CS4700/2700 Controllers Technical Reference for use with 46 and 66 Series Electric Fastening Tools and SD25 Electric Screwdrivers Rev 0.
xxxxxxxxxx CS2700/4700 Controllers Technical Reference_________________________________________ 24-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.
Safety: 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. Always use common sense and exercise caution when using these tools.
xxxxxxxxxx CS2700/4700 Controllers Technical Reference_________________________________________ • 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.
_____________________________________________________CS4100/2100 Controllers Technical Reference 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.
xxxxxxxxxx CS2700/4700 Controllers Technical Reference_________________________________________ Preface The CS4700/2700 controllers are functionally equivalent to the CS4100/2100. In fact, most of the internal electronics and software is identical. The CS4700/2700 packaging has been improved to be smaller and lighter. The CS4700/2700 Controller manufactured by CP techmotive tool is a component of one of the most powerful DC electric nutrunner fastening control systems available.
_____________________________________________________CS4100/2100 Controllers Technical Reference Conventions The following conventions are used throughout CP techmotive tool manuals for the safety of personnel, equipment, software, and data. (Not all of these conventions are used in every manual or guide.) The conventions include warnings, cautions and notes, as follows: WARNING! ! CAUTION! i NOTE: ? It can be dangerous to personnel and/or machine systems, if operating instructions are not followed.
xxxxxxxxxx CS2700/4700 Controllers Technical Reference_________________________________________ Table of Contents Product Dimensions, Weights and Power requirements .............................. 7 Product Compatibility Information ................................................................. 8 CS4700 Part Number Codes ............................................................................ 9 CS4700 General Information..........................................................................
_____________________________________________________CS4100/2100 Controllers Technical Reference Product Dimensions and Weight F1 F2 1 F3 2 ABC F4 3 DEF 4 5 6 GHI JKL MNO 7 8 9 PQRS TUV WXYZ . 0 +/- CLR ENTER DIMENSIONS in INCHES Weight: Approximate Weight = 30 LBS. (Weight will vary slightly depending on configuration) Input Voltage Requirements: CS2700 (115v) - 115vac +15%,-10%; 50/60 Hz (.5 to .75 kva recommended) CS2700 (230v) - 230vac +15%,-10%; 50/60 Hz (.5 to .
xxxxxxxxxx CS2700/4700 Controllers Technical Reference_________________________________________ Product Compatibility Information TCM compatibility 230v (or) 115/230v (Dual voltage capable) 230v (or) 115v (Screwdrivers) Revision & Part# It is generally recommended that 230vac (versus 115vac) be used in most industrial applications since periodic power loading can result in supply-line drops that could limit torque capability on soft-joint (demanding) torque applications The 4700 and 4746 (66 and 46 ser
_____________________________________________________CS4100/2100 Controllers Technical Reference Product Part Number Codes Product part# C4700 A 0 1 K 2 1 6 054 2 – Screwdriver 4 – 46/56/66 Codes for special options (See Below) 00 – 66/56 Series (or SD25 Screwdriver) 46 – 46 Series Pset Select Switch P – Present 0 – Not Present K – Keypad V – VS req’d 1 – 115V (C2100 only) 2 – 230V ** 2 – Standard Screwdriver conn.
xxxxxxxxxx CS2700/4700 Controllers Technical Reference_________________________________________ CS4700 General Information Units with Keypad/Display If the controller has a Keypad/Display, you may simply connect the tool, go into the Menu and select Defaults (pick TOOL I/O). This provides a quick way to get up and running immediately. On these units, you may prefer to use the Visual Supervisor (VS) program initially for even easier setup especially if the process is complex.
_____________________________________________________CS4100/2100 Controllers Technical Reference CCM+ Based Block Diagram FIELD Upgrade Considerations CS4700/4746/2700 Controllers are considered BASIC models if they have only a TCM. Adding a CCM makes the unit “Ethernet capable.” With the CCM in place, it is possible to add the Fieldbus capability and/or the Keypad/Display option.
xxxxxxxxxx CS2700/4700 Controllers Technical Reference_________________________________________ Units with CCM+ (Ethernet capable) All Flash updates can be done simply from the CS4700 Controller RS-232 computer port without going inside the box or moving any cables (as required of the original CCM units).
