s terms Transportation charges for materials shipped to the manufacturing facility for warranty repair are to be paid by the shipper SPX GSE tech motive tool will return items repaired or replaced under warranty prepaid Information and technical diagrams in this document are subject to change without notice Products and services referred to in this book may be either trademarks and or registered trademarks of their respective owners SPX GSE tech motive tool manufactures products under the GSE and tech motive tooP brand names in Novi MI 2002 SPX CORPORATION ALL RIGHTS RESERVED Acknowledgments Special thanks are extended to the following SPX GSE tech motive tool management software and hardware engineers who provided value information in the development and review of this manual Jim Grenier Tom Jozwiak Ken Lehoczky Larry Piggins Rick Szwast Steve Urbanski Bill Welch Karen R Francis technical writer Linda J Ashley editor Preface The GSE tech motive tool 54000 Mini Controller with Ethernet typically is used with tech motive tool Intelligent nutrunners in a multi spindle fastening system that communicates with other operations in an assembly process over an Ethernet network
13. 2 2 44 2241 2 1 7 Think Salty m 2 1 General MashiTie S BEBE s ade adii D du cota A 2 2 sicul TT m 2 3 Identifying the Components 3 1 Erant PAL o oe oai e e an dan e a ten b f UP d PEN ER 3 2 BRE cot 3 2 Paramelel Oel OWO i su ED CUN 3 3 ACCESS bx Eat 3 3 Top and Bottom Panel 3 3 BC 3 3 Inteibue S LO Conhec Oi 3 3 25 sen 3 4 ITI 3 4 5 422 3 5 Ethernet cid S Eia Hd ERN RU CY SUE REN A X RA Y OA CEN NUR 3 5 Printer Barcode COHteeclel 3 5 SDLG 22
14. N TO CHAS GRD GN YL BK RD ETHERNET TYPICAL INPUT DO8B GRD 424 Figure 9 2 CS4000 Mini Controller with Ethernet Wiring of Standard Ethernet N Chapter 9 Technical Information JUMPER IN THE April 2002 T 38324 A Page 9 5 CS4000 Mini Controller with Ethernet This page is left blank intentionally Page 9 6 T 38324 A PRELIMINARY DRAFT 39 30 38324 Index 10Base T 1 2 5 16 485 network cable 6 7 A AC power 4 4 AC Power Cord 3 3 address switch 3 6 6 4 Address switches 3 12 Application Program Interface 1 2 8 4 B backplane 3 6 3 11 6 4 8 1 Address switches 3 12 DIP switches 3 12 fuse 3 12 8 2 I O board 3 13 battery 3 6 3 10 baud rate 3 12 C Clear Outputs 4 5 communications port 5 19 Cycle bad 4 6 Cycle Finish 4 6 Cycle good 4 6 D daisy chain 6 7 DOM 3 9 default gateway 5 1 Device Control Module 3 6 3 10 battery 3 6 3 10 digital I O 1 2 1 6 3 16 DIP switches 3 12 disconnect switch 2 3 Dual Power Supply 3 13 dual purpose input 4 5 E electrical drawings 2 4 electrical fires 2 4 electrical hazards 2 3 electrical wiring 2 4 enclosure components 3 7 interior 3 1 window
15. Replacement Parts If at any time you need to replace or order new parts for your CS4000 Mini Controller with Ethernet you can select from any item in Table 8 1 Table 8 1 Replacement Parts Quantity Description Part Number 1 27A Tool Control Module 49 4100 03C5 1 8A Tool Control Module TCM 49 4100 01CL5 1 24V DC Power Supply 12 20 5007 1 Ethernet Interface Card 420959 38093 1 Fuse 1ASB Littelfuse 39001 5x20 mm 13 10 61001 2 Fuse 5pico Littelfuse 255 500 13 10 4050 1 Limit Selector Switch Amp Part Number 436037 1 16 30 0940 1 Backplane 420890 35327 1 Connector Module Assembly 244000 38183 1 Interbus S Module Weiland Part Number 83 031 1300 1 41 30 0300 NOTE All part numbers used in Table 8 1 are GSE tech motive tool part numbers unless otherwise specified May 2002 T 38324 A Page 8 1 CS4000 Mini Controller with Ethernet Replacing Main Power Fuses Main Power F1 and F2 15A 250V SLO BLO Littelfuse 313015 or equivalent part number 13 10 1015 Refer to Figure 3 3 on page 3 4 to locate the main power fuses on the CS4000 Mini Controller bottom panel Replacing Backplane Fuses Backplane F2 and F3 0 5 250V subminiature PICO Littelfuse 255 500 or equivalent part number 13 10 4050 NOTE The backplane fuse F2 part number 13 10 4050 is not the same as the main power fuse F2 part number 13 10 1015 refer to Replacing Main Power Fus
16. 1 7 programmable discrete output 4 7 Programmable Logic Controller 1 2 3 3 R remote bus 3 17 remote input circuit schematic 4 8 remote relay output schematic 4 8 repairs 2 3 RJ 45 connector 1 1 modular jack 5 16 router software 5 1 RS 232 port 1 1 3 5 5 3 RS 232 cable 7 1 RS 422 port 1 7 3 5 RS 485 port 1 1 6 7 S safety electrical 2 2 2 3 safety glasses 2 3 SDLC I O Network Connector 3 5 servo amplifier 3 6 3 10 3 18 fuse 3 6 3 10 servo amplifier boards 3 9 servo amplifier fuse 3 9 Siemens 3964R barcode protocol 1 7 3 15 spindle 3 8 subnet mask 5 1 synchronization input output 4 7 synchronization output 4 7 Synchronous Data Link Control 1 1 1 4 T T 568B standard wiring system 5 16 TCM subcomponents 3 9 Telnet 5 23 tool cable 3 5 4 1 Tool Connector 3 4 Tool Control Module 3 8 8 1 fuse 3 6 Top and Bottom Panel 3 1 Transmission Control Protocol Internet Protocol TCP IP 1 1 1 2 3 1 3 5 V Visual Supervisor 1 1 3 15 7 1 network setup 5 1 permanent mode 5 13 portable mode 1 6 voltage 2 3 4 8 input 4 4 VSMain ini 5 14 6 2 Index 2 T 38324 A 39 30 38324 Part Number 39 30 38324 SPX ICD dterh mutive a SPX Corporation 42860 Nine Mile Road Novi MI 48375 4122 USA Phone 248 596 0600 Toll free 800 795 7875 Fax 248 596 0601 Website www gsetechmotive com 2002 SPX Corporation All rights reserved 4
17. 16 T 38324 A 39 30 38324 Chapter 3 Identifying the Components Table 3 2 describes the LEDs Table 3 2 Description of LEDs on the Side of the Interbus S Module LED Name Description 24V Power Supply Steady yellow light indicates the 24V power supply is connected to the Interbus S module Remote Bus Connected Steady green light indlicates the remote bus is connected Figure 3 2 shows the position of the six pin input terminal nine pin output terminal and LEDs on the top of the Interbus S module Each LED lights up steadily to indicate the current state of I O connections Data Refresh Remote Bus LED Disabled LED Figure 3 12 Interbus S Module Top View Table 3 3 describes the LEDs Table 3 3 Description of LEDs on the Top of the Interbus S Module LED Name Description Data Refresh BA Steady green light indicates data is being refreshed Remote Bus Disabled RD Steady red light indicates the remote bus is disabled May 2002 T 38324 A Page 3 17 CS4000 Mini Controller with Ethernet Ground Fault Circuit Interrupter The Ground Fault Circuit Interrupter is wired in series from the AC power input to the servo amplifier It monitors both
18. 7 oelscting tha Application 5 6 Figure 5 8 Error Message Displayed when the Attempted Connection Fails 5 7 Figure 5 9 Error Message Following An Unsuccessful Flash Attempt 5 7 Figure 5 10 Second Error Message Following An Unsuccessful Flash Attempt 5 7 Figure 5 11 Confirming the IP Address Subnet Mask and Default Gateway 5 8 Figure 5 12 Selecting the Set TINI Application Info Menu 5 10 Figure 5 13 Viewing the Application Settings Window General Info tab 5 11 Figure 5 14 Selecting the Application Settings Window Address tab 5 11 Figure 5 15 Selecting the Application Settings Window Comm Options tab 5 12 Figure 5 16 VSMain ini configured for an Ethernet 5 14 Figure 5 17 Select the Icon and Enter A Name for the Hyperterminal Connection 5 18 Figure 5 18 Select Communications POM ss ssi indere Dod exes tne 5 19 Figure 5 19 Setting the Communications Port Settings 5 20 Figure 5 20 Hyperterminal Window Showing Ethernet Interface Card TINI Lodin NERIS Deedes T TT yobs 5 21 Figure 5 21 Opening the Command Pr
19. 8 2 Etherflash exe 5 3 Ethernet 1 7 Ethernet cable 1 2 5 1 5 16 testing 5 24 twisted pair 5 16 Ethernet Connector 3 5 Ethernet Flash Utility 5 2 5 10 Ethernet interface card 1 1 3 6 3 13 3 14 5 1 8 1 initialization 3 15 sub components 3 14 Ethernet Interface Flash Utility 5 1 5 3 5 5 extinguishers 2 4 F fastening control system 1 1 Front Panel 3 1 fuse 2 3 3 6 8 1 pullers 2 3 substitutes 2 3 fuses 3 6 G gateway 5 1 ground fault circuit interrupt 1 1 Ground Fault Circuit Interrupter 3 5 3 6 3 18 H Hyperterminal 5 17 VO cable 4 1 Connector Module Assembly 8 1 Port 3 4 wiring scheme 4 9 4 10 I O board 3 13 input active 4 7 inactive 4 7 Intelligent Tools 1 1 Interbus S I O Port 3 3 Interbus S module 1 2 3 6 3 16 8 1 Internet Protocol version 4 5 2 IP address 5 1 5 22 5 24 May 2002 T 38324 A Index 1 CS4000 Mini Controller with Ethernet L LED 3 9 3 15 3 17 LED display 3 2 Limit Selector Switch 8 1 Local Area Network 1 1 1 4 3 1 3 5 5 1 6 7 M main power fuse 3 18 8 2 Manual Calibration 4 5 multi purpose switch 4 5 N network address 6 4 nutrunner 1 1 4 4 4 5 output current 4 8 P Parameter Set Switch 3 3 parameter sets 4 6 ping 5 17 pinout 4 11 5 16 Plant Floor Communication System 3 12 potentiometer 3 9 power supply 3 6 3 15 3 17 4 3 4 6 8 1 printer cable 4 1 Printer Barcode port
20. AC power leads to the servo amplifier ensuring that current flowing in one lead is the same as the current flowing out the other lead If due to a ground fault the GFCI detects a net difference in the AC power exceeding 30 milliamps 30mA or 300 Amps it shuts off the AC power to the servo amplifier automatically Switch in ON position Figure 3 13 Ground Fault Circuit Interrupter Fuses The main power fuses use a 15A 250V SLO BLO Littelfuse 326015 or equivalent part number 13 10 1015 Page 3 18 T 38324 A 39 30 38324 4 Installing the CS4000 Mini Controller with Ethernet This chapter shows you how to mount and wire the 54000 Mini Controller with Ethernet Mounting the CS4000 Mini Controller with Ethernet The CS4000 Mini Controller with Ethernet is installed vertically with the back flat against the mounting surface Allow sufficient space around the controller to attach the power cable tool cable I O cable and printer cable Also be sure to allow space to remove the cover from the enclosure CAUTION Mount the CS4000 Mini Controller with Ethernet away from moving machinery and lift trucks on a structure that does not vibrate Do not mount the CS4000 Mini Controller with Ethernet near large electrical systems motors welding equipment or in an area of temperature or moisture extremes Figure 4 1 shows the dimensions and mounting holes o
21. As soon as you start the program a message appears in the TINI Ethernet Interface Flash Utility window shown in Figure 5 1 This is the normal operation of the program and you can still proceed to the next step Ethernet Interface Flash Utility Flash Com Help Not Connected Choose Com Port gt Open Com Port to proceed Figure 5 1 Message Upon Starting the TINI Ethernet Interface Flash Utility May 2002 T 38324 A Page 5 3 CS4000 Mini Controller with Ethernet 9 Select the RS 232 serial communications port on your laptop that you will be using to send data to the attached Ethernet interface card This is the communications port to which the null modem cable is attached a Click the Com Port menu in the TINI Ethernet Flash Utility window See Figure 5 2 ZATINI Ethernet Interface Flash Utility Elash Com Port Help Open COM Port Gose Rat om Port gt Open Com Port to proceed Figure 5 2 Selecting the COM Port Menu b From the Com Port menu select Open COM Port c Inthe Select COM Port to Open window there is a drop down list of communication ports that you can open from COM1 to COMB Select COM1 for your laptop computer See Figure 5 3 Select COM Port to Open ES Figure 5 3 Selecting 1 RS 232 Port NOTE If for some reason COM is unavailable you may select different communications port If you do select a
22. Flash menu select Set TINI Application Info FS Ethernet Interface Flash Utility ected on COM1 sh function to proceed Application Settings were not Updated Figure 5 12 Selecting the Set TINI Application Info Menu Option Page 5 10 T 38324 A 39 30 38324 Chapter 5 Setting Up the Ethernet The Application Settings window shown in Figure 5 13 opens to display the General Info tab This window shows you details of the last successful flash of an application file to the Ethernet interface card You cannot change this information it is automatically updated by the TINI Ethernet Flash Utility whenever a successful flash occurs Application Settings Figure 5 13 Viewing the Application Settings Window General Info tab 3 Select the Ip Address tab a From the Application Settings window click on the Ip Address tab See Figure 5 14 Application Settings Figure 5 14 Selecting the Application Settings Window Ip Address tab May 2002 T 38324 A Page 5 11 CS4000 Mini Controller with Ethernet 4 To change the IP address subnet mask and or default gateway a Click on the IP Address Subnet Mask or Default Gateway field b Enter the new value C Repeat Steps a and b for all the fields you want to change 5 Select the Comm Options tab a From the Application Settings window click on the Comm Options tab See Figure 5 15 Application Settin
23. Module TCM that includes Servo amplifier Servo amplifier fuse inside e Device Control Module DCM e DCM battery e Backplane e Address switch e TCM fuse e DCM fuse e TCM I O power supply 24 VDC e Ethernet interface card e nterbus S digital I O module optional e Ground Fault Circuit Interrupter e Fuses See Figures Figure 3 4 and Figure 3 3 Page 3 6 T 38324 A 39 30 38324 Chapter 3 Identifying the Components owe d Eus Sk Emend Em Interbus S Module Optional Control Module i Exterior Wall Ethernet Interface NDLE FAULT Power Supply Backplane Figure 3 4 Components Inside the Enclosure of the 54000 Mini Controller with Ethernet NOTE The AC power cord is described in Top and Bottom Panel earlier in this chapter May 2002 T 38324 A Page 3 7 CS4000 Mini Controller with Ethernet Tool Control Module The Tool Control Module TCM shown in Figure 3 5 is a device that controls a single DC electric tool The TCM and its attached tool are referred to as a spindle The TCM houses both the servo amplifier and Device Control Module For the location of the inside the CS4000 Mini Controller with Ethernet see Figure 3 4 on page 3 7 Thumbscrews f Side Panel 3 3 f 2 X PEAK
