6159939130 CS7000 Controller Hardware Overview Manual With Ethernet/CCM Information for use with 177 and 277 Series Electric Fastening Tools CP Ref.
4-Hour Technical Support Toll Free in the U.S. and Canada: 1-877-224-7377 All other countries: (001) 248-348-6280 between 8 a.m. and 5 p.m. Eastern Standard Time (EST) NOTE: Chicago Pneumatic Tool Company (CP) in 2005 acquired and changed the name of GSE tech-motive tool to CP Techmotive. Product Information may be found on www.cp.com. NOTE: The part number for the Visual Supervisor (VS) software program is 464000-03330 (CP part number 6150040915) NOTE: A variety of related technical manuals in .
LIMITED WARRANTY CP Techmotive warrants its PRODUCTS to be free from defects in materials and workmanship for the lesser of (1) one year from the date of shipment from the manufacturing facility in Michigan, U.S.A.
6159939130 CS7000 Controller Hardware Overview Manual CUSTOMER SATISFACTION Please Read This! As a valued customer, your opinion and satisfaction are important to CP Techmotive. Please let us know what you think of our product(s). Write the part number and serial number of the product(s) you have purchased before you begin our brief online survey. The numbers are located on a sticker affixed to the handle of the nutrunner or screwdriver, and exterior or interior of the controller.
Preface Preface The CS7000 Controller manufactured by CP techmotive is a 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 data acquisition. Microprocessors in both the fastening tool and the controller s tool control module (TCM) enable the system to perform to levels of accuracy while providing easy set-up and operation previously unattainable.
159939130 CS7000 Controller Hardware Overview Manual 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! It can be dangerous to personnel and/or machine systems, if operating instructions are not followed. The information appears in a box in italicized boldface type.
Preface Abbreviations Some of the most common abbreviations used throughout this manual include the following: API application program interface ESD electro-static discharge GFCI ground fault circuit interrupter I/O input/output IEC International Electrotechnical Commission IEEE Institute of Electrical and Electronic Engineers IP internet protocol kbps kilo-bits per second kVA kilovolt-ampere LAN local area network LED light emitting diode mbps million bits per second PCI periphera
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Contents Contents Who Should Use This Manual...............................................................................................i How to Use This Manual ........................................................................................................i Conventions ...........................................................................................................................ii Abbreviations .........................................................................................
6159939130 CS7000 Controller Hardware Overview Manual Grounding ........................................................................................................................... 3-4 I/O Wiring ............................................................................................................................ 3-4 Connector Pinout Definitions........................................................................................... 3-8 Tool Connector “26 pin” (Metal SMC) – Front View .....
Contents Figures Figure 2-1. Figure 2-2. Figure 2-3. Figure 2-4. Figure 2-5. Figure 2-6. Figure 2-7. Figure 2-8. Figure 2-9. Figure 3-1. Figure 3-2. Front Panel View ..................................................................................................2-2 Turning the Rotary Actuator to the ON Position .................................................2-3 Top Panel View ....................................................................................................2-4 Bottom Panel View .....
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Chapter 1. Think Safety First! 1. 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. If, however, safety precautions are overlooked or ignored personal injury to the operator can result.
6159939130 CS7000 Controller Hardware Overview Manual • 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.
Chapter 1. Think Safety First! 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-todate and 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.
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Chapter 2. Identifying the Components 2. Identifying the Components This chapter is designed to familiarize you with the components of the CS7000 Controller. It has four sections to help you locate all the major components easily: • Front Panel • Top Panel • Bottom Panel • Enclosure Interior Each section includes figures that call out the components. Descriptions of the components follow the figures.
6159939130 CS7000 Controller Hardware Overview Manual Front Panel Figure 2-1 shows the front panel components of the CS7000 Controller. Descriptions are provided in clockwise order, starting with the latch. Figure 2-1.
Chapter 2. Identifying the Components Latch The latch keeps the front panel of the controller closed. To open it you need a key (part number 31-80-0414). Rotary Actuator The rotary actuator is a safety device that allows you to open the enclosure door only when the disconnect switch is in the OFF position. The rotary actuator is mechanically interlocked with the disconnect switch, which is located inside the enclosure.