_____________________________________________________CS4100/2100 Controllers Technical Reference Location of Major Components CS2700 with Door open TCM Internal Frame of CS2700 AIM (Fieldbus Module) TDM CCM (Communications Module ) (Display Module) Internal ITI board Bottom Connector bd Backplane (CS2700 only) 24vdc power supplies Digital I/O power CCM & add-on option power Line Filter GFCI Circuit Breaker / On-Off switch ______________________________________________________________________
xxxxxxxxxx CS2700/4700 Controllers Technical Reference_________________________________________ Keypad/Display Operation Entering SETPOINTS Via the Keypad The detachable version of VS (VS loaded onto a laptop PC that is connected to the controller) can be used as an enhanced local programming facility, as not all setpoint functions are available via the keypad.
_____________________________________________________CS4100/2100 Controllers Technical Reference LIMITATIONS of the Keypad The optional Keypad/Display provides continuous information about torque, angle, parameter sets (psets) and cycle counts. It also allows you to select psets and change many setpoints from the keypad.
xxxxxxxxxx CS2700/4700 Controllers Technical Reference_________________________________________ Keypad Display Characteristics If a setpoint falls outside of the tool’s capability or internally contradicts the operation of the tool, the setpoint change will be rejected. You may still need to connect the VS program to address some setup issues.
_____________________________________________________CS4100/2100 Controllers Technical Reference Comm/Diag (Comm. RS232 Setup & Diagnostics ) A null-modem cable that provides an RS-232 connection (typically 9 pin-d female on both ends) is required for setup of the CCM module. This cable plugs into the CS4700 Mini Controller Comm/Diag port.
xxxxxxxxxx CS2700/4700 Controllers Technical Reference_________________________________________ Printer/Barcode (RS232 Printer output & barcode input) PRINTER PORT Characteristics: OUTPUT ONLY 9600 baud (8 data, no parity, 1 stop bit). Data stream is sent without handshaking following each cycle. ----------------SAMPLE PRINTER OUTPUT FORMAT (TCM backplane DIP Sw # 8 OFF)----------#0110 Sp:01-01 H 15.1 Nm L 3 Deg #0110 Sp: 01 01 H XX15.
_____________________________________________________CS4100/2100 Controllers Technical Reference BARCODE PORT Characteristics: INPUT ONLY 9600 baud (8 data, no parity, 1 stop bit). Note that this RS232 INPUT port will watch for specially formatted input strings for the purpose of AutoCal. from an instrument such as the M290 Torque Audit device. Refer to Visual Supervisor Manual for Barcode setup and capability details. Some of the selectable modes and options are as follows: 1. 2. 3. 4. 5. 6.
xxxxxxxxxx CS2700/4700 Controllers Technical Reference_________________________________________ Connecting to Visual Supervisor (Ethernet) . Setting Up and Configuring the Single-Channel Controller 1. 2. 3. 4. Determine the TCP/IP address information that will be designated for CS47XX/2700 Controller. On the console session above, use the “ipconfig” command to enter in this information. Typically; the mask may be something like 255.255.255.0; the Gateway 0.0.0.
_____________________________________________________CS4100/2100 Controllers Technical Reference Sample Console Session ____________________________________________________________________________________________ September 2005 Page 21
xxxxxxxxxx CS2700/4700 Controllers Technical Reference_________________________________________ Examples of Network Topologies (CS4100 = CS4700) ____________________________________________________________________________________________ Page 22 39-30-43083
_____________________________________________________CS4100/2100 Controllers Technical Reference Fieldbus Capabilities The CS4700 Contoller can interface to one field bus: DeviceNet, Profibus, Ethernet-IP and others are available in order to exchange I/O and data with PLCs and other devices. Only certain hard-coded data mapping configurations are available over fieldbus. Presently, enabling the fieldbus I/O and selecting the data type can be done via the Console/Debug port.
xxxxxxxxxx CS2700/4700 Controllers Technical Reference_________________________________________ FieldBus Data Mapping Types: Default - …………..Small General purpose data mapping Std (Standard) –…. Expanded output data and setpoints GM8 & GM4 - ……..