24. NODWOI Lost n as rib Bite ad vut 8 3 RS 422 Siemen Ss 3964P IHIGITRGE ite cit th kn tati bea ed a 8 4 Application Program Interface 8 4 Technical Information curii uua ne ni iuna nc tina potiua diua 9 1 Cr err 9 1 Index 1 May 2002 T 38324 A Page ix CS4000 Mini Controller with Ethernet Figures Figure 1 1 Example of an Ethernet Network with a Connected Portable Laptop 1 3 Figure 1 2 Example 0rd 495 1 5 Figure 3 1 gieiidm in mie LR 3 2 Figure 3 2 Top Paral VIEW esca o ott go tto c A 3 3 Figure 3 3 Panel VIEW 3 4 Figure 3 4 Components Inside the Enclosure of the CS4000 Mini Controller WIT TUS INGE ES 3 7 Figure 3 5 Front pow Nem EE 3 8 Figure 3 6 Rear View of the and Location of the Servo Amplifier Fuse 3 9 Figure 3 7 DCM Board and DCM Battery Location eene 3 10 Figure 3 8 CS4000 Mini Controller with Ethernet 3 11 Figure 3 9 edic 3 13 Figure 3 10 Ethernet Interface Card suus ce malian Chu
25. Network Address Each controller attached to the 485 network requires its own address If you have a computer attached to four controllers you have a total of five devices attached to the 485 network and each one needs its own address Network addresses for a 485 network link are set using the address switch SW 1 found on the backplane of each Tool Control Module TCM inside the controller enclosure See Figure 3 8 on page 3 11 for the position of the address switch SW 1 The address switch consists of eight DIP switches Each DIP switch is set in binary as ON or OFF The ON binary values for switch positions 1 2 3 4 5 and 6 are 1 2 4 8 16 32 respectively Table 6 1 Switch Positions Representing Binary Numbers Switch Binary Number 1 2 4 8 16 32 Od Po NOTE Switches 7 and 8 are not used to set the address The address number you assign is equal to the total value of all the switch positions that you set to ON Table 6 2 shows you how to set the first 32 addresses on the network Table 6 2 Setting Address Switches To set the following Set these Address Keep these DIP address number switches ON switches OFF Address 1 1 2 3 4 5 6 7 8 Address 2 2 1 3 4 5 6 7 8 Address 3 m2 3 4 5 6 7 8 Address 4 3 1 2 4 5 6 7 8 Address 5 ES 2 4 5 6 7 8 Address 6 DAS 1 4 5 6 7 8 Page 6 4 T 38324 A 39 30 38324 Chapter 6 Setti
26. ON CYCLE ON ENABLE REVERSE DISCRETE INPUT 47 DISCRETE INPUT 8 IMIT SET SELECT BO SELECT B2 R SUPPLY DISCRETE OUTPUT 1 DISCRETE OUTPUT 2 DISCRETE OUTPUT 5 DISCRETE OUTPUT 4 DISCRETE OUTPUT 5 DISCRETE OUTPUT 6 SYNC IN OUT TO REMOTE 1 O CONNECTOR PIN 1 AND E SYNCHRONIZATION TO Example of CS4000 Controller Remote Wiring Sinking Outputs Page 4 10 T 38324 A 39 30 38324 Chapter 4 Installing the CS4000 Mini Controller with Ethernet Connector Pinout Definitions Pinout definitions are provided for the tool RS 422 network RS 232 printer barcode and Interbus S connectors Tool Connector 3 4 SHIELD Nos notlisied Noconnection Connector B WHT FORWARD REVERSEINPUT D YE A ISCRETEINPUT amp 8 ORN LIMITSETSELECTB2INPUT FINISHED BU VIO 2002 38324 4 11 CS4000 Mini Controller with Ethernet RS 422 Connector BNWT xb OUT B 4JVb5 X TXD OUT D SHIELD AE B AD WWHUBRNN X TIXD OUT D 3 WHTON Je BXDbOUD GRNWHT F 2 9 _ BLUWHT SHIELD COMMON Pin Designation Wire Color Ref ec XD Pin Designation Wire Color Ref
27. Prompt NOTE If the Hyperterminal window does not appear when you hit the ENTER key make sure the jumper J1 labeled Prog on the Ethernet interface card is removed You are now ready to log on to the Ethernet network via the Ethernet interface card 6 Login to the attached Ethernet interface card a Atthe TINI Login prompt enter root b Atthe Password prompt enter tini May 2002 T 38324 A Page 5 21 CS4000 Mini Controller with Ethernet 7T Enter ping followed by the IP address of the computer or controller on the Ethernet network that you want to test NOTE The IP adaress of the Ethernet interface card is the same as the IP address of the computer or controller to which it is attached For example if the IP address of another controller in the Ethernet network is 10 1 100 177 then you would enter ping 10 1 100 177 and would look like this TINI ping 10 1 100 177 If ping is successful you see a message in the Hyperterminal window similar to Got a reply from node 10 1 100 177 10 1 100 177 Sent 1 request s got 1 reply s TINI If ping is unsuccessful you see a message returned in the Hyperterminal window similar to Node 10 1 100 177 10 1 100 177 was unreachable Sent 1 request s got 0 reply s TINI 8 Repeat Step 7 for every IP address that you want to test 9 When you are finished testing the network logout of Hyperterminal a Atthe TINI prompt enter logout
28. See Figure 5 9 EtherFlash Ed X ru Figure 5 9 Error Message Following An Unsuccessful Flash Attempt When the connection to the Ethernet interface card fails the flash process also fails When you receive this message click OK and a new window is displayed See Figure 5 10 pm TINI Ethernet Interface Flash Utility Figure 5 10 Second Error Message Following An Unsuccessful Flash Attempt May 2002 T 38324 A Page 5 7 CS4000 Mini Controller with Ethernet There are three possible reasons that a flash fails e The null modem cable has been inserted into the 9 pin connector J7 on the Ethernet interface card incorrectly e The jumper J1 labeled Prog on the Ethernet interface card has been installed incorrectly e Anincorrect cable has been used to connect the laptop to the Ethernet interface card You must use the GSE tech motive tool null modem cable part number 41 41 0109FN After checking the above points repeat Steps 9 10 and 11 until the error messages fail to appear and the TINI Ethernet Flash Utility begins flashing the application file to the Ethernet interface card NOTE If you cannot successfully flash the Ethernet interface card from your laptop computer consult a GSE tech motive tool engineer 12 Confirm or change the IP address subnet mask and default gateway When the application file is flashed to the Ethernet interface card the Application Settings window is displayed T
29. TORQUE 2 AN f PEAK TORQUE LOW Q ANGLE H Front Panel ANGLE LOW Ww A V tech motive tuul OOL CONTROL MODULE N 49 4100 01C5 Figure 3 5 Front View of the TCM Page 3 8 T 38324 A 39 30 38324 Chapter 3 Identifying the Components The TCM has a small four digit display a column of nine indicator LEDs and two potentiometers The LEDs provide status and condition information about the connected nutrunner The indicator LEDs are labeled The potentiometers are labeled READY GOOD BAD PEAK TORQUE HI PEAK TORQUE LOW TACH GAIN ANGLE HI ANGLE LOW SPINDLE FAULT MOTOR ENABLE SPEED TRIM When the TCM is removed from the controller the two servo amplifier boards servo amplifier fuse DCM board and full backplane containing the address switch and TCM fuse can be seen Figure 3 6 is a rear view of the TCM It allows you to see where the two servo amplifier boards servo amplifier fuse and DCM are located Descriptions of the TCM sub components follow the figure Servo Amplifier Board Servo Amplifier Fuse 20A 250V Servo Amplifier Board Device Control Module DCM Figure 3 6 Rear View of the TCM and Location of the Servo Amplifier Fuse May 2002 Page 3 9 CS4000 Mini Controller with Ethernet Servo Amplifier The servo amplifier is a three phase brushless DC motor controller that prov
30. by a period Each group of decimal digits represents a much longer binary number For example 10 1 100 146 Many organizations divide their networks into sub networks The sub network is identified in a section of the IP address and the subnet mask specifies which part of the IP address contains the address of the sub network The subnet mask is read by the router software The subnet mask is specified in the same format as the IP address but here it is informing the router software that reads the IP address which part of the address holds the subnetwork identifier For example 255 255 255 0 In the above example 255 represents a binary number of 1 which tells the router software reading the address that this is the combined network and subnetwork section of the IP address The 40 represents a binary number that is also 0 and it tells the software reading the address not to look at the final part of the address that identifies a specific device When the information reaches the specified subnetwork then the final part of the IP address is read to identify the final destination in this case the individual controller or computer attached to the Ethernet network In the case of the Ethernet interface card installed inside the CS4000 Mini Controller with Ethernet the IP address subnet mask and default gateway are stored in the motherboard to which the Ethernet interface card is attached This allows you to transfer Ethernet i
31. data collection diagnostics and configuration functions but the individual controllers may also have changes made to them These changes are then communicated back to the computer via the Ethernet and the change recorded in Visual Supervisor Figure 1 1 Example of an Ethernet Network with a Connected Portable Laptop Chapter 1 Overview CS4000 mini CONTROLLER A laptop running Visual Supervisor is attached via an RS 232 compatible port and used to make setup changes for an individual controller on or off the network May 2002 T 38324 A PRELIMINARY DRAFT Page 1 3 CS4000 Mini Controller with Ethernet Using a 485 Network using SDLC In a 485 network the controller is linked to a LAN via cable between the first controller s RS 485 connector and the port for the Synchronous Data Link Control SDLC card installed on the host computer Each controller in the 485 network is connected to the next in a daisy chain fashion The computer is connected to the first controller the first controller is connected to the second controller and so on until the network terminates with the last controller See Figure 1 2 In this mode of operation you can have as many as 32 TCMs attached and running from a single supervising computer This type of network requires Pentium class computer 500 MHz or above e Microsoft Windows NT version 4 0 or above Atleast 128 MB RAM e Installed SDLC card
32. describes the steps you must take to create this connection e Setting up Visual Supervisor for a stand alone controller e Using RS 232 cables Setting Up Visual Supervisor Install Visual Supervisor on the laptop computer that will be attached to the CS4000 Mini Controller During installation of Visual Supervisor on the computer the installation program will give you the choice to install Visual Supervisor in permanent or portable mode You must select portable mode To find out details describing how to install Visual Supervisor refer to the Visual Supervisor User s Guide part number 39 30 34823 There is no requirement to edit VSMain ini Using RS 232 Cables May 2002 The type of cable used to connect the laptop computer to the controller is known as a null modem cable part number 41 41 0109FN To attach the laptop computer to the controller insert the RS 232 cable into the RS 232 port on the bottom panel of the controller and insert the other end into the RS 232 compatible port on the laptop T 38324 A Page 7 1 CS4000 Mini Controller with Ethernet This page is left blank intentionally Page 7 2 T 38324 A 39 30 38324 8 Maintenance Troubleshooting Maintenance of the 54000 Mini Controller with Ethernet consists of replacing fuses and cleaning the enclosure window The Troubleshooting section of this chapter gives possible solutions to problems and describes how to locate a malfunction in the Ethernet network
33. interface card You can change the Ethernet application program or the TCP IP information by using TINI Ethernet Interface Flash Utility on a laptop connected to the Ethernet interface card via J7 Refer to Chapter 4 Installing the CS4000 Mini Controller with Ethernet for further details You can also obtain diagnostics information on the state of the Ethernet network through the Ethernet interface card using Hyperterminal Refer to Chapter 8 Maintenance Troubleshooting for further details Table 3 1 describes the LEDs on the Ethernet interface card Each LED lights up steadily or flashes to indicate the current state of I O connections Table 3 1 Description of Ethernet Interface Card LEDs LED Name Description LED1 5V Steady red light indicates the power supply is connected to the Ethernet interface card LED2 A Flashing red light indicates communication between the controller and the host device of the Ethernet LAN using the Application Program Interface LED3 Flashing red light indicates Visual Supervisor communication between the controller and the host device of the Ethernet LAN LEDA C Flashing red light indicates local Visual Supervisor communication between the controller and any PC that is attached to it via an RS 232 connection LED5 D Flashing red light indicates communication Siemens 3964R between the controller and the scanner using the RS 422 communications port LED6
34. know the IP address or subnet mask setting use the TINI Ethernet Flash Utility to read them Refer to Procedure 5 2 on page 5 10 for details Working with the IP Address Subnet Mask and Default Gateways The Internet Protocol IP address identifies each individual device on a network It is read by router software which directs information across the network The computer that controls the flow of data in and out of a company s network is the gateway between the company network and any other networks attached to it Sometimes you may need to know the IP address of the gateway computer as well often referred to as the default gateway Without a correct IP address for each device on the network and a subnet mask if the network is divided into smaller sections called subnetworks the Ethernet network cannot function correctly In the case of a controller the IP address identifies the position of that specific controller on the local area network LAN and it is needed to successfully transfer data in and out of the controller across the network May 2002 T 38324 A Page 5 1 CS4000 Mini Controller with Ethernet The IP address consists of 32 bits Internet Protocol version 4 IPv4 and is most often depicted in a dot address This is the format in which you must enter IP addresses for the 54000 Mini Controller with Ethernet software It is called a dot address because the address is divided into four groups of decimal digits separated
