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Chapter 3. Installing the CS7000 Controller

____________________________________________________________________________________________
December 2005

Page 3-3

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.

NOTE:

????

The maximum no-load speed of a nutrunner is based on a
nominal AC input voltage of 220V depending on the type of
controller; if the actual input voltage is lower, the maximum no
load speed of the nutrunner will be lower than specified.

CAUTION!

Failure to provide the proper power source can cause the
following problems in your CS7000 Fastening System:

•

The nutrunner might shut down before it reaches the
target torque during a rundown cycle.

•

The nutrunner might not operate when a cycle-on
signal is applied to the system.

•

The maximum free speed of the nutrunner might be
lower than specified.

Input Power Protection

A circuit breaker or fuses positioned between the AC input and the servo amplifier provides the
controller with short circuit protection.

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Содержание CS7000

Страница 1: ...dware Overview Manual With Ethernet CCM Information for use with 177 and 277 Series Electric Fastening Tools CP Ref NO 6159939130 Techmotive P N 39 30 41365 December 2005 CP Techmotive 22705 Heslip Drive Novi Michigan 48375 USA 6159939130 ...

Страница 2: ... part number 6150040915 NOTE A variety of related technical manuals in pdf format may be downloaded from www cp com Click on the Technical Info link on the left column Select Technical Documentation Scroll through the list to find the title of the product you require and click CP Techmotivemanufactures products under the CP CP Techmotive and tech motive tool brand names Information and technical d...

Страница 3: ...he Buyer CP Techmotive only that the PRODUCTS shall be free of defects in materials and workmanship and offers no other warranty In the event that a product is repaired or replaced under the terms of the warranty the warranty period for the repaired or replacement product shall be limited to the remaining portion of the original warranty Any warranty extended by the original manufacturer of periph...

Страница 4: ... 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 Tool Label Controller Label To complete the survey 1 Visit our website www cp com and click www gsetechmotive com 2 Click the Customer Satisfaction Survey link located below the gray buttons ...

Страница 5: ...e and a CP techmotive 177 or 277 Series nutrunner The powerful CP techmotive Visual Supervisor software program is used for system setup fastening data collection and diagnostics Who Should Use This Manual This manual is written for the engineers technicians and users who will set up and or operate the CS7000 Controller with any of the Intelligent 177 and 277 Series nutrunners How to Use This Manu...

Страница 6: ...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 CAUTION There may be damage to equipment and loss of software and data if operating instructions are not followed The information is indented and in italicized boldface type NOTE Inform...

Страница 7: ...hnical 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 peripheral component interconnect TCM tool control module TCP IP transmission control protocol internet protocol RAM random access memory SDLC synchronous data link control STM sta...

Страница 8: ...159939130 CS7000 Controller Hardware Overview Manual ____________________________________________________________________________________________ Page iv 39 30 41365 This page is left blank intentionally ...

Страница 9: ...32 Connector VS Setup 2 5 SDLC 485 I O Network Connector Optional 2 5 Ethernet 10Base T and 9 pin D Communications Diag Setup 2 5 I O Connector 2 6 Enclosure Interior 2 6 Gen2 Tool Control Module TCM 2 8 Servo Amplifier 2 9 Gen2 Device Control Module DCM 2 9 Communications Control Module CCM Optional 2 10 Backplane 2 11 Backplane Fuses 2 11 DIP Switch Settings 2 12 Power Supply 2 12 Ground Fault C...

Страница 10: ...r 26 pin Metal SMC Front View 3 8 I O Connector Front View 3 9 TCM IN and OUT Network Connectors Front View 3 9 RS 232 Connector Front View 3 9 Printer Computer Diagnostics RS 232 Connector Front View 3 10 Programming the CS7000 Controller In General 3 10 Programming the CS7000 with Ethernet CCM 3 10 4 Technical Information 4 1 Replacement Parts 4 1 Cleaning the Enclosure Window 4 1 Assembly Drawi...

Страница 11: ...re of the CS7000 Controller 2 7 Figure 2 6 Front View of the TCM 2 8 Figure 2 7 Communications Control Module CCM 2 10 Figure 2 8 CS7000 Controller Backplane 2 11 Figure 2 9 Ground Fault Circuit Interrupter 2 12 Figure 3 1 CS7000 Controller Dimensions of the Front and Bottom Panel 3 2 Figure 3 2 Remote Input Circuit Schematics 3 7 Tables Table 3 1 19 Position Remote I O Connector Pinout Signal Nam...

