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Chicago Pneumatic CS7000 manual

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Table of contents for the manual

  • Page 1

    December 2005 i CS7000 Controller Hardware Overview Manual With Ethernet/CCM Information for use with 177 and 277 Series Electric Fastening Tools CP Ref. / N O : 6159939130 Techmotive P/N : 39-30-41365 December 2005 CP Techmotive 22705 Heslip Drive Novi, Michigan 48375 USA 6159939130[...]

  • Page 2

    December 2005 ii 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[...]

  • Page 3

    December 2005 i LIMITED W ARRANTY 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. OR (2) one-million cycles except for the products noted below: CP Techmotive crowfoot, tubenut and hold & drive he[...]

  • Page 4

    6159939130 CS7000 Controller Hardware Overview Manual ____________________________________________________________________________________________ Page ii 39-30-41365 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 [...]

  • Page 5

    Preface December 2005 i 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 controlle[...]

  • Page 6

    6159939130 CS7000 Controller Hardware Overview Manual ____________________________________________________________________________________________ Page ii 39-30-41365 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,[...]

  • Page 7

    Preface ____________________________________________________________________________________________ December 2005 Page iii 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 I[...]

  • Page 8

    6159939130 CS7000 Controller Hardware Overview Manual ____________________________________________________________________________________________ Page iv 39-30-41365 (This page is left blank intentionally.)[...]

  • Page 9

    Contents December 2005 v Contents Who Should Use This Manual ............................................................................................... i How to Use This Manual ........................................................................................................ i Conventions .................................................[...]

  • Page 10

    6159939130 CS7000 Controller Hardware Overview Manual ____________________________________________________________________________________________ Page vi 39-30-41365 Grounding ........................................................................................................................... 3-4 I/O Wiring ..................................[...]

  • Page 11

    Contents ____________________________________________________________________________________________ December 2005 Page vii Figures Figure 2-1. Front Panel View ..................................................................................................2 -2 Figure 2-2. Turning the Rotary Actuator to the ON Position ..........................[...]

  • Page 12

    6159939130 CS7000 Controller Hardware Overview Manual ____________________________________________________________________________________________ Page viii 39-30-41365 (This page is left blank intentionally.)[...]

  • Page 13

    Chapter 1. Think Safety First! December 2005 1-1 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 persona[...]

  • Page 14

    6159939130 CS7000 Controller Hardware Overview Manual ____________________________________________________________________________________________ Page 1-2 39-30-41365 • 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[...]

  • Page 15

    Chapter 1. Think Safety First! ____________________________________________________________________________________________ December 2005 Page 1-3 Electrical Safety Only qualified and properly trained personnel should perform electrical/electronic troubleshooting and repair. Consider the following electrical system safety guidelines: • Before you[...]

  • Page 16

    6159939130 CS7000 Controller Hardware Overview Manual ____________________________________________________________________________________________ Page 1-4 39-30-41365 (This page is left blank intentionally.)[...]

  • Page 17

    Chapter 2. Identifying the Components December 2005 2-1 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 t[...]

  • Page 18

    6159939130 CS7000 Controller 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[...]

  • Page 19

    Chapter 2. Identifying the Components ____________________________________________________________________________________________ December 2005 Page 2-3 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 t[...]

  • Page 20

    6159939130 CS7000 Controller Hardware Overview Manual Page 2-4 39-30-41365 T op 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 Vie[...]

  • Page 21

    Chapter 2. Identifying the Components ____________________________________________________________________________________________ December 2005 Page 2-5 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. Inst[...]

  • Page 22

    6159939130 CS7000 Controller Hardware Overview Manual Page 2-6 39-30-41365 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[...]

  • Page 23

    Chapter 2. Identifying the Components ____________________________________________________________________________________________ December 2005 Page 2-7 Figure 2-5. Components Inside the Enclosure of the CS7000 Controller[...]

  • Page 24

    6159939130 CS7000 Controller Hardware Overview Manual Page 2-8 39-30-41365 Gen2 T ool 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. Front View of the TCM WARNING! ! ! ! ! [...]

  • Page 25

    Chapter 2. Identifying the Components ____________________________________________________________________________________________ December 2005 Page 2-9 The TCM has a small four-digit display, a column of nine indicator LEDs, and two potentiometers. The LEDs provide status and condition information about the connected nutrunner. The indicator LEDs[...]