35. speed and other information into the controller You simply plug in the tool power up the system program the desired tightening parameters and begin production A complete fastening system is made up of the 54000 Mini Controller with or without Ethernet tech motive tool nutrunner 46 66 or 116 Series and a standard tech motive tool cable The CS4000 Mini Controller with Ethernet houses one Tool Control Module with fuses and ground fault circuit interrupt protection The powerful tech motive tool Visual Supervisor software program is used for system setup graphing and diagnostics Visual Supervisor runs on a computer attached to the controller using e An Ethernet link using an Ethernet interface card and an Ethernet RJ 45 port A485 network link using a Synchronous Data Link Control SDLC card and RS 485 port e An 5 232 compatible serial port NOTE To find out more about using the Visual Supervisor software refer to the Visual Supervisor User s Guide part number 39 30 34823 Receiving Sending and Storing Data You can use the following methods to link one or more controllers to the Visual Supervisor program and or I O communications devices e An Ethernet link to a local area network LAN Here the controller has the standard Transmission Control Protocol Internet Protocol TCP IP an Ethernet interface card and an Ethernet RJ 45 port e 485 network link to a LAN Here the computer uses
36. use a printer The printer can be used to generate hard copies of torque or torque and angle readings system configuration information or statistical data upon command from the controller This port can also be used to receive barcode information SDLC I O Network Connector The 10 position female RS 485 connector enables a permanent network connection to and from the controller other controllers in the network and a permanently connected computer RS 232 Connector The nine position asynchronous RS 232 compatible serial output connector allows you to use a laptop computer The laptop computer can be running the Visual Supervisor software program the Ethernet Interface Flash Utility or other program that allows you to program also referred to as flash the latest Device Control Module and Tool Control Module firmware into the controller Ground Fault Circuit Interrupter The 250V Ground Fault Circuit Interrupter part number 13 20 2000 is a safety device approved by Underwriters Laboratories that is designed to protect you from potentially dangerous electrical shock May 2002 T 38324 A Page 3 5 CS4000 Mini Controller with Ethernet Fuses Fuse 1 and Fuse 2 are 15A 250V SLO BLO fuses Littelfuse 326015 or equivalent part number 13 10 1015 Enclosure Interior The enclosure interior for the CS4000 Mini Controller with Ethernet includes the following components and sub components e Control
37. voltage is not present e Install temporary wiring as safely as possible and replace it with permanent wiring as soon as possible Install grounding wherever it is needed in the final installation If modifications are made to the system wiring drawings must be revised to illustrate this change e Know how to deal with electrical fires properly Keep carbon dioxide and powder extinguishers handy Page 2 4 T 38324 A 39 30 38324 3 Identifying the Components The 54000 Mini Controller with Ethernet houses all the standard functions of the standard CS4000 Mini Controller but also has the ability to communicate across an Ethernet Local Area Network LAN using the standard Ethernet protocol Transmission Control Protocol Internet Protocol TCP IP This chapter is designed to familiarize you with the components of the 54000 Mini Controller with Ethernet It has three sections to help you locate all the major components easily Front Panel e Top and Bottom Panel Enclosure Interior Each section includes figures that call out the components Descriptions of the components follow the figures May 2002 T 38324 A Page 3 1 CS4000 Mini Controller with Ethernet Front Panel Figure 3 1 shows the front panel components of the CS4000 Mini Controller with Ethernet AC Power Cord LED Display Access Screws CS4000 mini SYSTEM CONTROLLER N o H Parameter
38. 02
39. 15 16 Turn OFF power to the controller WARNING Make sure the power is OFF before you remove the TCM High voltage when the power is ON can result in electrical shock or electrocution and also damage to the TCM Using a No 2 cross tip Phillips head screwdriver turn the access screws on the outside of the enclosure counterclockwise to loosen them Finish removing them by hand Open the enclosure door and locate the Tool Control Module Locate the TCM and the two thumbscrews that fasten the TCM to the backplane The screws are located on the upper right and lower left corners of the TCM Turn the two thumbscrews counterclockwise to loosen them and carefully remove them placing them somewhere safe until you need them again Pull the TCM from the top edge rocking it gently to loosen it from the backplane Remove the TCM and place it in a safe location such as on a work table Locate the address switch SW 1 for the network address See Figure 3 8 on page 3 11 for the position of the address switch SW 1 on the TCM backplane from which the TCM was removed Make sure the switch is set properly The address can be any consecutive number 1 through 32 Install the TCM using the positioning pins on the upper left corner and middle right of the backplane to position the TCM on the backplane Press the TCM gently but firmly back into place in the controller enclosure By hand install the access screws back in
40. 324 A Page v CS4000 Mini Controller with Ethernet This page is left blank intentionally Page vi T 38324 A 39 30 38324 Contents I I I NM iii Who Should Use This Manual M Dur iii How to Use ThS Natal eee iii ADDO VIGO S incision V OVENI N ss cess soe tgs o binos marie ME dd 1 1 Receiving Sending and Storing 1 1 Using EWITiemmal ood oie reni diva orsi e ee aont ee IR oes i d 1 2 Example of a Permanent Embedded Ethernet Network 1 3 Using 485 Network using 5 4 1 1 4 Example of a Permanent Embedded 485 1 5 Using 54000 and Mini Controllers with 1 5 Using the HS 232 Serial rans dni aes vri aia Ee ida 1 6 Using an Interbus S Digital Module 22 1 6 Using the Siemens 3964R Barcode 1 7 Deciding How to Set Up the Controller
41. 5 6A Select Switch 47 8 Cie P Figure 3 1 Front Panel View NOTE The AC power cord is described in the Top and Bottom Panel section later in this chapter LED Display The LED display shows you the torque or torque and angle value for the most recent rundown It also scrolls messages for the operator For example if a barcode scan is required before the next rundown the operator sees a barcode prompt on the LED display Page 3 2 T 38324 A 39 30 38324 Chapter 3 Identifying the Components Parameter Set Switch Turn the dial to select the parameter set you wish to use for the next rundown Select parameter sets using the parameter set switch or Visual Supervisor Access Screws The access screws keep the front panel of the controller fastened To un fasten them you need a No 2 cross tip Phillips head screwdriver Top and Bottom Panel Figure 3 2 shows the top panel components of the CS4000 Mini Controller with Ethernet AC Power Cord Interbus S I O Connector MW Optional Figure 3 2 Top Panel View AC Power Cord A power cord connection is available on the top of CS4000 Mini Controller with Ethernet The power cords it accepts are the 6 ft American style 20A 240V AC power cord part number 299250 32835 or the 2 5 m European style 10A 240V power cord part number 22 30 1021 Interbus S I O Connector A nine position serial Interbus S connector may be mounted optionally on
42. 8324 Chapter 5 Setting Up the Ethernet 3 Select the communications port you want to use for the Hyperterminal connection See Figure 5 18 This is the communications port to which the null modem cable is attached Usually COMI is the communications port selection but you may choose any communications port on the computer Connect Figure 5 18 Select Communications Port May 2002 T 38324 A Page 5 19 CS4000 Mini Controller with Ethernet 4 Specify the communications port settings See Figure 5 19 a Setthe Bits per second field to 115200 Set the Data bits field to 8 Set the Parity field to None Set the Stop bits field to 1 Set the Flow Control field to Hardware Click OK o om COM1 Properties Figure 5 19 Setting the Communications Port Settings When you click OK Hyperterminal attempts to make a connection with the attached Ethernet interface card Page 5 20 T 38324 A 39 30 38324 Chapter 5 Setting Up the Ethernet 5 Hit the ENTER key on the computer keyboard to view the login prompt TINI login See Figure 5 20 AAG Ethernet MINI HyperTerminal Iof x File Edit View Call Transfer Help Dis e soles cs Welcome to slush Version 1 02c TINI login Connected 0 02 19 Auto detect 1152008 amp N 1 SCROLL CAPS Capture Printecho Figure 5 20 Hyperterminal Window Showing Ethernet Interface Card TINI Login
43. Black wire external Discrete output 3 Output function becomes true When Set Defaults is clicked VS sets White Green wire internal these outputs to Blue Black wire external Discrete output 4 J Cycle Finish Cycle good L Cycle bad In Cycle White Violet wire internal Black White wire external Discrete output 5 White Blue wire internal Red White wire external Discrete output 6 White Gray wire internal Green White wire external Page 4 6 T 38324 A 39 30 38324 Table 3 1 Output common White Brown wire internal Blue white wire external CS4000 24 VDC Blue wire internal Black Red wire external Discrete output 7 Brown wire internal White Red wire external Synchronization common Violet wire internal Blue Red wire external Chapter 4 Installing the CS4000 Mini Controller with Ethernet 19 Position Remote Connector Pinout Signal Names and Descriptions Continued 1 2 Synchronization in out White Orange wire internal Orange Red wire external This bi directional signal is used for synchronizing two or more spindles in a multi spindle fastening application It is connected to both the synchronization output Discrete output 8 and the synchronization input Discrete input 6 If Sync is set to On the synchronization output becomes active when a fastening cycle is started When the nutrunner output torq
44. CS4000 Mini Controller with Ethernet CS4000 mini SYSTEM CONTROLLER Technical Reference Manual SPX GSE 55 24 Hour Technical Support Toll Free 1 877 224 7377 SPX GSE tech motive tool manufactures products under the GSE and tech motive tooP brand names Please Note Advanced Assembly Group has a new name We are now L 34tech mutive tamil This change of name is not yet reflected in the documentation for this product where you will still find the old logo and company name The new address is SPX GSE tech motive tool 42860 Nine Mile Road Novi MI 48375 4122 The toll free service number remains the same 1 877 224 7377 LIMITED WARRANTY Except for perishable items such as the fuses and batteries SPX GSE tech motive tool warrants its GSE tech motive tool brand fastening products GSE brand sensors and instruments and fastening systems to be free from defects in materials and workmanship for one year from the date of shipment from the manufacturing facility The obligation of SPX GSE tech motive tool is limited to repairing or at their option replacing the products and components which upon verification at the manufacturing facility in Novi Michigan USA prove to be defective SPX GSE tech motive tool shall not be liable for installation charges for expenses of the Buyer for repairs or replacement for damages from delay or loss of use or other indirect or consequential damages of any kind SPX GS
45. Conventions The following conventions are used throughout this manual for the safety of personnel equipment software and data The conventions include warnings cautions and notes as follows WARNING Information inside the WARNING box concerns the protection of either personnel or an action that could result in a systems failure The information is indented and in italicized boldface type CAUTION Information next to CAUTION concerns the protection of equipment software and data The information is indented and in italicized boldface type NOTE Information next to the NOTE caption is designed to bring your attention to a certain characteristic of software or hardware operation The information is indented and italicized Page iv T 38324 A 39 30 38324 Abbreviations Some of the most common abbreviations used throughout this manual include the following API GFCI T O IEEE IP kbps kVA LAN LED mbps PCI TCM TCP IP RAM SDLC TINI V Application Program Interface Ground Fault Circuit Interrupter Input Output Institute of Electrical and Electronic Engineers Internet Protocol kilo bits per second kilovolt ampere Local Area Network Light Emitting Diode million bits per second Peripheral Component Interconnect Tool Control Module Transmission Control Protocol Internet Protocol Random Access Memory Synchronous Data Link Control TINI Internet Interface Volts Preface May 2002 T 38