Страница 12: ...59939130 CS7000 Controller Hardware Overview Manual ____________________________________________________________________________________________ Page viii 39 30 41365 This page is left blank intentionally ...

Страница 13: ...ry might occur CP techmotive 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 can result in serious personal injury General Machine Safety FOR YOUR OWN SAFETY READ THE INSTRUCTION...

Страница 14: ...cation 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 MAINTAIN TOOLS IN TOP CONDITION Keep tools properly lubricated and clean If any wires become frayed or expose...

Страница 15: ...n 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 attemp...

Страница 16: ...59939130 CS7000 Controller Hardware Overview Manual ____________________________________________________________________________________________ Page 1 4 39 30 41365 This page is left blank intentionally ...

Страница 17: ...igned 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 ...

Страница 18: ...ler Hardware Overview Manual Page 2 2 39 30 41365 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 Front Panel View ...

Страница 19: ... positions of the disconnect switch Turn the rotary actuator clockwise to turn on power to the controller The arrow on the rotary actuator must rotate 90 degrees from to as shown in Figure 2 2 Figure 2 2 Turning the Rotary Actuator to the ON Position Parameter Select Switch The parameter select switch selects the next parameter set that will be used by the tool The limits for the parameter set are...

Страница 20: ...65 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 Bottom Panel View ...

Страница 21: ...tput connector allows you to communicate with the controller using a laptop computer The laptop computer runs the VS software program that allows you to program torque or torque and angle limits and operating modes into the controller Refer to the Visual Supervisor User s Guide part number 39 30 34823 for details NOTE The laptop computer also allows you to program also referred to as flash the lat...

Страница 22: ...te control and or monitoring devices such as external annunciator lamps or remote cycle on contacts Refer to I O Wiring in Chapter 3 Installing the CS7000 Controller for pinout details Enclosure Interior The enclosure interior for the CS7000 Controller includes the following components and sub components Sub panel that includes Disconnect switch Power supply 24 VDC Circuit breaker Fuses Ground fau...

Страница 23: ... Identifying the Components ____________________________________________________________________________________________ December 2005 Page 2 7 Figure 2 5 Components Inside the Enclosure of the CS7000 Controller ...

Страница 24: ...tool are referred to as a spindle The TCM houses both the servo amplifier and DCM Figure 2 6 Front View of the TCM WARNING 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 A bus voltage present light on the front of the unit will extinguish when the bus voltage has dropped below approxim...

Страница 25: ... DC motor controller that provides electrical power to the nutrunner motor It receives control signals from the 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 Additionall...

Страница 26: ...ity 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 Communications Control Module CCM ...

Страница 27: ...____________ December 2005 Page 2 11 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 ...

Страница 28: ...hrysler Plant Floor Communication System PFCS formatting Power Supply A 1 3A 24V power supply provides power for external I O use Ground Fault Circuit Interrupter GFCI The 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...

Страница 29: ... 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 ...

Страница 30: ...6159939130 CS7000 Controller Hardware Overview Manual Page 2 14 39 30 41365 This page is left blank intentionally ...

Страница 31: ...y 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 Also be sure to allow space to open the door on the enclosure CAUTION Mount the CS7000 Controller away from moving machinery and lift trucks on a structure that does not vibrate Do not mount the CS7000 Controller near large electrical system...

Страница 32: ... 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 ...

Страница 33: ...load speed of a nutrunner is based on a nominal AC input voltage of 220V depending on the type of controller if the actual input voltage is lower the maximum no load speed of the nutrunner will be lower than specified CAUTION Failure to provide the proper power source can cause the following problems in your CS7000 Fastening System The nutrunner might shut down before it reaches the target torque ...

Страница 34: ...oes not accommodate I O 9 through 12 These extended I O must be wired to the backplane directly if they are required DCMII revision 3 00 or higher also supports 128 parameter sets and 16 sequences NOTE The 14 shell 19 pin strain relief mating connector for the I O connector is part number 23 10 5200 PT06A 14 19P SR Table 3 1 19 Position Remote I O Connector Pinout Signal Names and Descriptions Pin...

Страница 35: ...aults is clicked VS sets these three inputs to select which of the eight internal limit or parameter sets are used for a fastening cycle as follows F Limit Set Select B1 input Green wire internal Blue wire external Limit Set B2 Input B1 Input B0 Input 1 inactive inactive inactive 2 inactive inactive active 3 inactive active inactive 4 inactive active active 5 active inactive inactive 6 active inac...