_____________________________________________________CS4100/2100 Controllers Technical Reference TYPE: Std (standard) Outputs Byte Bit Description 0 0 1 2 3 4 5 6 7 0-7 0-7 0-7 0-7 0-7 0-7 0-7 0-7 0-7 0-7 0-7 0-7 0-7 0-7 Parameter Set Selected Bit 0 Parameter Set Selected Bit 1 Parameter Set Selected Bit 2 Parameter Set Selected Bit 3 System Fault Cycle Finished Cycle Good Cycle Bad Peak Torque (IEEE Floating Point) Final Angle (16 bit integer, 0 to 65535) Torque HighLimit (IEEE Floating Point) Torque
xxxxxxxxxx CS2700/4700 Controllers Technical Reference_________________________________________ TYPE: GM8/GM4 Outputs NOTE: The difference between GM4 & GM8 is that GM8 mode adds the PVI on the inputs ? Byte Bit Description 0 0 1 2 3 4 5 6 7 0 1 2 3 4 5-7 0 1 2 3-7 0-7 Bypass Release 1 Job Unused Unused Parameter Set Selected Bit 0 Parameter Set Selected Bit 1 Parameter Set Selected Bit 2 Global Accept InCycle Unused System Fault Cycle Finished EPR Unused Good GM Red GM Yellow Unused Unused Byte
_____________________________________________________CS4100/2100 Controllers Technical Reference TYPE: Bcin (Barcode input) st NOTE: This option is 1 available in CCM version 1.10.
xxxxxxxxxx CS2700/4700 Controllers Technical Reference_________________________________________ TYPE: SEQ (Sequence Support) Outputs Byte 0 1 2 3 4-7 8-9 10-13 14-17 18-21 22-23 24-25 26-27 28-31 Bit Description 0 1 2 3 4 5 6 7 0 1 2 3 4 5 6 7 0 1 2 3 4 5 6 7 0-7 0-7 0-7 0-7 0-7 0-7 0-7 0-7 0-7 0-7 Sequence Set Selected Bit 0 Sequence Set Selected Bit 1 Sequence Set Selected Bit 2 Sequence Set Selected Bit 3 (Gen2 only…..
_____________________________________________________CS4100/2100 Controllers Technical Reference Determining INPUT Sources It is possible that INPUTS can enter into the single-channel CS4700 Controller from several sources. Below is a list of some potential sources and their relative priority. 1. 2. 3. 4. 5. VsSetup assignments a. Tool switches b. Digital inputs (via a 19-pin connector etc.) c.
xxxxxxxxxx CS2700/4700 Controllers Technical Reference_________________________________________ For reference, the table below shows the input mapping for the DCM when one of the above defaults (in the prior table) is selected. (For GM- or FORD-specific default input mapping, see the GM/Ford special applications section). DCM Input DEFAULT#1 Input#1 Input#2 Input#3 Input#4 Input#5 Input#6 Input#7 Input#8 Tool Cycle trig. Sync. Calibrate Tool Direction Sw Tool Aux. Sw.
_____________________________________________________CS4100/2100 Controllers Technical Reference DeviceNet (Slave) Setup and Configuration Anybus DeviceNet card AIM board (see AIM section) . 5-pos DeviceNet connector (see below for pinout) 8 Position Dip switch settings on “DeviceNet” card DeviceNet Baud Rate 125k 250k 500k (Reserved) 5 SW.1 OFF OFF ON ON SW.
xxxxxxxxxx CS2700/4700 Controllers Technical Reference_________________________________________ Fieldbus Diagnostics Example for DeviceNet (Debug Console) >aim Anybus Interface Module is active. HW Config: 00, SW Version: 1.01 I/O mode: gm4 (4 bytes in, 4 bytes out) Anybus Module is attached. Vendor ID: 1 Serial Number: A0017B83 Module SW Version: 1.09 Boot Loader Version: 1.34 Fieldbus Type: 25 - DeviceNet Dip Switches: 0xBC Address: 60 Baudrate: 500 AppInt SW Version: 2.16 Fieldbus SW Version: 1.
_____________________________________________________CS4100/2100 Controllers Technical Reference Profibus (Slave) Setup and Configuration Profibus Module Status Indicators: Once the controller is powered up and the profibus module is initialized, LED #3 will be red, and all others will be off. Once communications is established with the master, LED#2 will be green, and all others will be off.