46. E Flashing yellow light indicates communication between the Ethernet interface card and the TCM LED7 Steady green light indicates successful power up initialization of the Ethernet interface card software May 2002 T 38324 A Page 3 15 CS4000 Mini Controller with Ethernet Interbus S Module The Interbus S digital I O module part number 41 30 0300 is optional and is supplied only when it is specified at the time of order When it is included in the controller enclosure it provides another interface usually to an external remote PLC The module is housed inside the CS4000 Mini Controller with Ethernet enclosure See Figure 3 4 on page 3 7 Figure 3 11 shows the position of LEDs on the side of the Interbus S module Each LED lights up steadily to indicate the current state of I O connections 24V Power Remote Bus Supply LE 2 Connected LED Jd Wad p PU AD CSI ADS 7 AVACVARACACAUAR AR Nom CN Nec Nou E wile NC CAN AN AR ACACAG FONDS Nad Figure 3 11 Interbus S Module Side View Page 3
47. E INPUT 8 FINISH LED NN A ACCEPT LED NN ne EJECT LED Ni Es SYNC IN OU OUTPUT amp DI COMMON O POWER SUPPLY SYNC 1 0 PIN OTHER SPINDLES S 2M gt gt 25 gt gt DISCRETE OUTPUT 7 TO SYNC COMMON PIN V COM 3U SYNC COMMON SAME AS S V OF OTHER SPINDLES S INPUT COMMON OUTPUTS SIDE A TIED TO 24 VDC OUTPUT PINS SUPP Figure 4 4 Example of CS4000 Controller Remote I O Wiring Sourcing Outputs May 2002 T 38324 A Page 4 9 CS4000 Mini Controller with Ethernet synchronization NNECTOR FROM OUTPUT LATCH OPTIONAL S Figure 4 5 is an example of the remote I O wiring scheme that shows how to change the jumpers for voltage sink It shows one of the many ways the remote I O feature controller can be used To ensure that you operate the fastening system properly refer to the guidelines in Table 4 2 for output requirements The locations of jumpers JP1 to JP9 are important see Figure 3 8 on page 3 11 for the their locations on the backplane The jumpers allow you to select between 24V DC applied to an output or ground applied to an output To change to voltage sink configuration cut trace from pin 1 to 2 and solder in place a jumper between pins 2 and 3 to take the I O pin to ground NOTE JP9 ties discrete output 8 to discrete input 6 for spindle CYCLE
48. E tech motive tool extends this warranty only upon proper use of the product in the application for which it is intended The warranty does not cover products that have been modified without the approval of SPX GSE tech motive tool or which have been subjected to unusual physical or electrical stress or from or upon which the original identification marks have been removed or altered Whenever the design of the system in which it is to be incorporated originates with the Buyer the warranty is limited specifically to furnishing the controllers and nutrunners free of defects in materials and workmanship and assumes no responsibility for implied warranties of fitness for purpose or use In the event that a product is repaired or replaced under the terms of the warranty the warranty period of the repaired or replacement product shall be limited by the agreed upon level of warranty purchased by the customer Industrial installations are warranted by SPX GSE tech motive tool for repairs at the installation site only if the customer contracts with SPX GSE tech motive tool to perform checkout and final adjustment at the installation site and for the training of customer personnel in the operation and maintenance under the system Under such conditions SPX GSE tech motive tool agrees to perform field service for 90 days from date of checkout without charge for labor or materials The customer shall pay for travel expenses of SPX GSE tech motive tool personnel
49. Information OOL CONNECTION EI ADDITIONA ON SHEE CONNECTOR MODULI _ 299290 56102 VV VV VV VV 24V DCM RE RS422 TX RS422 TX B RS RX C 422 RS422 RX D YYYYYYYY TO DCM AC MATING CONNECTOR PTO6A 12 INPUT VVVVVVYYVY VV VY V YY VY D 6 amp DO 88 OUTPUT COMMON 24 DO 7B OUTPUT COMMON TARR VN 24V OUTPUT COMMON RINTER BARCODE AAAA TXD OUT XD OUT RXD IN RXD IN CLK OUT OUT 2MMON YYYYYY N 3 NV ISOLATED 1 0 GRD XD OUT XD OUT RXD IN RXD IN F1 OPTION 1A USE 313001 FUSE 2390 SE 255 500 CHAS GRD Figure 9 1 CS4000 Mini Controller with Ethernet Wiring of Standard Ethernet and Interbus S Module May 2002 T 38324 A PRELIMINARY DRAFT Page 9 3 CS4000 Mini Controller with Ethernet This page is left blank intentionally Page 9 4 T 38324 A PRELIMINARY DRAFT 39 30 38324 CONNECTOR MODULE MBLY 38183 TYPICAL OUTPUT 14 COM2 56551
50. R OPERATE SOLENOID VALVES LIMIT SWITCHES OR RELAYS MANUALLY as this practice can create dangerous unexpected machine movements SECURE THE TOOL Tools that develop torque can produce hazardous torque reactions Always be sure that the tool is properly fixtured to absorb reaction as a fastener is tightened Never operate a tool capable of high torque without proper fixturing SECURE WORK Avoid situations where the part being fastened breaks loose and can cause damage NEVER TOUCH OR ATTEMPT TO STOP MOVING MACHINERY OR PARTS WITH YOUR HANDS OTHER PARTS OF YOUR BODY OR MAKESHIFT DEVICES DO NOT OPERATE THE TOOL WHILE UNDER THE INFLUENCE OF ALCOHOL DRUGS OR MEDICATION THAT CAN IMPAIR YOUR JUDGMENT REPORT ALL UNSAFE WORKING CONDITIONS OR PRACTICES TO YOUR SUPERVISOR AND OR SAFETY DEPARTMENT FOR CORRECTION WEAR APPROVED SAFETY GLASSES AT ALL TIMES DO NOT WEAR JEWELRY especially bracelets and rings while operating the fastening tools Keep hands and fingers away from all rotating parts and avoid situations where clothing can become tangled in the tool Secure loose fitting clothing neckties and long hair Wear medical alert identification cautiously DO NOT OVERREACH Keep proper footing and balance at all times KEEP YOUR WORK AREA CLEAN Do not work on or near slippery floors or surfaces Avoid situations where the tool reacts against unexpected obstacles Do not operate electrical equipment while standing on a wet floor
51. Ue tai ER Lina 3 14 Figure 3 11 Interbus S Module Side View rar tna nnno kun en nera ho ni cao 3 16 Figure 3 12 interbus S Module TOD 3 17 Figura 3 13 Ground Fault Circuit IHterrapter 3 18 Figure 4 1 CS4000 Mini Controller with Ethernet 4 2 Figure 4 2 Power Gonngetion Hegilireitienis Av UMS Fen ong 4 3 Figure 4 3 Remote Inp t d uae 4 8 Figure 4 4 Example of CS4000 Controller Remote I O Wiring Sourcing Outputs 4 9 Figure 4 5 Example of CS4000 Controller Remote I O Wiring Sinking Outputs 4 10 Figure 5 1 Message Upon Starting the TINI Ethernet Interface Flash Utility 5 3 Figure 5 2 Selecting the COM Port iae nat 5 4 Figure 5 3 Selecting COMT HS 232 snnt Loue hee cor pa cn Rape bi 5 4 Figure 5 4 Establishing A Successful Connection via 8 0 Figure 5 5 Error Message Displayed when COM is Already In Use 5 5 Figure 5 6 Selecting the Flash CODBOF qaaa ien rola sad mari a tuti pata a 5 6 Figure 5
52. When used in this context the controller contains an Ethernet interface card and the RJ 45 connector that is used to link it to a host computer that contains an Ethernet network card The Ethernet interface card in each device enables communication via the network hub The 54000 Mini Controller with Ethernet can optionally communicate over a 485 network For this application it has an RS 485 connector and is linked to a host computer that contains a Synchronous Data Link Control SDLC card In either scenario the host computer is loaded with the tech motive tool Visual Supervisor VS setup graphing and diagnostics program Version 3 20 is used to program the parameters of each tech motive spindle controller and nutrunner in the network remains on the host computer and is thus said to operate in permanent mode When operating a nutrunner off network in a single spindle stand alone system the controller is programmed using VS from a laptop PC which is linked via cable to the RS 232 serial port on the controller Because the laptop can be disconnected from one CS4000 Mini Controller and reconnected to another VS is said to operate in portable mode An optional Interbus S module can be added to the CS4000 Mini Controller with Ethernet typically to connect the controller to a Programmable Logic Controller PLC The module adds eight soft programmable digital inputs and eight soft programmable digital outputs to the system Who Sho
53. ace card lets you connect individual controllers to a host device forming a LAN using TCP IP The card comes with its own software and fits into the interior of the CS4000 Mini Controller with Ethernet forming a connection with the Ethernet connector on the bottom panel of the controller To attach to the Ethernet network you need an Ethernet connector on the computer that will be the host and an Ethernet cable with RJ 45 modular jacks attached to both ends One of these RJ 45 modular jacks plugs into the Ethernet connector on the PC and the other plugs into the Ethernet connector on the controller Figure 3 10 shows the Ethernet interface card and its sub components 9 position LED 2 to LED 7 serial port J7 A 3 c E 2 Cm Cm Cm Cm B CB Pe n A 9 es E at iD te A zy st R C COM1 J21 4 2 J22 MEC ua WE 530 S mum L E coo NN gt 7 Ethernet connector J12 Figure 3 10 Ethernet Interface Card Page 3 14 T 38324 A 39 30 38324 Chapter 3 Identifying the Components The nine position RS 232 serial port J7 is used for setup and diagnostics of the Ethernet
54. am being run by the host computer grays out every field for that particular controller When the laptop PC is no longer connected to the controller the host computer can once again make changes NOTE To attach and use a laptop to view edit or collect data from a controller on a network you must have Visual Supervisor version 3 20 or higher installed on the host and laptop computers and DCM 4 06 or higher installed on the controllers Using an Interbus S Digital I O Module The optional Interbus S module can be added to the controller to provide eight soft programmable digital inputs and eight soft programmable digital outputs You can assign the function of these inputs and outputs using the Visual Supervisor program Refer to the Visual Supervisor User s Guide part number 39 40 34823 for details You can use the Interbus S module to connect the controller to a Programmable Logic Controller PLC When the PLC reads a barcode successfully for example it sends a signal as an Interbus S module input into the controller that tells the controller to allow the operator to perform a rundown The controller then sends a signal to the PLC as an Interbus S module output that indicates when a good rundown or a bad rundown has been performed Page 1 6 T 38324 A 39 30 38324 Chapter 1 Overview Using the Siemens 3964R Barcode Protocol The RS 422 port on the controller supports the Siemens 3964R barcode protocol This protocol provides an er
55. an SDLC card inserted into a free Peripheral Component Interconnect PCI slot and an RS 485 port on the controller CAUTION The 485 network and Ethernet link perform the same function If you set up the controller to use the 485 network you will not need the Ethernet link nor vice versa e An RS222 serial link to a laptop computer using the RS 232 serial port May 2002 T 38324 A Page 1 1 CS4000 Mini Controller with Ethernet e digital I O communications link using the optional Interbus S digital I O module in the controller The Interbus S module does not connect the controller to a network but does allow I O communications between the controller and a Programmable Logic Controller PLC or other similar device To help you decide which method you require read the rest of this chapter If you choose the Ethernet or 485 network method the Visual Supervisor software installed on the computer attached to the network allows you to make changes to controllers across the network and monitor them This supervisory computer is commonly referred to throughout this manual as the host Itis also possible to connect a laptop via a cable and the RS 232 compatible serial port to any controller on the network and make individual changes to that controller Refer to Using the RS 232 Serial Port later in this chapter for details NOTE To program controllers across the network and successfully use an attached laptop to view edit or c
56. d Atleast 64 MB RAM for Windows 95 98 or 2000 or 128 MB RAM for Windows NT e Installed Ethernet Interface Card in the controller and the computer e Visual Supervisor installed in permanent mode e Shielded 10Base T cable and Ethernet connector In this configuration the host computer running Visual Supervisor provides data collection diagnostics and configuration functions for all the controllers but the hub is the connection point for the LAN See Figure 1 1 for details To set up an Ethernet network refer to Chapter 5 Setting Up the Ethernet Page 1 2 T 38324 A 39 30 38324 Example of a Permanent Embedded Ethernet Network Using Mini Controllers with Ethernet Pentium Class Computer running Windows 95 98 2000 CS4000 Mini Controllers with Ethernet or Windows NT version 4 0 or above It also has an i installed Ethernet interface card Each controller hasan ES Visual Supervisor is running on the computer plus an optional Application Program Interface API for data collection Ethernet connector Al Y Ethernet Card amp Qi S Ol CS4000 mini CS4000 mini CS4000 mini CONTROLLER CONTROLLER lif CONTROLLER e o 605066 NOTE Each controller is attached to the hub which is in turn attached to the host computer Visual Supervisor provides