Страница 36: ...e 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 R Synchronization in out White Orange wire internal Orange Red wire external NOTE This feature only functions when JP8 and JP9 are set to defaults S Output common White Brown wire internal Blue white wire ...

Страница 37: ...or input requirements Table 3 2 Guidelines for Proper Operation of the Controller I O Signals Discrete Inputs Unit Highest permissible input voltage 30 V Lowest permissible input voltage 5 V Minimum guaranteed input activation 10 V Maximum guaranteed input deactivation 1 5 V Discrete outputs Unit Maximum output current 360 mA Maximum voltage 28 Volts DC NOTE Installing J8 supplied 24 VDC to output...

Страница 38: ...nt View Pin Designation Wire Color Ref Function 1 RED POWER PHASE 2 5 ORN WHT 24 VOLTS 6 WHT ORN COMMON 12 WHT BR CLK 13 BR WHT CLK 14 BLU WHT TXD 15 WHT GRN RXD 16 GRN WHT RXD 19 GRN POWER SHIELD 20 WHT POWER PHASE 1 21 BLK POWER PHASE 3 22 GRN RESOLVER SHIELD 23 GRN SIG SHIELD 25 GRN YEL TOOL FRAME GRD 26 WHT BLU TXD Nos not listed No connection 10 WHT RED RESOLVER R1 11 WHT BLK R2 8 WHT S1 24 W...

Страница 39: ... WHT BLK DISCRETE OUTPUT 1 FINISHED K WHT RED DISCRETE OUTPUT 2 ACCEPT L WHT GRN DISCRETE OUTPUT 3 REJECT M WHT YEL DISCRETE OUTPUT 4 N WHT BLU DISCRETE OUTPUT 5 P WHT GRY DISCRETE OUTPUT 6 R WHT GRN SYNC IN OUT S WHT BRN OUTPUT COMMON T BU 24V U BRN DISCRETE OUTPUT 7 V VIO SYNC COMMON TCM IN and OUT Network Connectors Front View Pin Designation Wire Color Ref Function A BRN WHT TXD OUT B WHT BRN ...

Страница 40: ...nterfaces to many Customer specific networks Also future capabilities will include Fieldbus and Keypad displays A Null modem cable that provides an RS 232 connection Typically 9 pin d female on both ends will be required for setup of the CCM module This cable will plug into the CS7000 communications diagnostics port If using Hyper terminal use 9600 baud 8 data no parity and one stop bit Hit the En...

Страница 41: ... Power Supply 12 20 5007 1 Fuse 1A SB Littelfuse 39001 5x20 mm 13 10 61001 2 Fuse 20A MDA 20 13 10 0555 NOTE All part numbers used in Table 4 1 are CP techmotive part numbers unless otherwise specified Cleaning the Enclosure Window Use only water based cleaners to clean the plastic window Other solvents may damage the window Assembly Drawings Assembly and wiring diagrams are available for the CS70...

Страница 42: ...ccess 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 Alternatively you can also contact CP techmotive at 42860 Nine Mile Road Novi MI 48375 4122 ...

Страница 43: ...al purpose input 3 4 E electrical drawings 1 3 fires 1 3 hazards 1 3 wiring 1 3 enclosure components 2 7 interior 2 1 window 4 1 extinguishers 1 3 F front panel 2 1 fuse 1 3 4 1 pullers 1 3 substitutes 1 3 G ground fault circuit interrupter 2 6 2 12 I I O cable 3 1 connector 2 6 3 9 Port 2 6 power 2 6 input active 3 6 inactive 3 6 Input AC Receptacle 2 5 L latch 2 3 LED 2 9 LED display 2 3 M Manua...

Страница 44: ... programmable discrete output 3 6 R remote input circuit schematic 3 7 repairs 1 3 rotary actuator 2 3 RS 232 connector 2 5 3 9 port 2 5 S safety glasses 1 3 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 T tool cable 3 1 Tool Connector 2 5 3 8 Tool Control Module 2 8 top panel 2 ...

Страница 45: ... This page left blank intentionally ...

Страница 46: ...Index 5 2 39 30 41365 www cp com Please find your local contact at www cp com U S English Printed in USA Copyright 2005 CP techmotive Novi MI USA ...

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