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_____________________________________________________CS4100/2100 Controllers Technical Reference Profibus Network Configuration Before the module can be used on a Profibus-DP network some basic settings must be configured. Baud Rate The baud rate on a Profibus-DP network is set during configuration from the master. The module features auto baud rate detection and the user does not have to configure the baudrate. Supported baud rates: 1. 9.6 kbit/s 2. 19.2 kbit/s 3. 45.45 kbit/s 4. 93.75 kbit/s 5. 187.
xxxxxxxxxx CS2700/4700 Controllers Technical Reference_________________________________________ Fieldbus Diagnostics Example for Profibus (Debug Console) ======================================================================= Profibus ======================================================================= aim > Anybus Interface Module is active. HW Config: 00, SW Version: 1.02E I/O mode: default (1 byte in, 7 bytes out) Anybus Module is attached.
_____________________________________________________CS4100/2100 Controllers Technical Reference Ethernet/IP or Modbus/TCP (Slave) Setup and Configuration ____________________________________________________________________________________________ September 2005 Page 37
xxxxxxxxxx CS2700/4700 Controllers Technical Reference_________________________________________ NOTE: ? Ethernet-IP/Modbus-TCP are considered fieldbus entities. Look for the settings to be “AIM” commands rather than “ipconfig” commands. How to change between Ethernet IP and Modbus TCP Server Modes To set to Modbus mode using the diags console, at the console prompt type aim config +modbus, then press enter. This will disable the EthernetIP server on the anybus module.
_____________________________________________________CS4100/2100 Controllers Technical Reference Fieldbus Diagnostics Example for Ethernet-IP Setup (Debug Console) ======================================================================= EthernetIP (or Modbus-TCP) ======================================================================= aim > Anybus Interface Module is active. HW Config: 00, SW Version: 1.01 I/O mode: gm4 (4 bytes in, 4 bytes out) Anybus Module is attached.
xxxxxxxxxx CS2700/4700 Controllers Technical Reference_________________________________________ Optional PC-boards (Technical Details) . Communications Control Module (+) (CCM - CP p/n 420981-40311) JP1 – Battery connect to non-volatile memory RS-232 Diag RS-232 Flash/VS Remote LEDs Ethernet 10-base-T Battery #DL2430 (JP3) X-bus (CAN) Termination jumper SDLC to external network 24 VDC in/out CCM PLUS MAC address etc.
_____________________________________________________CS4100/2100 Controllers Technical Reference CCM FIELD UPDATES The CCM may require software updates in the field. CP Techmotive’s Winflash utility should work as it does normally with the existing TCM product. When the CCM PLUS is used, the RS-232 port that is used for VS-detachable now also becomes the FLASH port for DCM,CCM and all internal boards downstream from the CCM.
xxxxxxxxxx CS2700/4700 Controllers Technical Reference_________________________________________ downstream devices, the baud rate and the termination resistor do not matter. Typically, these will be set properly at the factory, but this could become an issue on a field-upgrade. If the baud rates are wrong, the devices will not communicate at all.
_____________________________________________________CS4100/2100 Controllers Technical Reference TDM Module (CP part# 421000-41298) (Used in Keypad/Display option) 24vdc LED To LED Display backlight (Flash port (Direct to PIC) 24vdc in/out 5v LED2 To Display New REV. TDM’s J17 – LED Y J16 - LED G J15 - LED R CAN in/out R,G,Y connector Sw.2 Sw.3 0 0 1 0 0 1 1 1 Sw.1 = CAN Baud 125k 250k 500k* 20k RS-232 (Not used) To Keypad Blinks if running Key-press CCM comm.
xxxxxxxxxx CS2700/4700 Controllers Technical Reference_________________________________________ SPECIAL APPLICATION: PFCS (Ethernet or Terminal Server) Important note: CCM1.12 adds the ability to configure PFCS without the need to enter nd into the console for units with a keypad/display. The CCM’s SW2 (2 dip switch) can force PFCS to be enabled. A special menu will then be available which will permit all of the PFCS configurations. Setting up to Link to a PFCS Host on Ethernet 1. 2. 3. 4. 5. 6.