57. d appropriate set of electrical drawings for that station Remove metal items such as rings metal necklaces wristwatches and jewelry as these can create electrical hazards Wear medical alert identification cautiously Wear safety glasses but avoid wearing those that have metal rims or metal side shields It may be necessary to troubleshoot equipment while the power is ON ONLY qualified trained personnel should do this During these instances open only the panels doors or covers which need to be opened Know the voltage present at all points before you begin troubleshooting Use properly insulated tools when working on electrical equipment to reduce the possibility of shock Make sure the insulation is adequate to safeguard against the high voltages present If you must work on the electrical system be sure the main disconnect switch on the power panel is in the OFF position and locked out with locks from each trade involved in the repair Do not attempt to modify or repair the machine without the approval of the proper authorities Use approved fuse pullers when changing fuses Never use jumper wires or fuse substitutes to replace specified fuses May 2002 T 38324 A Page 2 3 CS4000 Mini Controller with Ethernet e Always use fuses of a capacity smaller than or equal to the safe capacity of the line or the equipment it serves e Before you work on any circuit check it with an appropriate testing device to be sure
58. different port make sure that the null modem cable is inserted into this port in Step 3 If you select a different communications port instead of 1 then you will see that port substituted wherever you see COM1 written in this procedure d Click OK Page 5 4 T 38324 A 39 30 38324 Chapter 5 Setting Up the Ethernet The TINI Ethernet Interface Flash Utility attempts to connect to the communications port you specified in Step 9 When the attempt is successful the message shown in Figure 5 4 is displayed pm TINI Ethernet Interface Flash Utility Figure 5 4 Establishing A Successful Connection via COM1 When another utility or program is using the port the attempt to establish connection fails and the message shown in Figure 5 5 is displayed EtherFlash X lt Figure 5 5 Error Message Displayed when COM1 is Already In Use When you receive this error message click OK terminate any other utilities or programs that may be using the 1 port and start this procedure again from Step 9 May 2002 T 38324 A Page 5 5 CS4000 Mini Controller with Ethernet 10 Flash the application file to the Ethernet interface card a Click the Flash menu in the TINI Ethernet Interface Utility window b From the Flash menu click Flash TINI pm TINI Ethernet Interface Flash Utility Flash Flash TINI Figure 5 6 Selecting the Flash TINI Option 11 From the list of files
59. displayed to you in the Open window open the application file you want to use to flash the Ethernet interface card The application file is a binary file that adheres to the following naming convention GseTiniTcmV9 99X tbin where 9 99X represents the version number of the application For example GseTiniTcmV1 03C tbin is the binary file for version 1 03C of the application a Click on the application file displayed in the Open window See Figure 5 7 b Click Open 21 amne Aaaa GseTiniT emV1 03A tbin GseTiniTemV1 03B tbin GseTiniTemV1 03C tbin L Figure 5 7 Selecting the Application File Page 5 6 T 38324 A 39 30 38324 Chapter 5 Setting Up the Ethernet The TINI Ethernet Flash Utility connects to the Ethernet interface card via the COM port you specified in Step 9 When the communications connection is successful the yellow LED LED6 on the Ethernet interface card stops blinking and the flash utility begins flashing the application file to the Ethernet interface card Refer to Table 3 1 on page 3 15 for a complete description of the LEDs on the Ethernet interface card If an error occurs and the connection to the Ethernet interface card cannot be established the message shown in Figure 5 8 is displayed ETHERFLASH X Figure 5 8 Error Message Displayed when the Attempted Connection Fails When you receive this error message click OK and a new window is displayed
60. e card NOTE To use the ping command TCF IP must be installed on the Windows operating system of your computer If the ping command is unavailable see your System Administrator If parts of the network become unable to communicate you can ping a controller and or computer on the network from a different controller or computer also on the network to determine if there are any physical malfunctions such as a bad cable connection A successful ping indicates that the physical network is functioning correctly and it is therefore likely that a software malfunction is causing the communication problem An unsuccessful ping indicates that the physical network is not functioning correctly In this case you should check the network connections and test the Ethernet cables to find the source of the problem Refer to the Testing Ethernet Network Cables section later in this chapter You can test the network using the ping command from the computer permanently attached to it or you can use a laptop computer temporarily attached to an Ethernet interface card inside a controller on the network If you are using a laptop computer you must make sure that it is attached to the Ethernet interface card correctly To do this follow Steps 1 to 5 of Procedure 5 1 on page 5 2 To use the ping command from a laptop computer attached to the Ethernet network you can set up a Hyperterminal connection Use Procedure 5 4 to set up Hyperterminal so you can ping the net
61. econd controller added to VSMain ini Comm2Devices Devices 1 Devicel DCM DevicelIPAddress IP address of the controller 5 When you finished editing VSMain ini save your changes and exit Notepad a Click the File menu in Notepad b From the File menu select Save c From the File menu select Exit VSMain ini is now ready to support an Ethernet network The new settings take effect the next time you start Visual Supervisor Using Ethernet Network Cables The type of Ethernet cable you need to connect the CS4000 Mini Controller with Ethernet to the Local Area Network LAN is known as 10Base T The name is an Institute of Electrical and Electronics Engineers IEEE standard identifier for this type of cable The 10 refers to the transmission speed of 10 million bits per second Mbps The Base refers to baseband signaling which means only Ethernet signals are carried on this cable and the T represents twisted pair When you look at an Ethernet cable you see four pairs of wires each pair twisted together into a double helix formation This is how the cable receives its designation as a twisted pair The twisted pair cabling combats interference and helps keep the integrity of signals sent down the cable The double helix configuration produced by twisting the wires together creates symmetrical noise signals in each wire that cancel each other out thus reducing the noise level and interference of the signal t
62. enter a single port for an SDLC channel Typically a 485 network only has a single SDLC channel to which all the controllers are connected Your changes to this section of VSMain ini should end up looking similar to this Communications Detachable 0 Ports 1 CommOcx1 SDLC In the above sample the network consists of a single SDLC channel to which all the computer and controllers are connected Locate the heading in VSMain ini labeled Comm1Devices Create an entry for a device that is a controller and identify the controller as a Device Control Module DCM Each device is labeled as Device1 Device2 and so on Device is the first controller on the network Device2 is the second controller on the network until the list finishes with the last controller on the network Your changes to this section of VSMain ini should end up looking similar to this CommlDevices Devices 4 Devicel DCM Device2 DCM Device3 DCM Device4 DCM In the above sample there are four devices connected to the network and each one is a DCM May 2002 T 38324 A Page 6 3 CS4000 Mini Controller with Ethernet 4 When you are finished editing VSMain ini save your changes and exit Notepad a Click the File menu in Notepad b From the File menu select Save c From the File menu select Exit VSMain ini is now ready to support a 485 network The new settings take effect the next time you start Visual Supervisor Assigning A
63. erator or service technician you should become familiar with the contents of this manual before operating servicing or maintaining any part of the CS4000 Mini Controller with Ethernet including the 66 Series fastening tools Familiarization with all components of the system can minimize the possibility that an accident or injury might occur GSE tech motive tool assumes no responsibility for personal injury or damage to equipment resulting from misuse of these tools After reviewing this manual you should also review all safety procedures provided by your company and the equipment installer WARNING Failure to follow these steps may result in serious personal injury May 2002 T 38324 A Page 2 1 CS4000 Mini Controller with Ethernet General Machine Safety FOR YOUR OWN SAFETY READ THE INSTRUCTION MANUAL THOROUGHLY PRIOR TO OPERATING THE TOOL DO NOT WORK IN A DANGEROUS ENVIRONMENT Do not use power tools in a damp or wet location or expose them to rain oils or corrosive fluids KNOW THE LOCATION OF POWER DISCONNECTS AND EMERGENCY STOP BUTTONS PRIOR TO OPERATING THIS EQUIPMENT KEEP ALL ELECTRICAL PANELS CLOSED DURING OPERATION High voltage present inside enclosure panels can result in personal injury Do NOT bypass or defeat electrical safety devices Turn the power actuator to the OFF position prior to any servicing or maintenance of the controller OBSERVE ALL GOVERNMENT AND OR COMPANY POWER LOCKOUT STANDARDS NEVE
64. erbus S I O module or a link via the RS 422 port The following chapter describes the basic components of the controller so you can familiarize yourself with them before you install it Chapter 4 Installing the 84000 Mini Controller with Ethernet describes how to mount the controller and how to make sure you fulfill its power requirements Chapter 5 Setting Up the Ethernet Chapter 6 Setting Up the 485 Network and Chapter 7 Setting Up the RS 232 Link describe how to install the various components that have been discussed in this chapter May 2002 T 38324 A Page 1 7 CS4000 Mini Controller with Ethernet This page is left blank intentionally Page 1 8 T 38324 A 39 30 38324 2 Think Safety First Working with fastening tools can be dangerous if safe and proper procedures are not followed As with all machinery certain hazards can be involved with the operation of the product Using these tools with respect and caution will considerably lessen the possibility of personal injury however if normal safety precautions are overlooked or ignored personal injury to the operator may result Always use common sense and exercise caution when using these tools They can produce high torque that unless properly compensated for could cause personal injury Remember your personal safety is your responsibility Only GSE tech motive tool qualified service technicians should perform the procedures covered in this manual If you are an op
65. es above Make sure you quote the correct part number when ordering replacements F4 5x20 mm 1A SLO BLO SB 250V Littelfuse 239001 or equivalent part number 13 10 61001 Refer to Figure 3 8 on page 3 11 to locate the backplane fuses Cleaning the Enclosure Window Use only water based cleaners to clean the plastic window Other solvents may damage the window Page 8 2 T 38324 A 39 30 38324 Chapter 8 Maintenance Troubleshooting Troubleshooting This section describes some of the problems you may encounter with the Ethernet network RS 422 Siemens 3964R interface and the Application Program Interface API and gives brief descriptions of how you might attempt to solve each problem Ethernet Network When the Ethernet network needs troubleshooting you can e Refer to Testing the Ethernet Network in Chapter 5 Setting Up the Ethernet to find out how to use the ping command through Hyperterminal or Telnet applications Refer to Table 3 1 on page 3 15 for a list of LEDs that exist on the Ethernet interface card within the CS4000 Mini Controller e Use the TINI Ethernet Flash Utility to modify the Ethernet interface card application settings and disable unnecessary functions the latter may help if the troubleshooting problem is related to thru put performance To find out how to update the application settings refer to Updating Application Settings in Chapter 5 Setting Up the Ethernet Table 8 2 describes some common p
66. gs x General Info Ip Address Comm Options v Enable V5 Communications over Ethernet Enable 3864R Communications 39 4 Baud Rate 57600 3964A Byte Timeout 201 Figure 5 15 Selecting the Application Settings Window Comm Options tab NOTE When an option is enabled there is a check mark in the box next to it When an option is disabled the box is empty Click on the box to toggle the option between enabled and disabled 6 To change the communication options a Click on Enable API Communications over Ethernet to enable or disable the Application Program Interface When you disable this option programs cannot request data from the API over the Ethernet Click on Enable V8 Communications over Ethernet to enable or disable Visual Supervisor communications over the Ethernet When you disable this option all Ethernet communications to and from Visual Supervisor are terminated Click on Enable 3964R Communications to enable or disable the Siemens 3964R communications protocol used to transfer data to and from the barcode scanner attached to the RS 422 port Page 5 12 T 38324 A 39 30 38324 Chapter 5 Setting Up the Ethernet d Click on the drop down menu next to 3964R Baud Rate to change the baud rate used for communications to and from the barcode scanner attached to the RS 422 port You can select from the following baud rates 1200 19200 e 2400 e 38400 4800 e 57600
