SPX Cooling Technologies CS4000 manual

CS4000 Mini Controller with Ethernet Techni cal Reference Manual[...]

24-Hour Technical Suppor t Toll Fr ee: 1-877-224-7377 SPX GSE tech-motive tool manufactures products under the GSE and tech-motive tool ® brand names.[...]

Please Note: has a new name. W e are now This change of name is not yet reflected in the documentation for this product w here you w ill still find the old logo and company name. The new address is: SPX GSE tech-motive tool 42860 Nine M ile Road, Novi M I 48375-4122 The toll free service number remains the same: 1-877-224-7377.[...]

LIMITED W ARRANTY 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 y ear from the date of shipment from the manufacturing facility. Th[...]

A ck now le dgments Special thanks are extended to the follow ing SPX GSE tech-motive tool m ana ge ment, soft war e and hardw are engineers w ho provided value information in the development and revi ew of this m anual. Jim Gren ier Tom Joz w ia k Ken Leho czk y Larr y Piggins Rick Szwast Steve Urbansk i Bill Welch Karen R. Francis, tech nical w r[...]

May 2002 T-38324-A Page iii Preface The GSE tech-motive tool CS4000 Mi ni Control ler wi th Ethern et typi cally is used w ith tech-motive tool Intelligent nutrunners in a multi-spindl e fastening system that communicates w ith ot he r ope rations in an ass embly process over an Ethern et netw ork. When used in this context, th e controller contain[...]

CS4000 Mini Controller with Ethernet Page iv T-38324-A 39-30-38324 If y ou w ant to us e the CS4000 Min i Controlle r with Ethernet w ith a netw ork or laptop com puter, refe r to Chapter 5. Setting Up the Ethernet, Chapter 6. Setting Up the 485 N etwork and Chapter 7. Setting Up the RS-232 Link th at describe the m ethods by w hich y ou can con ne[...]

Preface May 2002 T-38324-A Page v A bbrev iations Some of the most c ommon abb r eviati ons used througho ut this manual i nc lude t he foll o wing: API Application Program In terface GFCI Ground Fault Circuit Interrupter I/O Input /Outpu t IEEE Institute of Electrical an d Electronic Engineers IP Intern et Protocol kbps kilo-bits per second kVA ki[...]

CS4000 Mini Controller with Ethernet Page vi T-38324-A 39-30-38324 (This page is left blank intentionally .)[...]

May 2002 T-38324-A Page vii Contents Preface ....................................................................................................................... . ........... iii W ho S hould Use T h is M a nua l ....................................................................................... iii How to Use T h is M a nua l .............[...]

CS4000 Mini Controller with Ethernet Page viii T-38324-A 39-30-38324 E n c l o s u r e Int e r i o r ......................................................................................................... 3-6 T ool Cont r ol Modul e ................................................................................................. 3 - 8 Ser v o A m[...]

Contents May 2002 T-38324-A Page ix 7. Se tt ing Up t h e RS - 232 Lin k .......................................................................................... 7 - 1 S e tting Up V i s u a l S up e r v i s or ...................................................................................... 7-1 Usi ng RS - 232 Ca b le s ....................[...]

CS4000 Mini Controller with Ethernet Page x T-38324-A 39-30-38324 Figures Figu r e 1 - 1. E x a m ple of an Ethe r net Net w o r k w i th a Conne c ted Po r table Lapto p ............. 1 - 3 Figu r e 1 - 2. E x a m ple of a 485 Net w o r k .............................................................................. 1 - 5 Figu r e 3 - 1. F r ont P[...]

Contents May 2002 T-38324-A Page xi F i gu r e 6 - 1. VS M ain.ini c on f igu r ed f or a 485 Net w o r k ........................................................ 6 - 2 Figure 6-2. Net w ork Addre ss DIP S w it c h Set f or Addre ss ‘5 ’ ............................................ 6-5 F i gu r e 9 - 1. CS4000 Mini Cont r oller w i th Ethe r ne[...]

CS4000 Mini Controller with Ethernet Page xii T-38324-A 39-30-38324 (This page is left blank intentionally .)[...]