_____________________________________________________CS4100/2100 Controllers Technical Reference If controller is equipped with a “Keypad Display” The DIAG screen on the display will show the condition of the PFCS connection as either “OK” or “Err”. Whether the unit has a “Keypad Display” or not, the console can provide more extensive diagnostics information.
xxxxxxxxxx CS2700/4700 Controllers Technical Reference_________________________________________ Max Retries :3 Ack Timeout : 5 seconds Keep Alive Interval : 120 seconds Reconnect Interval : 10 seconds Machine ID assigned by PFCS. Barcode disabled. Result buffering disabled. >pfcs port 16101 PFCS is enabled. PFCS Server Address : 10.120.16.116 PFCS Server Port : 16101 Max Retries :3 Ack Timeout : 5 seconds Keep Alive Interval : 120 seconds Reconnect Interval : 10 seconds Machine ID assigned by PFCS.
_____________________________________________________CS4100/2100 Controllers Technical Reference SPECIAL APPLICATION: GM (General Assembly Engineering) The CS47XX/2700 Controller has an Ethernet interface that complies with the latest specification for sending data to the GM server. It also has a DeviceNet interface that complies with the GM specification.
xxxxxxxxxx CS2700/4700 Controllers Technical Reference_________________________________________ In order to meet this specification and the required light patterns for all of the various conditions (not shown here) here are some rules to setting up the controller: 1. The “GM” Red/Yellow/Green lights must be mapped instead of the standard R/Y/G lights (This should already be done if “Defaults” were loaded after the box was set to GM mode) 2.
_____________________________________________________CS4100/2100 Controllers Technical Reference Console/keypad based Default selections: 3* - Typical Selection DEFAULT# 1 2 3* 4 Parameter Set Select Tool Running control Fieldbus Fieldbus DCM physical I/O Keypad Fieldbus Operator switches on tool Operator switches on tool Operator switches on tool Default Selection (DCM inputs) table (GM MODE): DCM Input Input#1 Input#2 Input#3 Input#4 Input#5 Input#6 Input#7 Input#8 Tool Cycle trig.
xxxxxxxxxx CS2700/4700 Controllers Technical Reference_________________________________________ CONNECTOR PIN DEFINITIONS 5 Pin-DIN male Device-Net Connector Turck #RSF 571-2M/S630 PIN 1 2 3 4 5 Description Shield No connection within CS4100 (24v field) Isolated Common (Device-Net Ground ) CAN_H CAN_L Optional Bypass/Release Pendant Connector Optional Stack-Light Connector 4-pin Micro Female Connector Crouse-Hinds #5000118-4 5-pin Micro Female Connector Crouse-Hinds #5000129-332 Field mate: Turck #
_____________________________________________________CS4100/2100 Controllers Technical Reference SPECIAL APPLICATION: FORD The CS47XX has an Ethernet interface compliant with Ford specification PF3000.The basic steps to setup a CS47XX controller for Ford follows: Note that the CCM DipSwitch SW2 Swtich# 2 & 3 can force the FORD drivers without the console. Also, units with the keypad/display can be used to setup most/all of the required settings. 1. 2.
xxxxxxxxxx CS2700/4700 Controllers Technical Reference_________________________________________ SPECIAL APPLICATION: Screwdrivers When setting up the CS2700 Controller for use with an SD25 Series screwdriver the VS Default settings are used to map the I/O to fit typical screwdriver applications. A typical function times the operation of the headlights to the Cycle Start mode of operation. However, when it is set up for typical operation, the CS2700 Controller does not comply with GM specifications.
_____________________________________________________CS4100/2100 Controllers Technical Reference General Troubleshooting (Basic) CONTROLLER TYPE Symptom Possible Solution CS4700/2700 Controller (Any configuration) Tool Won’t run 1. No tool detected scrolling message * Suspect tool/ITI board * Suspect TCM 2. Invalid Parameters scrolling message * Hook up VS (run VsSetup & Correct) 3. No LIGHTS on TCM * Verify circuit breaker/GFCI * If TCM is Rev.K or higher, the fuse on the TCM servo may be blown.
xxxxxxxxxx CS2700/4700 Controllers Technical Reference_________________________________________ General Block Diagram (Data/History/Barcodes) ____________________________________________________________________________________________ Page 54 39-30-43083
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