6159939130 CS7000 Controller Hardware Overview Manual Top Panel Figure 2-3 shows the top panel components of the CS7000 Controller. Figure 2-3. Top Panel View Bottom Panel Figure 2-4 shows the bottom panel components of a CS7000 Controller. Connector configurations will vary depending on the model. Figure 2-4.
Chapter 2. Identifying the Components Tool Connector A 26 position metal (SMC) connector is the interface between the 177 and 277 Series nutrunner cable and control electronics. Refer to Connector Pinout Definitions in Chapter 3. Installing the CS7000 Controller for pinout details. Input AC Power The CS7000 Controller is shipped with a 6-ft power cable with Hubble connector 2321-CY. Power is 220 VAC. Refer to Chapter 3 for details.
6159939130 CS7000 Controller Hardware Overview Manual I/O Connector The 19-position remote I/O connector provides the interface between external control/monitoring devices and the internal control electronics. CP techmotive 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).
Chapter 2. Identifying the Components Figure 2-5.
6159939130 CS7000 Controller Hardware Overview Manual Gen2 Tool Control Module (TCM) The TCM, shown in Figure 2-6, 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 DCM. Figure 2-6. WARNING! ! Page 2-8 Front View of the TCM This servo contains a fast discharge circuit to discharge the internal capacitors within a few seconds. However, you should still be careful when handling the TCM.
Chapter 2. 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.
6159939130 CS7000 Controller Hardware Overview Manual Communications Control Module (CCM) “Optional” The CCM module provides Ethernet (10Base-T) connectivity from the CS7000 Controller. This interface may be to Visual Supervisor systems on the LAN or possibly custom interfaces to customer networks. In addition the CCM (in the future) be capable of various communications functions such as Fieldbus connections. The CCM module will also be capable of handling a keypad/display function. Figure 2-7.
Chapter 2. Identifying the Components Backplane The backplane is a printed circuit board into which many of the internal component cables plug. Figure 2-8. CS7000 Controller Backplane Backplane Fuses F1 and F2 are the main 220V line fuses (MDA-20). F4 is a 1A Pico fuse used to protect the external 24 VDC. F5 is a spare fuse.
6159939130 CS7000 Controller Hardware Overview Manual DIP Switch Settings DIP switch block SW1 is used to configure the SDLC address. These are binary encoded to provide addresses 1 through 32 (zero is not a valid address). For Ethernet this address should be set to 1. DIP switch block SW2 is for special options. Position #1 can force the unit into the FLASH program mode. Position #2 configures the printer port for DaimlerChrysler Plant Floor Communication System (PFCS) formatting. Power Supply A 1.
Chapter 2. Identifying the Components Disconnect Switch The disconnect switch is mechanically interlocked with the rotary actuator to prevent the enclosure door from opening if the disconnect switch is in the ON position. Refer to Front Panel earlier in this chapter for details about the rotary actuator. Circuit Breaker/Fuses The circuit breaker/Fuses protects the controller circuitry during an overload condition.
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Chapter 3. Installing the CS7000 Controller 3. Installing the CS7000 Controller This chapter shows you how to mount the CS7000 Controller, discusses the basic issues involved in placing the CS7000 Controller in your facility and shows you how to wire it. Mounting the CS7000 Controller The CS7000 Controller is installed vertically with the back flat against the mounting surface. Allow sufficient space around the controller to attach the power cord, tool cable, I/O cable and printer cable.
6159939130 CS7000 Controller Hardware Overview Manual Figure 3-1. CS7000 Controller Dimensions of the Front and Bottom Panel To mount the controller use four 1/4-20-in bolts or screws. Emissions and Susceptibility The CS7000 Controller meets the EC directives IEC 61000-6-2 (1999) and IEC 61000-6-4 (1997). It does not radiate excessive electromagnetic or noise radiation, or interfere with other controllers and/or electronic devices in its vicinity.