May 2002 T-38324-A Page 1-1 1. Overview The GSE tech-motive tool C S4000 Mini Con troller w ith Eth ernet is th e control com ponent of one of the most po werful DC ele ctric nutrunner fastening c o ntro l systems availab l e. T he system uses 100% digital technology to ensure accurate and reliable fastenin g, and torque angle data acquisition. Mic[...]

CS4000 Mini Controller with Ethernet Page 1-2 T-38324-A 39-30-38324 • A digital I/O com mun ications link, using the optional Interbus-S digital I/O m odule in the controller. The Interbus-S m odule does not connect the controller to a netw ork, but does allow I/O comm unications betw een the cont roller and a Programm able Logic C ontroller (PLC[...]

Chapter 1. Ov erview May 2002 T-38324-A PRELIMINA RY DRA FT Page 1-3 Example of a “Permanent” (Embedded) Ethernet Netw ork (Using M i ni Control l e r s w ith Ethernet) NOTE: Each contr oller is attached to the hub, whic h is in turn attached to the hos t computer. Visual Super visor provides data c ollection, diagnostic s and configuration fun[...]

CS4000 Mini Controller with Ethernet Page 1-4 T-38324-A 39-30-38324 Using a 485 Netw ork using SDLC In a 485 net work, t he controller i s linke d to a LAN, v ia cable betw een the f irst controll er’s RS- 485 connector an d the port f or the Sy nchronou s Data Li nk Cont rol (SDLC) card i nstalled on the host compu ter. Each controlle r in the 4[...]

Chapter 1. Ov erview May 2002 T-38324-A PRELIMINA RY DRA FT Page 1-5 Example of a “Permanent” (Embedded) 485 Netw ork (Using CS4000 KDM and M ini Controllers w i th SDLC) Figure 1-2. Example of a 485 Network NOTE: The computer is attached to the firs t controller, the firs t controller is attached to the second c ontroller, and so on until the [...]

CS4000 Mini Controller with Ethernet Page 1-6 T-38324-A 39-30-38324 Using the RS-232 Serial Po rt In this config uration, a laptop P C loaded with the Visu al Supervisor software is linked to the controller’s RS-232 serial port. S ee Figure 1- 1 on page 1-3. Becau se the laptop can be discon nected from one Min i Controller and reconnected to ano[...]

Chapter 1. Ov erview May 2002 T-38324-A Page 1-7 Using the Siemen s 3964R Barcode Proto col The RS- 422 port on the con troller support s the Siem ens 3964R barcode protocol. This protocol provides an error checked poin t-to-poin t met hod of sen ding barcode data to t he controller. If the controller receives a corrupt or incom plete barcode, the [...]

CS4000 Mini Controller with Ethernet Page 1-8 T-38324-A 39-30-38324 (This page is left blank intentionally .)[...]

May 2002 T-38324-A Page 2-1 2. Think Safety First! Working wi th fast ening t ools can be dang erous if s afe and proper procedu res are not foll owed. A s w ith all machin ery, certain h azards can be involved w ith the operation of the produ ct. Using these tools with respect and caution w ill co nsiderably lessen the possibility of personal inju[...]

CS4000 Mini Controller with Ethernet Page 2-2 T-38324-A 39-30-38324 General Machine Safety • FOR YOUR OWN SAFETY READ T HE INSTRUCTION MANUAL THOROUGHLY PRIOR TO OPERATING THE TOOL. • DO NOT WORK IN A DANGEROUS ENVIRONMENT. Do not us e power tool s in a damp or wet location or expose them to rain, oils, or corrosive fluids. • KNOW T HE LOCATI[...]

Chapter 2. Think Safety First! May 2002 T-38324-A Page 2-3 • MAIN T AI N TOOLS IN TOP CONDITION. Keep tools prope rly lubrica ted and cle an. If any wires become fray ed or exposed, replace them im mediately . Prevent dirt, grease or contaminants from getting into the tool. • REDUCE THE RISK OF UNINTENTIONAL STARTING. Be caref ul how the t ool [...]

CS4000 Mini Controller with Ethernet Page 2-4 T-38324-A 39-30-38324 • Alway s use fuses of a capacity sm aller than or equal to the safe capacity of the line or the equipment it serv es. • Before you work on any circuit, check it with an appropriate testing device to be sure voltag e is not present. • I nstall temporary w iring as safely as p[...]

