CS4000 Mini Controller with Ethernet Technical Reference Manual
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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.
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.
Preface The GSE tech-motive tool CS4000 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. 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).
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.
Preface Abbreviations Some of the most common abbreviations used throughout this manual include the following: May 2002 API Application Program Interface GFCI Ground Fault Circuit Interrupter I/O Input/Output 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 Peripheral Component Interconnect TCM Tool Control Module TCP/IP Transmis
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Contents Preface ................................................................................................................................... iii Who Should Use This Manual ....................................................................................... iii How to Use This Manual ................................................................................................ iii Conventions.........................................................................................................
CS4000 Mini Controller with Ethernet Enclosure Interior......................................................................................................... 3-6 Tool Control Module................................................................................................. 3-8 Servo Amplifier ................................................................................................ 3-10 Device Control Module ....................................................................................
Contents 7. Setting Up the RS-232 Link.......................................................................................... 7-1 Setting Up Visual Supervisor ...................................................................................... 7-1 Using RS-232 Cables.................................................................................................... 7-1 8. Maintenance/Troubleshooting ....................................................................................
CS4000 Mini Controller with Ethernet Figures Figure 1-1. Figure 1-2. Example of an Ethernet Network with a Connected Portable Laptop............. 1-3 Example of a 485 Network.............................................................................. 1-5 Figure 3-1. Figure 3-2. Figure 3-3. Figure 3-4. Figure 3-5. Figure 3-6. Figure 3-7. Figure 3-8. Figure 3-9. Figure 3-10. Figure 3-11. Figure 3-12. Figure 3-13. Front Panel View...........................................................................
Contents Figure 6-1. Figure 6-2. VSMain.ini configured for a 485 Network........................................................ 6-2 Network Address DIP Switch Set for Address ‘5’............................................ 6-5 Figure 9-1. CS4000 Mini Controller with Ethernet Wiring of Standard Ethernet and Interbus-S Module........................................................................................... 9-3 CS4000 Mini Controller with Ethernet Wiring of Standard Ethernet ...............
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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.
CS4000 Mini Controller with Ethernet • A 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.
Chapter 1. Overview Example of a “Permanent” (Embedded) Ethernet Network (Using Mini Controllers with Ethernet) Pentium Class Computer running Windows 95, 98, 2000 or Windows NT, version 4.0 or above. It also has an installed Ethernet interface card. Each controller has an Ethernet connector. Ethernet Card Visual Supervisor is running on the computer, plus an optional Application Program Interface (API) for data collection.
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.
Chapter 1. Overview Example of a “Permanent” (Embedded) 485 Network (Using CS4000 KDM and Mini Controllers with SDLC) CS4000 Mini Controller each contains one Tool Control Module (TCM) Pentium Class Computer running Windows NT, version 4.0 or above, with an SDLC card and RS-485 port on each controller.
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.
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 error 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.
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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.
CS4000 Mini Controller with Ethernet General Machine Safety Page 2-2 • 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.
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.
CS4000 Mini Controller with Ethernet Page 2-4 • Always use fuses of a capacity smaller than or equal to the safe capacity of the line or the equipment it serves. • Before you work on any circuit, check it with an appropriate testing device to be sure voltage is not present. • 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.
3. Identifying the Components The CS4000 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 CS4000 Mini Controller with Ethernet.
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 te iv ot m 4 ch 3 l oo t e 5 6 7 2 1 Parameter Select Switch 8 * Figure 3-1. Front Panel View NOTE: The AC power cord is described in the Top and Bottom Panel section later in this chapter.
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.
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. I/O Connector Fuses Tool Connector FUSE 1 FUSE 2 RS-422 Connector I/O Ground Fault Circuit Interrupter (GFCI) ETHERNET TCM SDLC NETWORK IN OUT RS422 A RJ-45 Ethernet Connector RS-232 Connector RS232 PRINTER/BARCODE Printer/Barcode Connector SDLC I/O Network Connector Figure 3-3.
Chapter 3. Identifying the Components Tool cables are available in lengths of: • 3 ft / 0.91 m (part number 51-3066-0003) • 6 ft / 1.83 m (part number 51-3066-0006) • 10 ft / 3.05 m (part number 51-3066-0010) • 15 ft / 4.57 m (part number 51-3066-0015) • 30 ft / 9.14 m (part number 51-3066-0030) • 50 ft / 15.24 m (part number 51-3066-0050) • 70 ft / 21.
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).