Chapter 3. Installing the CS7000 Controller Meeting the AC Input Power Requirements For proper operation, the controller must be connected to a stable power source. The supply source should be capable of delivering at least 1.5 kVA per channel at 220V for 177 Series tools. For the 277 Series tools, at least 2KVA per channel is recommended. The voltage tolerance for 220V controllers is 208 to 250 VAC.
6159939130 CS7000 Controller Hardware Overview Manual Grounding WARNING! ! The GFCI 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. Failure to follow this safety guideline can result in serious personal injury. It is extremely important that you connect the CS7000 Controller enclosure properly to an earth ground.
Chapter 3. Installing the CS7000 Controller Table 3-1. Pin 19-Position Remote I/O Connector Pinout Signal Names and Descriptions (Continued) Signal Description B Forward/Reverse input (White wire internal) (White wire - external) When Set Defaults is clicked, VS sets this input to the direction the nutrunner turns in a fastening cycle: If this input is active when a fastening cycle is started, the nutrunner will run in the forward (fastening or tightening) direction.
6159939130 CS7000 Controller Hardware Overview Manual Table 3-1. Pin M N P R 19-Position Remote I/O Connector Pinout Signal Names and Descriptions (Continued) Signal Description Discrete output #4* (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) J = Cycle Finish, K = Cycle Good, L = Cycle Bad, N = In Cycle.
Chapter 3. Installing the CS7000 Controller A remote input circuit schematic is shown in Figure 3-2. Figure 3-2. Remote Input Circuit Schematics To ensure that you operate the fastening system properly, refer to Table 3-2 for input requirements. Table 3-2. Guidelines for Proper Operation of the Controller I/O Signals Discrete Inputs Highest permissible input voltage 30 V Lowest permissible input voltage -5 V Minimum guaranteed input activation 10 V Maximum guaranteed input deactivation 1.
6159939130 CS7000 Controller Hardware Overview Manual Connector Pinout Definitions Pinout definitions are provided for the tool, I/O, TCM network, RS-232 and printer connectors. Tool Connector “26 pin” (Metal SMC) – Front View Pin Designation 1 5 6 12 13 14 15 16 19 20 21 22 23 25 26 Nos.
Chapter 3.
6159939130 CS7000 Controller Hardware Overview Manual Printer/Computer/Diagnostics (RS-232) Connector – Front View Pin Designation 2 3 5 7 8 Wire Color (Ref) BLU GRN BLK RED YEL Function RXD TXD GND RTS CTS Programming the CS7000 Controller (In General) After you have mounted the controller and become familiar with its basic components, you must program it with the required fastening strategy and parameter set limits before you can begin fastening operations.
Chapter 4. Technical Information 4. Technical Information Maintenance of the CS7000 Controller consists of replacing fuses and cleaning the enclosure window. Replacement Parts If, at any time, you need to replace or order new parts for your CS7000 Controller. Table 4-1. Qty.
6159939130 CS7000 Controller Hardware Overview Manual Contact Information NOTE: ? You will need to prefix American telephone numbers with the International Access Code for the U.S. when calling from another country. If you require additional technical information about the CS7000 Controller, call 1-877-224-7377 from inside the U.S. or Canada, or (001) 248-596-0600 from outside the U.S. or Canada, or visit our website at http://www.gsetechmotive.com.
Chapter 5. Index 5.
6159939130 CS7000 Controller Hardware Overview Manual pinout, 3-8 Plant Floor Communication System, 2-12 potentiometer, 2-9 power supply, 2-6, 2-12, 3-5, 4-1 printer cable, 3-1 printer connector, 2-5, 3-10 programmable discrete output, 3-6 safety, electrical, 1-1, 1-3 SDLC/485 I/O network connector, 2-5, 3-9 servo amplifier, 2-6, 2-9, 2-12 spindle, 2-8 synchronization input/output, 3-6 synchronization output, 3-6 R T remote input circuit schematic, 3-7 repairs, 1-3 rotary actuator, 2-3 RS-232 connecto
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www.cp.com Please find your local contact at: www.cp.com Index-5-2 U.S.