May 2002 T-38324-A Page 3-1 3. Identify ing the Components The CS4000 Min i Controller w ith Ethernet houses all the standard f uncti ons of th e standard CS4000 Mini Controller, but also has the ability to commun icate across an Ethernet Local Area Netw o rk (LA N) usin g the st andard Ethernet protocol, Transm ission Control Protocol /Internet Pr[...]

CS4000 Mini Controller with Ethernet Page 3-2 T-38324-A 39-30-38324 Front Panel Figu re 3-1 show s the fron t panel com ponents of the CS 4000 Mini Cont roller w ith Ethe rnet. Figure 3-1. Front Panel View NOTE: The AC power c ord is desc ribed in the Top and Bottom Panel section later in this chapter. LED Display The LED display show s you th e to[...]

Chapter 3. Identify ing the Components May 2002 T-38324-A Page 3-3 Parameter Set Switch Turn the dial to select the parameter set y ou w ish to use for the nex t rundown . Select parameter sets using th e parameter set switch or Visual Supervisor. Access Screws The access screw s keep the f ront panel of th e controller fasten ed. T o un-fasten the[...]

CS4000 Mini Controller with Ethernet Page 3-4 T-38324-A 39-30-38324 Figu re 3-3 show s the bottom panel com ponents of the C S4000 Mini Con troller w ith Eth ernet. Descriptions are prov ided in clockw ise order, starting w ith the I/O connector. Figure 3-3. Bottom Panel View I/O Connector The 19-position remote I/O connector provides the interface[...]

Chapter 3. Identify ing the Components May 2002 T-38324-A Page 3-5 Tool cables are available in lengt hs of: • 3 ft / 0.91 m (part n umber 51- 3066-0003) • 6 ft / 1.83 m (part n umber 51- 3066-0006) • 10 ft / 3.05 m (part n umber 51- 3066-0010) • 15 ft / 4.57 m (part n umber 51- 3066-0015) • 30 ft / 9.14 m (part n umber 51- 3066-0030) •[...]

CS4000 Mini Controller with Ethernet Page 3-6 T-38324-A 39-30-38324 Fuses Fuse 1 an d Fuse 2 are 15A, 250V, SL O-BLO fus es, Littelfu se 326015 or equivalen t (part nu mber 13-10- 1015). Enclosure Inte rior The enclosu re interior for th e CS4000 Mini C ontroller w ith Eth ernet inclu des the foll owing compon ents an d sub-com ponent s: • Tool C[...]

Chapter 3. Identify ing the Components May 2002 T-38324-A Page 3-7 Figure 3-4. Components Inside the Enclosure of the CS4000 Mini Controller with Ethernet NOTE: The AC power c ord is desc ribed in Top and Bottom Panel earlier in this chapter. Backpla ne Ethernet I nterfac e Card Exte rior Wall AC Power Cord Tool Control Module Power Supply Interbus[...]

CS4000 Mini Controller with Ethernet Page 3-8 T-38324-A 39-30-38324 T ool Control M odul e The Tool Control Module (TCM), show n in Figu re 3-5, is a device th at controls a sing le DC electric tool. The TCM and its attached tool are referred to as a spindle. The TCM houses both th e servo ampl ifier and Dev ice Control Modu le (DCM). For th e loca[...]

Chapter 3. Identify ing the Components May 2002 T-38324-A Page 3-9 The TCM has a small four-digit display , a column of nin e indicator LEDs, and two potentiometers. The LEDs p rovid e status and c onditio n information ab out the co nne cted nutr unner. T he indic ator LEDs are labeled: • READY • ANGLE HI • GOOD • ANGLE LOW • BAD • SPI[...]

CS4000 Mini Controller with Ethernet Page 3-10 T-38324-A 39-30-38324 Servo Amplifier The servo am plifier is a three- phase, brush less DC m otor controller that provides electrical pow er to the nutrunner motor. I t r eceives control signals fro m the Device Contro l Mo dule (DCM). B ased on the state of these inputs, th e servo amplifier energ iz[...]

Chapter 3. Identify ing the Components May 2002 T-38324-A Page 3-11 Backplane The backplane (part num ber 420890-35327) is a prin ted circuit board i nto w hich m any of the in ternal compon ent cables plug. It als o contains address s witch SW-1, an d the DCM fus e, F4. See Figure 3-8. Figure 3-8. CS4000 Mini Controller with Ethernet Backplane Dev[...]