  • Page 26

    6159939130 CS7000 Controller Hardware Overview Manual Page 2-10 39-30-41365 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 [...]

  • Page 27

    Chapter 2. Identifying the Components ____________________________________________________________________________________________ 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 [...]

  • Page 28

    6159939130 CS7000 Controller Hardware Overview Manual Page 2-12 39-30-41365 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 c[...]

  • Page 29

    Chapter 2. Identifying the Components ____________________________________________________________________________________________ December 2005 Page 2-13 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 Fr[...]

  • Page 30

    6159939130 CS7000 Controller Hardware Overview Manual Page 2-14 39-30-41365 (This page is left blank intentionally.)[...]

  • Page 31

    Chapter 3. Installing the CS7000 Controller December 2005 3-1 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 [...]

  • Page 32

    6159939130 CS7000 Controller Hardware Overview Manual Page 3-2 39-30-41365 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 ex[...]

  • Page 33

    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 pe[...]

  • Page 34

    6159939130 CS7000 Controller Hardware Overview Manual Page 3-4 39-30-41365 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 [...]

  • Page 35

    Chapter 3. Installing the CS7000 Controller ____________________________________________________________________________________________ December 2005 Page 3-5 Table 3-1. 19-Position Remote I/O Connector Pinout Signal Names and Descriptions (Continued) Pin Signal Description B Forward/Reverse input (White wire internal) (White wire - external) When[...]

  • Page 36

    6159939130 CS7000 Controller Hardware Overview Manual Page 3-6 39-30-41365 Table 3-1. 19-Position Remote I/O Connector Pinout Signal Names and Descriptions (Continued) Pin Signal Description M Discrete output #4* (White/Violet wire - internal) (Black/White wire - external)) J = Cycle Finish, K = Cycle Good, L = Cycle Bad, N = In Cycle. N Discrete o[...]

  • Page 37

    Chapter 3. Installing the CS7000 Controller ____________________________________________________________________________________________ December 2005 Page 3-7 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 r[...]

  • Page 38

    6159939130 CS7000 Controller Hardware Overview Manual Page 3-8 39-30-41365 Connector Pinout Definitions Pinout definitions are provided for the tool, I/O, TCM network, RS-232 and printer connectors. T ool Connector “26 pin” (Metal SMC) – Front V iew Pin Designation Wire Color (Ref) Function 1 RED POWER PHASE 2 5 ORN/WHT + 24 VOLTS 6 WHT/ORN C[...]

  • Page 39

    Chapter 3. Installing the CS7000 Controller ____________________________________________________________________________________________ December 2005 Page 3-9 I/O Connector – Front View Pin Designation Wire Color (Ref) Function A BLK CYCLE ON INPUT B WHT FORWARD/REVERSE INPUT C GRY DISCRETE INPUT #7 D YEL DISCRETE INPUT #8 E RED LIMIT SET SELECT[...]

  • Page 40

    6159939130 CS7000 Controller Hardware Overview Manual Page 3-10 39-30-41365 Printer/Computer/Diagnostics (RS-232) Connector – Front View Pin Designation Wire Color (Ref) Function 2 BLU RXD 3 GRN TXD 5 BLK GND 7 RED RTS 8 YEL CTS Programming the CS7000 Controller (In General) After you have mounted the controller and become familiar with its basic[...]

  • Page 41

    Chapter 4. Technical Information December 2005 4-1 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. Replacement Parts Qty. Description Part Number 1 50A TCM GEN[...]

  • Page 42

    6159939130 CS7000 Controller Hardware Overview Manual Page 4-2 39-30-41365 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 insid[...]

  • Page 43

    Chapter 5. Index December 2005 5-1 5. Index A AC input, 3-3 Input Receptacle, 2-5 address switches, 2-6 B backplane, 2-11 battery, 2-9 bottom panel, 2-1 C circuit breaker, 2-6, 2-13 Clear Outputs, 3-4 connector I/O, 2-6, 3-9 printer, 2-5, 3-10 RS-232, 2-5, 3-9 SDLC/485, 2-5, 3-9 tool, 2-5, 3-8 Cycle Bad, 3-6 Finish, 3-6 Good, 3-6 D Device Control M[...]

  • Page 44

    6159939130 CS7000 Controller Hardware Overview Manual Index-5-2 39-30-41365 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 R remote input circuit schematic, 3-7 repairs, 1-3 rotary actuator, 2-3 RS-232 connector[...]

  • Page 45

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  • Page 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[...]