67. his window allows you to confirm or change the IP address subnet mask and default gateway being used See Figure 5 11 Application Settings Ea General Info p Address Comm Options IP Address 1 100 42 Subnet Mask 255 255 25 0 Default Gateway Figure 5 11 Confirming the IP Address Subnet Mask and Default Gateway To confirm the current settings for the IP address subnet mask and the default gateway click OK OR Page 5 8 T 38324 A 39 30 38324 Chapter 5 Setting Up the Ethernet To change the IP address subnet mask and or the default gateway being used a Click on the IP Address Subnet Mask or Default Gateway field b Enter the new value c Repeat Steps a and b for all the fields you want to change d Click OK 13 When the flash utility has finished flashing the application settings to the Ethernet interface card you can exit NOTE If you have another Ethernet interface card to flash disconnect the cables from the current Ethernet interface card and connect them to the next Ethernet interface card you want to flash There is no need to exit the TINI Ethernet Flash Utility first The COM port that you opened in Step 9 closes automatically when you exit the flash utility a Click the Flash menu in the TINI Ethernet Flash Utility window b From the Flash menu select Exit The flash utility closes down and exits you from the program OR The flash utility shu
68. ides electrical power to the nutrunner motor It receives control signals from the Device Control Module DCM Based on the state of these inputs the servo amplifier energizes the motor windings to rotate the motor The servo amplifier serves as a closed loop speed controller It modulates the motor winding currents in order to maintain a constant motor speed despite changes in load Additionally the servo amplifier can stop the motor quickly by way of dynamic braking The servo amplifier boards are paired with the DCM board and are housed inside the TCM A 20A 250V servo amplifier fuse part number 13 10 0700 is located on the first servo amplifier board Device Control Module The Device Control Module DCM is an electronic circuit board that contains powerful 80186EA processor It is paired with the servo amplifier inside the TCM The DCM is the brain of the CS4000 Controller with Ethernet It receives signals from the nutrunner control switches the set point inputs the nutrunner torque sensor and remote control inputs and generates the appropriate outputs to the servo amplifier control inputs the status output relays and the nutrunner status LEDs The DCM has plug in electrical connections It is easy to remove and replace A 3V lithium battery is located on the DCM board You must remove the DCM board from the TCM in order to replace this battery A generic 3V lithium battery Duracell DL 2450 Sanyo CR 2450 or similar can be used
69. ini Controller with Ethernet enclosure properly to an earth ground The CS4000 Mini Controller with Ethernet has a ground prong on the power cord if supplied but the AC outlet that will be used must be grounded properly as well Also make sure that all other machinery such as conveyors which will transport or hold parts that will come in physical contact with the nutrunner are properly grounded Page 4 4 T 38324 A 39 30 38324 Chapter 4 Installing the CS4000 Mini Controller with Ethernet Wiring The CS4000 Mini Controller with Ethernet is equipped with a 19 pin I O connector for field I O The settings described in Table 4 1 are Visual Supervisor VS default settings NOTE The 14 shell 19 pin strain relief mating connector for the connector is part number 23 10 5200 Table 4 1 19 Position Remote Connector Pinout Signal Names and Descriptions Cycle On Cycle On Enable This is a dual purpose input ERE When Set Defaults is clicked VS sets this input to Start this input functions as a cycle on input This means a fastening cycle be Black wire external started by either pressing the throttle trigger switch on the nutrunner OR by activating this input When remote mode for the spindle is set to enable this input functions as a cycle on enable input This means a fastening cycle can be started only by pressing both the throttle trigger switch on the nutrunner and activating this inpu
70. n the CS4000 Mini Controller with Ethernet May 2002 T 38324 A Page 4 1 CS4000 Mini Controller with Ethernet 7 50 190 50 6 00 1152 40 i 75 120 65 9 gt i KR 1 O O a 2 Li M o ID MR HO O H 17 00 4 15 25 387 351 NOTE All dimensions are in inches with tech mative tool millimeters in square brackets TOOL CONTROL 1 49 41 FMS C on reni 1 1 L J LN 1 E 6 35 Figure 4 1 CS4000 Mini Controller with Ethernet Dimensions To mount the controller you require four 1 4 20 in bolts or screws Page 4 2 T 38324 A 39 30 38324 Chapter 4 Installing the CS4000 Mini Controller with Ethernet Power and Connection Requirements WARNING 230 VAC SINGLE PHASE INPUT ONLY Internal capacitors store a high voltage charge and discharge slowly after external power is removed Figure 4 2 shows the power supply and connection requirements of the CS4000 Mini Controller with Ethernet MOUNTING FL Figure 4 2 Power Connection Requirements May 2002 T 38324 A Page 4 3 CS4000 Mini Controller with Ethernet Meeting the AC Input Power Requirements CAUTION Failure to provide the prope
71. net CommiDevices Devices 1 Devicel DCM DevicelIPAddress 10 Comm2Devices Devices 1 Devicel DCM DevicelIPAddress 10 Comm3Devices Devices 1 Devicel DCM DevicelIPAddress 10 Comm4Devices Devices 1 Devicel DCM DevicellPAddress 10 Readings Database Enabled 1 ConnectionString Provider Microsoft Jet OLEDB 4 0 Data Source C VS VsDCM Readings mdb Persist Security Info False Limit 20000 Programs To Start Programl VsStart exe Figure 5 16 VSMain ini configured for an Ethernet Network NOTE For a detailed technical description of each section of VSMain ini refer to the Visual Supervisor User s Guide part number 39 30 34823 Page 5 14 T 38324 A 39 30 38324 Chapter 5 Setting Up the Ethernet Use Procedure 5 3 to make the necessary changes to VSMain ini Procedure 5 3 Editing VSMain ini for an Ethernet Network 1 Open VSMain ini using Notepad Click the Start menu on the Windows NT desktop From the Start menu select Programs From the Accessories menu select Notepad a b From the Programs menu select Accessories d e Click the File menu in Notepad f From the File menu select Open g Inthe file name field enter C Windows VSMain ini 2 Locate the heading in VSMain ini labeled Communications and enter the number of Ethernet connections you need on the network for controllers Your changes to this
72. ng Up a 485 Network Table 6 2 Setting Address Switches continued To set the following Set these Address Keep these DIP address number switches ON switches OFF Address 7 12 8 4 5 6 7 8 Address 8 4 1 2 3 5 6 7 8 Address 9 1 4 2 3 5 6 7 8 Address 10 2 4 1 3 5 6 7 8 Address 11 1 2 4 3 5 6 7 8 Address 12 3 4 1 2 5 6 7 8 Address 13 1 3 4 2 5 6 7 8 Address 14 2 3 4 1 5 6 7 8 Address 15 1 2 3 4 5 6 7 8 Address 16 5 1 2 3 4 6 7 8 Address 17 5 2 3 4 6 7 8 18 2 5 1 3 4 6 7 8 Address 19 2 8 3 4 6 7 8 Address 20 ON 1 2 4 6 7 8 Address 21 1l 55 2 4 6 7 8 Address 22 DEN 1 4 6 7 8 Address 23 1 2 3 5 4 6 7 8 Address 24 4 5 1 2 3 6 7 8 Address 25 1 4 5 2 3 6 7 8 Address 26 2 4 5 1 3 6 7 8 Address 27 1 2 4 5 3 6 7 8 Address 28 3 4 5 1 2 6 7 8 Address 29 1 3 4 5 2 6 7 8 Address 30 2 9 4 5 1 6 7 8 Address 31 1 2 3 4 5 6 7 8 Address 32 6 Using the information in Table 6 2 Figure 6 2 shows you how to set address 5 1 2 ls 4 5 je 7 js Figure 6 2 Network Address DIP Switch Set for Address 5 May 2002 T 38324 A Page 6 5 CS4000 Mini Controller with Ethernet Use Procedure 6 2 to set the address on the backplane of the controller Procedure 6 2 Setting the Address for the Controller 1 10 11 12 13 14
73. ni for a 485 Network When you are using a 485 network you must also change VSMain ini manually In the following example shown in Figure 6 1 VSMain ini is configured to talk to four TCMs using a single SDLC channel Communications Detachable 0 CommOcx1 Sdlc Ports 1 Comml1Devices Devices 4 Devicel DCM Device2 DCM Device3 DCM Device4 DCM CommOcx1 SDLCAdapterType ESCCP SDLCBitRateIndex 4 Readings Database Enabled 1 ConnectionString Provider Microsoft Jet OLEDB 4 0 Data Source C VS VsDCM Readings mdb Persist Security Info False Limit 20000 Programs To Start Programl VsStart exe Figure 6 1 VSMain ini configured for a 485 Network NOTE For a detailed technical description of each section of VSMain ini refer to the Visual Supervisor User s Guide part number 39 30 34823 Page 6 2 T 38324 A 39 30 38324 Chapter 6 Setting Up a 485 Network Use Procedure 6 1 to make the necessary changes to VSMain ini Procedure 6 1 Editing VSMain ini for a 485 Network Open VSMain ini using Notepad Click the Start menu on the Windows NT desktop From the Start menu select Programs From the Accessories menu select Notepad a b From the Programs menu select Accessories d e Click the File menu in Notepad f From the File menu select Open g Inthe file name field enter C Windows VSMain ini Locate the heading in VSMain ini labeled Communications and
74. ntacts Refer to Wiring in Chapter 4 Installing the CS4000 Mini Controller with Ethernet for pinout details Tool Connector The 37 position connector is the interface between the 46 66 and 116 Series nutrunner cable and control electronics Refer to Connector Pinout Definitions in Chapter 4 Installing the 84000 Mini Controller with Ethernet for pinout details Page 3 4 T 38324 A 39 30 38324 Chapter 3 Identifying the Components Tool cables are available in lengths of e 3 ft 0 91 m part number 51 3066 0003 e 6ft 1 83m part number 51 3066 0006 e 10ft 3 05 m part number 51 3066 0010 e 15 4 57 m part number 51 3066 0015 e 30ft 9 14 m part number 51 3066 0030 50ft 15 24 m part number 51 3066 0050 e 70ft 21 34 m part number 51 3066 0070 RS 422 Connector The 10 position male asynchronous RS 422 serial I O connector enables the controller to receive a barcode read by a scanner The RS 422 communications currently supports the Siemens 3964R barcode protocol Ethernet Connector The RJ 45 Ethernet connector enables the controller to communicate and send data to and from a host device on the same Local Area Network LAN using standard Ethernet protocols Transmission Control Protocol Internet Protocol TCP IP Refer to Chapter 4 Installing the C 4000 Mini Controller with Ethernet for details Printer Barcode Connector The nine position asynchronous RS 232 compatible serial output connector allows you to
75. nterface cards from one controller to another controller without changing the IP address subnet mask or default gateway of that controller To change the IP address subnet mask or default gateway you change the value held in the motherboard by sending it the new values via the Ethernet interface card This process is called programming or flashing the Ethernet interface card You can use the TINI Ethernet Flash Utility to find and change the IP address subnet mask and default gateway of a specific controller while programming or flashing an Ethernet interface card or by using the Application Settings window To find out how to use the Application Settings window refer to Procedure 5 2 on page 5 10 Use Procedure 5 1 to program or flash the Ethernet interface card Procedure 5 1 Programming the Ethernet Interface Card 1 Turn OFF power to the controller WARNING Make sure the power is OFF before you open the enclosure door High voltage when the power is ON can result in electrical shock or electrocution and also damage to the TCM inside the enclosure 2 Using a No 2 cross tip Phillips head screwdriver turn the access screws on the outside of the enclosure counterclockwise to loosen them Finish removing them by hand 3 Open the enclosure door and locate the Ethernet interface card housed inside the controller Page 5 2 T 38324 A 39 30 38324 Chapter 5 Setting Up the Ethernet 4 Insert one of the female c
76. o a minimum CAUTION It is extremely important to maintain the twisted wires of the Ethernet cable to within half an inch or less of their termination point Table 5 1 shows the pinout used for the RJ 45 modular jack attached to both ends of the 10Base T cable that connects the controller to the network hub It uses the IEEE T 568B standard wiring system Table 5 1 Ethernet RJ 45 Modular Jack Pinout ON 2 WHDIGRN 3 RX BLU BLU 5 WHVBU 21 Unsed 6e 3s RA f WHT BRN 4 1 5 16 38324 39 30 38324 Chapter 5 Setting Up the Ethernet Ethernet cables are inserted into the Ethernet connector on the bottom panel of each CS4000 Mini Controller with Ethernet The other end of the Ethernet cable is connected to a network hub To connect the computer running Visual Supervisor to the network insert one end of an Ethernet cable into the RJ 45 socket on the computer and the other end into the same network hub that the controllers are attached to See Figure 1 1 on page 1 3 for a diagram showing the network connections Testing the Ethernet Network If a computer and or the controllers connected to each other via the Ethernet network become unable to communicate with each other you can test the network using a command called ping This command is available on all computers and on the Ethernet interfac
77. ollect data from a controller on the network you must have Visual Supervisor version 3 20 or higher installed on the host and laptop computers and DCM 4 06 or higher installed on the controllers The CS4000 Mini Controller with Ethernet also has an optional Application Program Interface which you can have built into each controller This allows you to collect rundown data and send it to a software application across the Ethernet network other than Visual Supervisor NOTE The can be run concurrently with Visual Supervisor allowing you to collect rundown data in Visual Supervisor and also send it to another application via the API Using Ethernet The Ethernet is a Local Area Network LAN technology developed by Xerox and then further developed by Xerox Digital Equipment Corporation DEC and Intel The CS4000 Mini Controller with Ethernet uses the most commonly installed type of Ethernet cable 10 This type of cable can provide transmission speeds of up to 10 million bits per second mbps and uses the standard Transmission Control Protocol Internet Protocol TCP IP communications protocol This is a permanent mode of operation in which the computer and controllers are connected via the same network hub See Figure 1 1 This type of network requires e Pentium Class computer 500 MHz or above e Microsoft Windows 95 98 2000 or Windows NT version 4 0 or above with TCP IP communications protocol installe