CS4000 Mini Controller with Ethernet Page 3-12 T-38324-A 39-30-38324 Backplane Fuses Fuse F4 is L ittelfuse 239001, 5x 20 mm , 1A, SLO BL O (SB) 250V (part number 13- 10-61001). Fuse F4 protects th e DCM board insi de the TCM. Fuses F2 an d F3 are Littelfus e 255.500, subm iniature 0.5A (part n umber 13- 10-4050). Fuse F2 protects the 24VDC to th e[...]

Chapter 3. Identify ing the Components May 2002 T-38324-A Page 3-13 I/O Board The I/O board show n in Figu re 3-9 is inserted in to a connector, J2, on the backplan e. It interfaces to all of the con nectors available on th e bottom of th e controller, see Figure 3- 3 on page 3-4. On the top side of t he I/O board are som e diagn ostic conn ections[...]

CS4000 Mini Controller with Ethernet Page 3-14 T-38324-A 39-30-38324 Ethernet Interface Card The Ethernet interf ace card (part num ber 420959-38093) is a printed circu it board into wh ich internal compo nent cab les o f the Ethe rnet ne t work are p lugged . It r equir es a 1 A, 5V p ower supp ly that it d raws from the 24VDC pow er supply inside[...]

Chapter 3. Identify ing the Components May 2002 T-38324-A Page 3-15 The nine- position RS-232 s erial port, J7, is used for setu p and diagnostics of the Ethernet in terface card. You can ch ange the Ethern et application program or the TCP/IP information by using TINI Ethernet Interf ace Flash Utility on a laptop connected to the Eth ernet interfa[...]

CS4000 Mini Controller with Ethernet Page 3-16 T-38324-A 39-30-38324 Interbus-S M odule The Interbu s-S dig ital I/O m odule (part num ber 41-30-0300) is opti onal and is supplied on ly w hen it is specified at the tim e of order. When it is included in th e controller enclosure, it prov ides another I/O interface, u sually to an external, rem ote [...]

Chapter 3. Identify ing the Components May 2002 T-38324-A Page 3-17 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[...]

CS4000 Mini Controller with Ethernet Page 3-18 T-38324-A 39-30-38324 Ground Fault Ci r c ui t I nterrupter The Ground Fault Circuit Interru pter (GFCI) is wired in series from the AC pow er input to the servo amplifier. It m o nitors both AC pow er leads to the servo amplifier, en suring that curren t flowin g in one lead is the sam e as the curren[...]

May 2002 T-38324-A Page 4-1 4. Installing the CS4000 Mini Controller with Ethernet This chapte r show s you how t o moun t and w ire the CS4000 Min i Controll er wit h Ethernet . Mounting the CS4000 Mini Controller w i th Ethernet The CS4000 Mini Controller w ith Eth ernet is in stalled vert ically w ith the back f lat agains t the mou nting surf a[...]

CS4000 Mini Controller with Ethernet Page 4-2 T-38324-A 39-30-38324 Figure 4-1. CS4000 Mini Controller w ith Ethernet Dimensions To moun t the control ler you require four 1/ 4-20-in bolts or screw s. NOTE: Al l dimensions are in inche s with millimeters in square b rackets.[...]

Chapter 4. Installing the CS4000 Mini Controller w ith Ethernet May 2002 T-38324-A Page 4-3 Pow er and Connection-Requirements WARNING! 230 VAC SINGLE PHASE INPUT ONLY. Internal capacitors store a high voltage charge an d discharge slow ly after external pow er is removed. Figu re 4-2 show s the pow er supply and conn ection requirem ents of th e C[...]

CS4000 Mini Controller with Ethernet Page 4-4 T-38324-A 39-30-38324 Meeting the A C Input Pow er Requirements CAUTION! Failure to provide the proper power source can cause the followin g problems in yo ur CS4000 Mini Controller with Ethernet : ! The nutrunner might shut down before it reaches the target torque during a rundown cycle. ! The nutrunne[...]