Chapter 3. Identifying the Components AC Power Cord Tool Control Module Interbus-S Module (Optional) Exterior Wall Ethernet Interface Card Power Supply Backplane Figure 3-4. Components Inside the Enclosure of the CS4000 Mini Controller with Ethernet NOTE: The AC power cord is described in Top and Bottom Panel earlier in this chapter.
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 (DCM). For the location of the TCM inside the CS4000 Mini Controller with Ethernet, see Figure 3-4 on page 3-7. Thumbscrews Side Panel Front Panel Figure 3-5.
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.
CS4000 Mini Controller with Ethernet Servo Amplifier The servo amplifier is a three-phase, brushless DC motor controller that provides 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.
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 JP8 Address Switch, SW-1 Jumper, JP9 +24VDC Input Fuse, F3 +24VDC Fuse to Tool, F2 +24V Input, J8 I/O Board, J2 Figure 3-8.
CS4000 Mini Controller with Ethernet Backplane Fuses Fuse F4 is Littelfuse 239001, 5x20 mm, 1A, 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 F3 protects the 24VDC used with the discrete I/O circuits. Address Switches Each TCM has a unique serial address.
Chapter 3. Identifying the Components I/O 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 (J19 and J20) for digital I/O. Digital I/O Connector, J20 Digital I/O Connector, J19 Ground Mounting Hole Ground Mounting Hole I/O Connector, J1 Figure 3-9. I/O Board Power Supply A 1.
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 interface card lets you connect individual controllers to a host device forming a LAN, using TCP/IP.
Chapter 3. Identifying the Components The nine-position RS-232 serial port, J7, is used for setup and diagnostics of the Ethernet 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.
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 I/O 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.
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.
CS4000 Mini Controller with Ethernet Ground Fault Circuit Interrupter The Ground Fault Circuit Interrupter (GFCI) is wired in series from the AC power input to the servo amplifier. It monitors both 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 .
4. Installing the CS4000 Mini Controller with Ethernet This chapter shows you how to mount and wire the CS4000 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.
CS4000 Mini Controller with Ethernet NOTE: All dimensions are in inches with millimeters in square brackets. Figure 4-1. CS4000 Mini Controller with Ethernet Dimensions To mount the controller you require four 1/4-20-in bolts or screws.
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. Figure 4-2.
CS4000 Mini Controller with Ethernet Meeting the AC Input Power Requirements CAUTION! Failure to provide the proper power source can cause the following problems in your CS4000 Mini Controller with Ethernet: ! The nutrunner might shut down before it reaches the target torque during a rundown cycle. ! The nutrunner might not turn when a cycle-on signal is applied to the system. ! The maximum free speed of the nutrunner might be lower than specified.
Chapter 4. Installing the CS4000 Mini Controller with Ethernet I/O 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 I/O connector is part number 23-10-5200. Table 4-1.
CS4000 Mini Controller with Ethernet Table 3-1.
Chapter 4. Installing the CS4000 Mini Controller with Ethernet Table 3-1. 19-Position Remote I/O Connector Pinout Signal Names and Descriptions (Continued) Pin R Signal Description 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).
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. 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.
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.
CS4000 Mini Controller with Ethernet 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.
Chapter 4. Installing the CS4000 Mini Controller with Ethernet Connector Pinout Definitions Pinout definitions are provided for the tool, I/O, RS-422, TCM network, RS-232, printer/barcode and Interbus-S connectors. Tool Connector Pin Designation 1 2 3 4 10 13 14 15 16 17 21 22 27 28 Nos.
CS4000 Mini Controller with Ethernet RS-422 Connector B A D H K J C E G F Pin Designation A B C D E F G H Wire Color (Ref) BRN/WHT WHT/BRN ORN/WHT WHT/ORN GRN/WHT WHT/GRN BLU/WHT GRN Function TXD+ OUT TXD- OUT RXD+ IN RXD- OUT Not used Not used SHIELD COMMON SHIELD Tool Control Module (TCM) Network Connector Pin Designation A B C D E F G H Wire Color (Ref) BRN/WHT WHT/BRN ORN/WHT WHT/ORN GRN/WHT WHT/GRN BLU/WHT GRN Function TXD+ OUT TXD- OUT RXD+ IN RXD- OUT CLK+ OUT CLK- OUT SHIELD COMMON SH
Chapter 4.
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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: • Programming the Ethernet interface card • Setting up Visual Supervisor for networks • Using Ethernet cables • 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.