78. om a laptop computer you can use the same steps to test the RS 422 Siemens 3964R interface until you reach Step 7 Instead of using the ping command use the tcm command Using the tcm command allows you to view information about the status of communications on the RS 422 port during the debugging process You can also use two other commands called tcm mask all and unmask VIN to log the RS 422 port activity Application Program Interface API The Application Program Interface API is a software application that runs separately but concurrently to Visual Supervisor It collects data and sends it to another software application If you have problems running the API check the version number of Device Control Module DCM software the controller is running You must have the DCM firmware at version 4 06 or higher to successfully run the API In order for API to collect data you must set Historyz VIN in VSMain ini on the VS host computer For further details about VSMain ini refer to the Visual Supervisor User s Guide part number 39 30 34823 Page 8 4 T 38324 A 39 30 38324 9 Technical Information Assembly Drawing The wiring diagrams for the CS4000 Mini Controller with Ethernet are shown in Figure 9 1 on page 9 3 and Figure 9 2 on page 9 5 May 2002 T 38324 A Page 9 1 CS4000 Mini Controller with Ethernet This page is left blank intentionally Page 9 2 T 38324 A 39 30 38324 Chapter 9 Technical
79. ompt Window esee 5 23 Page X T 38324 A 39 30 38324 Figure 6 1 Figure 6 2 Figure 9 1 Figure 9 2 Tables Table 3 1 Table 3 2 Table 3 3 Table 4 1 Table 4 2 Table 5 1 Table 6 1 Table 6 2 Table 8 1 Table 8 2 Procedures Procedure 5 1 Procedure 5 2 Procedure 5 3 Procedure 5 4 Procedure 5 5 Procedure 6 1 Procedure 6 2 Contents VSMain ini configured for a 485 Network 6 2 Network Address DIP Switch Set for Address 5 6 5 54000 Mini Controller with Ethernet Wiring of Standard Ethernet and iniaa A EM 9 3 CS4000 Mini Controller with Ethernet Wiring of Standard Ethernet 9 5 Description of Ethernet Interface Card 3 15 Description of LEDs on the Side of the Interbus S Module 3 17 Description of LEDs on the Top of the Interbus S Module 3 17 19 Position Remote Connector Pinout Signal Names and Descriptions 4 5 Guidelines for Proper Operation of the Controller I O Signals 4 8 Ethernet RJ 45 Modular Jack 442444 5 16 Switch Positions Representing Binary 6 4 Seting Address SWIICBS 6 4 gis EMIT E
80. onnectors on the null modem cable part number 41 41 0109FN into the 9 pin connector J7 on the Ethernet interface card See Figure 3 10 on page 3 14 As you open the enclosure door and look at the interior the Ethernet interface card is mounted in the top left of the enclosure NOTE You do NOT need to remove the card from the enclosure to attach the null modem cable The cable must be a full null modem GSE tech motive tool cable RJ 11 cable will not work 5 Insert the other end of the null modem cable which is also a female connector into the RS 232 port on the laptop computer It is recommended that you use the communications port COM1 If for some reason this is not available you may use any RS 232 port that is available Make sure you know which COM port you are using 6 Install jumper J1 labeled Prog on the Ethernet interface card Pull the jumper off the Ethernet interface card then carefully push the jumper on to pins 1 and 2 7 Turn ON power to the controller 8 Start the TINI Ethernet Interface Flash Utility The TINI Ethernet Interface Flash Utility is a program installed directly on to your laptop computer To start the program find the executable file Etherflash exe and double click on it NOTE The flash utility can be run from a floppy disk drive To do this put the disk in the laptop floppy disk drive select the drive using Windows Explorer and double click on the executable file Etherflash exe
81. puts NOTE Active means an input is connected to 24VDC Inactive means an input is either not wired or is wired to common May 2002 T 38324 A Page 4 7 CS4000 Mini Controller with Ethernet A remote input circuit schematic and remote I O schematics for sourcing and sinking outputs are shown in Figure 4 3 through Figure 4 5 2K OHMS 2K OHMS MOTE NNECTOR Vv V V V Figure 4 3 Remote Input Circuit Schematics To ensure that you operate the fastening system properly refer to Table 4 2 for input requirements Table 4 2 Guidelines for Proper Operation of the Controller Signals Um swspemesempsomge Xv _ Lowesrpemsstemunotae _ rim guaranteed museo wv erum guaranteed 15v Dwswecwuts Um wememsmacwen oa Page 4 8 T 38324 A 39 30 38324 Chapter 4 Installing the CS4000 Mini Controller with Ethernet Figure 4 4 is an example of the remote I O wiring scheme using the defaults voltage source for the jumpers It shows one of the many ways the remote I O feature of the controller can be used To ensure that you operate the fastening system properly refer to Table 4 2 for output requirements See Figure 3 8 on page 3 11 for the locations of JP1 to JP9 on the backplane NOTE JP9 ties discrete output 8 to discrete input 6 for spindle synchronization E ON ENABLE o el DISCRET
82. r power source can cause the following problems in your CS4000 Mini Controller with Ethernet nutrunner might shut down before it reaches the target torque during a rundown cycle nutrunner might not turn when a cycle on signal is applied to the system maximum free speed of the nutrunner might be lower than specified For proper operation especially during peak power draw periods be sure to connect the CS4000 Mini Controller with Ethernet to a clean source of AC power that is capable of maintaining the specified line voltage under the required load conditions If the AC line is subject to frequent over voltage and under voltage conditions some type of power line conditioning will be required NOTE The maximum no load speed of all tech motive tool nutrunners is based on an AC input voltage of 230V if the actual input voltage is lower the maximum no load speed of the nutrunner will be lower than specified It is recommended that the input voltage be between 208 and 250 VAC single phase A power source capable of delivering 1 to 1 5 should be sufficient in most applications Grounding WARNING The Ground Fault Circuit Interrupter cannot protect you against any potential difference that exists between the nutrunner body and any other metal fixturing or machinery You must observe the grounding requirements below as a safety protection It is extremely important that you connect the CS4000 M
83. rent menu structure Refer to the on line help supplied with the Windows operating system Click the Start menu on the Windows desktop From the Start menu select Programs c From the Programs menu select MS DOS Prompt A command prompt window opens using MS DOS shown in Figure 5 21 You are now ready to begin testing the Ethernet network Figure 5 21 Opening the Command Prompt Window May 2002 T 38324 A Page 5 23 CS4000 Mini Controller with Ethernet 2 Enter ping followed by the IP address of the computer or controller on the Ethernet network that you want to test NOTE The IP adaress of the Ethernet interface card is the same as the IP address of the computer or controller to which it is attached For example if the IP address of another controller in the Ethernet network is 10 1 100 177 then you would enter ping 10 1 100 177 It looks like this gt ping 10 1 100 177 If ping is successful you see a message returned in the command prompt window similar to Pinging 10 1 100 177 with 32 bytes of data Reply from 10 1 100 177 bytes 32 time 10ms L 255 Reply from 10 1 100 177 bytes 32 time 10ms L 255 Reply from 10 1 100 177 bytes 32 time 10ms L 255 Reply from 10 1 100 177 bytes 32 time 10ms L 255 c gt If ping is unsuccessful you see a message returned in the command prompt window similar to Pinging 10 1 100 177 with 32 bytes of data Request timed out Request timed o
84. roblems of the Ethernet network and TINI Ethernet interface card and gives possible solutions for each problem Table 8 2 Ethernet Common Problems and Solutions Problem Cause Solution No communication VsMain ini is not in Ethernet mode Correct VsMain ini IP address is incorrect Check IP address using the TINI Ethernet Interface Flash utility If the IP address is incorrect update or reprogram settings using the TINI Ethernet Interface Flash Utility Use the ping command to check new IP address No 24 VDC on Ethernet board Check 24 VDC power supply Check J1 connector is installed Check Ethernet cable Replace the cable if it is broken or damaged Tool Control Module Baud rate incorrect LED7 F is not Make sure the address swtich is not communicating with blinking on the TINI Ethernet interface card SW 1 DIP switch 7 is set to ON for the Ethernet network inside the controller correct 57600 baud rate No LEDs are illuminated Blown fuse on the 24 VDC power supply Check fuse on the 24 VDC on the TINI Ethernet power supply Interface card Repair or replace 24 VDC power supply May 2002 T 38324 A Page 8 3 CS4000 Mini Controller with Ethernet RS 422 Siemens 3964R Interface If you encounter problems with the RS 422 Siemens 3964R interface you can use Procedure 5 4 on page 5 17 Although this procedure describes how you test an Ethernet network fr
85. roller is attached to the second controller and so on until the termination point of the network The Visual Supervisor software provides data collection diagnostics and configuration functions as well as the connection point for the LAN LE ar mum dur Figure 1 2 Example of a 485 Network May 2002 T 38324 A PRELIMINARY DRAFT Page 1 5 CS4000 Mini Controller with Ethernet Using the RS 232 Serial Port In this configuration a laptop PC loaded with the Visual Supervisor software is linked to the controller s RS 232 serial port See Figure 1 1 on page 1 3 Because the laptop can be disconnected from one Mini Controller and reconnected to another VS is said to be operating in portable mode The controller in this scenario may not be part of a network typically so that it the cable and nutrunner comprise a stand alone fastening system This type of operation requires e Pentium class laptop computer Microsoft Windows 95 98 2000 or Windows NT version 3 0 or above e Atleast 64 MB RAM for Windows 95 98 or 2000 or 128 MB RAM for Windows NT e Visual Supervisor installed on the laptop in portable mode RS 232 cable and connector If the laptop PC is connected to a controller that is also connected to a network the host computer adopts any changes made by the laptop PC to the controller While the laptop computer is making changes the host cannot make setup changes to the same controller The Visual Supervisor progr
86. ror checked point to point method of sending barcode data to the controller If the controller receives a corrupt or incomplete barcode the scanner sends the barcode information again For example you might choose to attach a barcode scanner and controllers to the same RS 422 network A barcode is read by the scanner which then sends the barcode to every controller attached to the network This means you do not have to scan the barcode at each individual controller NOTE If for any reason the scanner does not send a barcode using the RS 422 port then the Printer Barcode port on each controller provides you with a backup You can always scan the barcode at an individual controller using a scanner attached to the Printer Barcode serial port until the scanner attached to the 5 422 port starts sending barcode data again For further details about the Siemens 3964R Barcode Protocol refer to the Protocol Definition of the 3964 3964R Procedures available from Siemens Siemens Part Number C79000 B8576 C191 01 Deciding How to Set Up the Controller It is more than likely that you will not need to use all methods of connecting the controller to a network and or external devices If you decide to use the 485 network link then you will not need the Ethernet link nor vice versa as they perform the same function You may or may not want the controller to communicate with a PLC and or an external barcode scanner in which case you do not need an Int
87. section of VSMain ini should end up looking similar to this Communications Detachable 0 Ports 4 CommOcx1 Ethernet CommOcx2 Ethernet CommOcx4 Ethernet In the above sample the computer is attached to a network hub to which four devices are connected Each device requires its own Ethernet communications channel The number of ports Ports 4 refers to the number of controllers that are connected to the network hub 3 Locate the heading in VSMain ini labeled Comm1Devices Create an entry for a device that is a controller specify an IP address for the controller and identify the controller as a Device Control Module DCM Each device has its own section called CommnDevices where n is the number of the device or controller in the network The IP address you enter for the controller is identical to the IP address of the Ethernet motherboard inside the controller Your changes to this section of VSMain ini should end up looking like this CommlDevices Devices 1 Devicel DCM DevicelIPAddress IP address of controller NOTE Enter the IP address in a decimal dot address format Refer to Working with IP Address Subnet Mask and Default Gateways earlier in this chapter for details May 2002 T 38324 A Page 5 15 CS4000 Mini Controller with Ethernet 4 Repeat Step 3 for each controller you are connecting to the Ethernet network Each device has its own section in VSMain ini The sample below shows settings for the s