Chapter 4. Installing the CS4000 Mini Controller w ith Ethernet May 2002 T-38324-A Page 4-5 I/O Wiring The CS4000 Min i Controlle r with Ethernet is equipped w ith a 19- pin I/O con nector for fi eld I/O. The settin gs descri bed in Table 4-1 are Visu al Supervi sor (VS) defau lt settin gs. NOTE: The 14-s hell, 19-pin strain r elief mating connecto[...]

CS4000 Mini Controller with Ethernet Page 4-6 T-38324-A 39-30-38324 Table 3-1. 19-Position Remote I/O C onnector Pinout Signal Names and Descriptions (Continued) Pin Signal Description E Limit Set Select B0 input (Red wire - internal) (Orange wire - external) W hen Set Defaults is clicked, VS sets these three inputs to select which of the eight int[...]

Chapter 4. Installing the CS4000 Mini Controller w ith Ethernet May 2002 T-38324-A Page 4-7 Table 3-1. 19-Position Remote I/O C onnector Pinout Signal Names and Descriptions (Continued) Pin Signal Description R Sy nchronization in/out (White/Orange wire - internal) (Orange/Red wire - external) This bi-directional signal is used for synchroniz ing t[...]

CS4000 Mini Controller with Ethernet Page 4-8 T-38324-A 39-30-38324 A rem ote input circuit schematic an d remote I/O schematics f or sourcing and sinking output s are shown in Figure 4 -3 thro ugh Fi gur e 4-5 . Figure 4-3. Remote Input Circuit Schematics To ensure th at you operate the fasten ing sy stem properly , refer to Table 4-2 f or input r[...]

Chapter 4. Installing the CS4000 Mini Controller w ith Ethernet May 2002 T-38324-A Page 4-9 Figure 4 -4 is a n e xample o f the remot e I/O wiring sc heme using the d efaults ( volta ge sour ce) fo r the jumpers. It s hows one of the m any way s the rem ote I/O feature of th e controller can be used. To ensu re that y ou operate the f astening sys [...]

CS4000 Mini Controller with Ethernet Page 4-10 T-38324-A 39-30-38324 Figure 4-5 is an exam ple of the rem ote I/O wiring scheme th at show s how to change the jum pers for voltage sin k. It show s one of the many ways the remote I/O f eature controller can be us ed. To ensure that y ou operate th e fasteni ng sy stem properly, ref er to the gu idel[...]

Chapter 4. Installing the CS4000 Mini Controller w ith Ethernet May 2002 T-38324-A Page 4-11 Connector Pinout Definitions Pinout def initions are provided f or the tool, I/O, RS-422, TCM n etwork, R S-232, printer/barcode an d Interbus -S connectors . T ool Connector Pin Designation W ire Color (Ref) Function 1 W HT POW ER PHASE 1 2 RED POW ER PHAS[...]

CS4000 Mini Controller with Ethernet Page 4-12 T-38324-A 39-30-38324 RS-422 Connector Pin Designation W ire Color (Ref) Function A BRN/W HT TX D+ OUT B W HT/BRN T XD- OUT C ORN/W HT R XD+ IN D W HT/ORN RXD- OUT E GRN/W HT Not used F W HT/GRN Not used G BLU/W HT SHIELD COMM ON DE F G K J C H A B HG R N S H I E L D T ool Contr ol M odul e (TCM ) Netw[...]

Chapter 4. Installing the CS4000 Mini Controller w ith Ethernet May 2002 T-38324-A Page 4-13 Interbus-S “O UT” Connector Pin Designation W ire Color (Ref) Function 1Y L D O 2 2G Y D I 2 3 BRN GND1 5R D + 5 V 6 GRN Not DO2 7P K N o t D I 2 9 W H RBST[...]

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May 2002 T-38324-A Page 5-1 5. Setting Up the Ethernet The CS4000 Mini Controller w ith Eth ernet can be con nected to an Ethe rnet Local A rea Network (LAN). This chapter describes the steps you m ust take to set up the Ethernet LA N: • Programm ing th e Ethernet interf ace card • Setting up Visual Sup ervis o r for networks • Using Et he rn[...]

CS4000 Mini Controller with Ethernet Page 5-2 T-38324-A 39-30-38324 The IP address con sists of 32-bits (In ternet Protocol version 4, IPv 4) and is m ost oft en depicted in a dot address. This is the f ormat in wh ich y ou mu st enter IP addres ses for th e CS4000 Mini C ontroller w ith Ethernet sof tware. It is called a dot addres s because the a[...]