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 CS4000 Mini Controller with Ethernet software. It is called a dot address because the address is divided into four groups of decimal digits separated by a period. Each group of decimal digits represents a much longer binary number. For example: 10.1.100.
Chapter 5. Setting Up the Ethernet 4. Insert one of the female connectors 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.
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. Figure 5-2. Selecting the COM Port Menu b. From the Com Port menu, select Open COM Port. c.
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. Figure 5-4. Establishing A Successful Connection via COM1 When another utility or program is using the COM1 port, the attempt to establish a connection fails and the message shown in Figure 5-5 is displayed. Figure 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…. Figure 5-6. Selecting the “Flash TINI…” Option 11. From the list of files 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.
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.
CS4000 Mini Controller with Ethernet There are three possible reasons that a flash fails: • The null modem cable has been inserted into the 9-pin connector (J7) on the Ethernet interface card incorrectly. • The jumper (J1) labeled ‘Prog’ on the Ethernet interface card has been installed incorrectly. • An incorrect 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).
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.
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.
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. Figure 5-13. Viewing the Application Settings Window General Info tab 3. Select the Ip Address tab. a.
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. Figure 5-15.
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 • 2400 • 38400 • 4800 • 57600 • 9600 e. Click on 3964R Byte Timeout (ms) and enter the timeout in milliseconds for the barcode scanner attached to the RS-422 port. 7. To save your changes, click OK.
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=Ethernet [Comm1Devices] #Devices=1 Device1=DCM Device1IPAddress=10.1.100.
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. a. Click the Start menu on the Windows NT desktop. b. From the Start menu, select Programs. c. From the Programs menu, select Accessories. d. From the Accessories menu, select Notepad. e. Click the File menu in Notepad. f. From the File menu, select Open. g. In the file name field enter “C:\Windows\VSMain.ini.” 2.
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 second controller added to VSMain.ini. [Comm2Devices] #Devices=1 Device1=DCM Device1IPAddress=[IP address of the controller] 5. 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.
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.
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. Figure 5-17.
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 COM1 is the communications port selection but you may choose any communications port on the computer. Figure 5-18.
CS4000 Mini Controller with Ethernet 4. Specify the communications port settings. See Figure 5-19. a. Set the Bits per second: field to 115200. b. Set the Data bits: field to 8. c. Set the Parity: field to None. d. Set the Stop bits: field to 1. e. Set the Flow Control: field to Hardware. f. Click OK. Figure 5-19. Setting the Communications Port Settings When you click OK, Hyperterminal attempts to make a connection with the attached Ethernet interface card.
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. Figure 5-20. Hyperterminal Window Showing Ethernet Interface Card (TINI) Login 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.
CS4000 Mini Controller with Ethernet 7. Enter ping followed by the IP address of the computer or controller on the Ethernet network that you want to test. NOTE: The IP address 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.
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 address of the controller.
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 address 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: c:\> ping 10.1.100.
6. Setting Up the 485 Network The CS4000 Mini Controller with Ethernet can 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: • Installing the SDLC card in the computer you want attached to the network. • Setting up Visual Supervisor for networks. • Assigning a network address for each controller. • Setting up cables for the network.
CS4000 Mini Controller with Ethernet Editing VSMain.ini 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.
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 1. Open VSMain.ini using Notepad. a. Click the Start menu on the Windows NT desktop. b. From the Start menu, select Programs. c. From the Programs menu, select Accessories. d. From the Accessories menu, select Notepad. e. Click the File menu in Notepad. f. From the File menu, select Open. g. In the file name field enter “C:\Windows\VSMain.ini.” 2.
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 Network Address Each controller attached to the 485 network requires its own address.
Chapter 6. Setting Up a 485 Network Table 6-2.
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. 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. 2. Using a No.
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.
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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 describes the steps you must take to create this connection: • Setting up Visual Supervisor for a stand-alone controller • Using RS-232 cables Setting Up Visual Supervisor Install Visual Supervisor on the laptop computer that will be attached to the CS4000 Mini Controller.
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8. Maintenance/Troubleshooting Maintenance of the CS4000 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. 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.
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 = 0.5A, 250V, subminiature PICO Littelfuse 255.
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: • Refer to Testing the Ethernet Network in Chapter 5.
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 from 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.
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.
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Chapter 9. Technical Information Figure 9-1.
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Chapter 9. Technical Information Figure 9-2.
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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 Etherflash.
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 O 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 Printe
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