88. t In addition it is also set to Clear Outputs This is a level sensitive input For the fastening cycle to proceed this input must remain active If this input becomes inactive at any time during the fastening cycle the cycle will be aborted and the nutrunner will stop running Forward Reverse input When Set Defaults is clicked VS sets this input to the direction the White wire internal nutrunner turns in a fastening cycle White wire external If this input is active when a fastening cycle is started the nutrunner will run in the forward fastening or tightening direction If this input is inactive when a fastening cycle is started the nutrunner will run in the reverse un fastening or loosening direction After a fastening cycle has started changing the state of this input has no effect on the fastening direction until the cycle on command from either the nutrunner or the cycle on input or both is de activated This means the input must be in the desired state BEFORE activation of the cycle start input Discrete Input 7 Defaults to Manual Calibration Gray wire internal Red wire external Discrete Input 8 Multi purpose switch input OR function with switch on tool Yellow wire internal Green wire external May 2002 T 38324 A Page 4 5 CS4000 Mini Controller with Ethernet Table 3 1 19 Position Remote Connector Pinout Signal Names and Descriptions Continued _____
89. talling the SDLC card in the computer you want attached to the network e Setting up Visual Supervisor for networks e Assigning a network address for each controller e Setting up cables for the network Installing the SDLC Card The SDLC card is plug and play It is installed using the Peripheral Component Interconnect PCI system and PCI slot on your computer Installing the SDLC card forms a connection between the microprocessor in the computer and any attached devices In this case you are attaching controllers as devices You will find a PCI slot on most computers If you cannot find the PCI slot on your computer refer to the manual that came with it Make sure your computer is switched off then insert the SDLC card into the PCI slot To install the SDLC card on your system start the computer and follow the instructions given to you by the Windows NT Operating System No further programming for the SDLC card is required Setting Up Visual Supervisor for a 485 Network Install Visual Supervisor on your computer During installation of Visual Supervisor on the computer the installation program will give you the choice to install Visual Supervisor in permanent or portable mode You must select permanent mode To find out how to install Visual Supervisor in more detail refer to the Visual Supervisor User s Guide part number 39 30 34823 May 2002 T 38324 A Page 6 1 CS4000 Mini Controller with Ethernet Editing VSMain i
90. the top of the 54000 Mini Controller with Ethernet This enables the controller to exchange up to eight digital inputs and outputs with an external Programmable Logic Controller PLC If an Interbus S module is not included in the controller the Interbus S I O connector is covered To find out details about the Interbus S module refer to the Interbus S Module section later in this chapter May 2002 T 38324 A Page 3 3 CS4000 Mini Controller with Ethernet Figure 3 3 shows the bottom panel components of the CS4000 Mini Controller with Ethernet Descriptions are provided in clockwise order starting with the I O connector Connector FA M Tool Connector RS 422 Connector Ground Fault Circuit Interrupter GFCI XS IN A OUT E RJ 45 Ethernet Connector RS 232 Connector ARCODE Printer Barcode Connector L SDLC I O Network Connector Figure 3 3 Bottom Panel View VO Connector The 19 position remote I O connector provides the interface between external control monitoring devices and the internal control electronics tech motive tool accessories such as socketrays are connected here The mating connector for this port is a 14 shell 19 pin strain relief SR connector part number 23 10 5200 The mating connector enables connection of your own remote control and or monitoring devices such as external annunciator lamps or remote cycle on co
91. to place in the enclosure door turning them clockwise to tighten them Finish tightening each access screw with a No 2 cross tip Phillips head screwdriver until each screw is secure Close the enclosure door on the controller Using a No 2 cross tip Phillips head screwdriver turn the locknuts on the outside of the enclosure clockwise to tighten them Turn ON power to the controller enclosure Repeat Steps 1 through 15 for each controller setting the address switch to a different address each time Page 6 6 T 38324 A 39 30 38324 Chapter 6 Setting Up a 485 Network Using 485 Network Cables The type of cable you need to connect the CS4000 Mini Controller with Ethernet to the LAN using the 485 link is the Bellden 8104 low capacitance computer cable or equivalent The computer and controllers form a daisy chain when they are networked together see Figure 1 2 on page 1 5 The cable is inserted in the RS 485 port on the bottom panel of the controller and either inserted into the RS 485 port controller next to it in the network or if it is the first controller in the network to the RS 485 port of the supervising computer May 2002 38324 Page 6 7 CS4000 Mini Controller with Ethernet This page is left blank intentionally Page 6 8 T 38324 A 39 30 38324 7 Setting Up the RS 232 Link The CS4000 Mini Controller with Ethernet can be connected to a laptop computer and serve a stand alone unit This chapter
92. ts down its connection to the COM port but remains open on the desktop a Click the Flash menu in the TINI Ethernet Flash Utility window b From the Flash menu select Com Port From the Com Port menu select Close COM Port 14 Close the CS4000 Mini Controller with Ethernet enclosure door 15 Turn OFF power to the controller 16 By hand install the access screws back into place in the enclosure door turning them clockwise to tighten them Finish tightening each access screw with a No 2 cross tip Phillips head screwdriver until each screw is secure 17 Turn ON power to the controller May 2002 T 38324 A Page 5 9 CS4000 Mini Controller with Ethernet Updating Application Settings After you have flashed an application file to the Ethernet interface card you may want to update settings without re flashing the entire application file again To do this the TINI Ethernet Flash Utility has a menu option that allows you to update the IP address subnet mask and default gateway values and enable or disable application functions for the Ethernet network and RS 422 link Use Procedure 5 2 to edit application settings Procedure 5 2 Editing Application Information 1 If necessary repeat Steps 1 to 9 from Procedure 5 1 on page 5 2 to connect the laptop to the Ethernet interface card inside the controller 2 Select TINI Application Info a Click the Flash menu in the TINI Ethernet Flash Utility window b From the
93. ttached computer When switch 7 is in the OFF position a baud rate of 9600 kbps is used When switch 7 is in the ON position a baud rate of 57600 kbps is used Switch 8 is used to set up the TCM for the PFCS Mode used by the DaimlerChrysler Plant Floor Communication System Page 3 12 T 38324 A 39 30 38324 Chapter 3 Identifying the Components Board The I O board shown in Figure 3 9 is inserted into a connector J2 on the backplane It interfaces to all of the connectors available on the bottom of the controller see Figure 3 3 on page 3 4 On the top side of the I O board are some diagnostic connections 19 and J20 for digital I O Digital Connector J20 Digital Connector J19 Ground 2 9 E Ground Mounting Hole B Mounting Hole SHa ooooo0Lll oo uoo Connector J1 Figure 3 9 Board Power Supply A 1 2A 24V power supply provides power for the TCM I O and Ethernet interface card May 2002 T 38324 A Page 3 13 CS4000 Mini Controller with Ethernet Ethernet Interface Card The Ethernet interface card part number 420959 38093 is a printed circuit board into which internal component cables of the Ethernet network are plugged It requires a 1A 5V power supply that it draws from the 24VDC power supply inside the controller and converts to the necessary voltage The Ethernet interf
94. ue reaches the Control Reference level the synchronization output is de activated At the same time the state of the synchronization input is sampled If it is still active because some other spindle has not reached the synchronization level yet it stops the nutrunner and waits for the synchronization input to become inactive Afterwards it re starts the nutrunner and finishes the fastening cycle This pin should be connected to the synchronization in out pin of all other spindles for which synchronization is desired NOTE This feature only functions when JP8 and JP9 are set to defaults This is connected to the negative terminal of the internal 24VDC I O power supply and is normally used as the common connection for the output signals This pin and pin is connected to the positive terminal of the internal 24VDC I O power supply and is normally used as the common connection for the input signals Pins U and J L M and P are the programmable discrete outputs Any one of these outputs will become active when its programmed output function becomes true The functions of these outputs are set with VS set output This is the common connection for the synchronization input output It should be connected to the synchronization common pin of all other spindles for which synchronization is desired Early units have these outputs fixed in the software Units with KDM software 2 5 or later have configurable out
95. uld Use This Manual This manual is written for the engineers technicians and users who will set up and or operate the 54000 Mini Controller with Ethernet with any of the Intelligent 46 66 or 116 nutrunners How to Use This Manual This manual provides installation maintenance and technical information about the CS4000 Mini Controllers with Ethernet This Preface provides conventions and abbreviations used throughout this manual If you have never used a CS4000 Mini Controller with Ethernet read this manual entirely The first three chapters will help you become familiar with safety requirements the location of components software and features If you are already familiar with the CS4000 Mini Controller look over Chapter 4 Installing the CS4000 Mini Controller with Ethernet which describes the power requirements and details the I O wiring and connectors May 2002 T 38324 A Page iii CS4000 Mini Controller with Ethernet If you want to use the CS4000 Mini Controller with Ethernet with a network or laptop computer refer to Chapter 5 Setting Up the Ethernet Chapter 6 Setting Up the 485 Network and Chapter 7 Setting Up the RS 232 Link that describe the methods by which you can connect the CS4000 Mini Controller to a network or laptop computer You will find Chapter 8 Maintenance Troubleshooting and Chapter 9 Technical Information provide you with technical details for maintaining and troubleshooting the controller
96. ut Request timed out Request timed out GINA 3 Repeat Step 2 for every IP address you want to test 4 When you are finished testing the network exit the command prompt window a Atthe C prompt enter exit The command prompt window closes and returns you to the Windows desktop When the ping command is successfully applied to the IP addresses you are testing you know that the physical network connections are working correctly If you still have a network problem it is likely to be the result of a software malfunction NOTE As well as the ping command described in Procedure 5 5 there are a number of other commands available such as ipconfig and tcm These commands can also be used to diagnose problems with an Ethernet network Consult a GSE tech motive tool engineer for details Testing Ethernet Network Cables It is important to test Ethernet cables whether you make them yourself or use ready made cables By doing this you make sure that they are in working order It is recommended that you test cables using a Remote Network Cable Tester that you can obtain from a computer networking retailer of your choice Page 5 24 T 38324 A 39 30 38324 6 Setting Up the 485 Network The 54000 Mini Controller with Ethernet be connected to a Local Area Network LAN using a 485 network link and a special Synchronous Data Link Control SDLC card This chapter describes the steps you must take to set up the LAN e Ins
97. work from a laptop computer and use Procedure 5 5 to ping the network from the host computer Procedure 5 4 Testing the Network From A Laptop Computer CAUTION Before you carry out this procedure make sure jumper J1 labeled Prog on the Ethernet interface card is pulled off pins 1 and 2 1 Open Windows Explorer on the Windows desktop NOTE Different versions of the Windows operating system may have a different menu structure Refer to the on line help supplied with the Windows operating system Click the Start menu on the Windows desktop From the Start menu select Programs From the Programs menu select Accessories From the Accessories menu select Communication o g9 From the Communication menu select Hyperterminal Click Hyperterminal May 2002 T 38324 A Page 5 17 CS4000 Mini Controller with Ethernet 2 Enter a name to identify this connection and select the Hyperterminal icon you want to use for it See Figure 5 17 a Enter a meaningful name for the Hyperterminal connection in the Name field b Select the shortcut Icon for the Hyperterminal connection and click on it c Click OK Connection Description Figure 5 17 Select the Icon and Enter Name for the Hyperterminal Connection NOTE When you next want to use this connection all you need to do is look for the shortcut icon under the Hyperterminal menu and then click on it Page 5 18 T 38324 A 39 30 3

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