Chapter 5. Setting Up the Ethernet May 2002 T-38324-A Page 5-3 4. Insert one of the fe male connectors on the null mode m cable (part number 41-41-0109FN) into the 9-pin connector (J7) on the Ethernet interface card. See Figure 3-10 on pa ge 3-14. As you open the enclosure door and look at the interior, the Ethernet interf ace car d is mounted in t[...]

CS4000 Mini Controller with Ethernet Page 5-4 T-38324-A 39-30-38324 9. Select the RS-232 serial communicat ions port on your laptop that you will be using to send data t o the att ached Ethern et interface card . This is the com m unications por t to which the null modem cable is attached. a. Click the Com Port m enu in the TINI Ethernet F lash Uti[...]

Chapter 5. Setting Up the Ethernet May 2002 T-38324-A Page 5-5 The T INI Ethernet Interf ace Flash Utility attempts to c onnect to the com m unications port you specified in Step 9. W hen the attempt is s uccess ful, the m essage s hown in Figure 5-4 is displayed. Figure 5-4. Establishing A Successful Connection via C OM1 W hen another utility or p[...]

CS4000 Mini Controller with Ethernet Page 5-6 T-38324-A 39-30-38324 10. F lash the app lication file t o the Ethern et interface card . a. Click the Flash m enu in the TINI Ether net Interfac e Utility window. b. From the Flash m enu, clic k F lash T INI… . Figure 5-6. Selecting the “Flash TINI…” O ption 11. From the list of files display e[...]

Chapter 5. Setting Up the Ethernet May 2002 T-38324-A Page 5-7 The T INI Ethernet Flash Utility connects to the Ethernet inter face c ard, via the COM port you specified in Step 9. W hen the comm unications connection is s ucces sful, the y ellow LED (LED6 on the Ethernet interf ace car d) stops blink ing and the flas h utility begins flas hing the[...]

CS4000 Mini Controller with Ethernet Page 5-8 T-38324-A 39-30-38324 There ar e three possible r easons that a flas h fails: • The null m odem cable has been ins erted into the 9-pin connec tor (J7) on the Ethernet interf ace card inc orrectly. • The j umper (J1) labeled ‘Prog’ on the Ether net interfac e card has been ins talled incorre ctl[...]

Chapter 5. Setting Up the Ethernet May 2002 T-38324-A Page 5-9 To c hange the IP address, s ubnet mas k and/or the def ault gateway being used: a. Click on the IP A ddress: , Subnet M ask: , or Default Gateway: field. b. Enter the new value. c. Repeat Steps a) and b) for all the f ields you w ant to change. d. Click OK . 13. W hen the flash utility[...]

CS4000 Mini Controller with Ethernet Page 5-10 T-38324-A 39-30-38324 Updating A ppli cati on Settings After y o u have flash ed an application file to the Eth ernet interface card, y ou may want to update settings w ithout re-f lashing the entire application file ag ain. To do this, the TINI Ethernet Flash Utility has a men u option that allows y o[...]

Chapter 5. Setting Up the Ethernet May 2002 T-38324-A Page 5-11 The Applic ation Settings window, shown in Figure 5-13, opens to display the General Info tab. T his window shows y ou details of the last succ essf ul flash of an application file to the Ethernet inter face c ard. You cannot change this info rm ation; it is automatic ally updated by t[...]

CS4000 Mini Controller with Ethernet Page 5-12 T-38324-A 39-30-38324 4. To change the IP address, subnet mask and/or default gateway: a. Click on the IP A ddress: , Subnet M ask: or Default Gateway: field. b. Enter the new value. c. Repeat Steps a) and b) for all the f ields you w ant to change. 5. Select the Co mm Options tab . a. From the Applica[...]

Chapter 5. Setting Up the Ethernet May 2002 T-38324-A Page 5-13 d. Click on the drop-down menu nex t to 3964R Baud Rate to change the baud r ate used for com munic ations to and fr om the bar code scanner attac hed to the RS-422 port. You can select fr om the following baud rates: • 1200 • 19200 • 2400 • 38400 • 4800 • 57600 • 9600 e.[...]

CS4000 Mini Controller with Ethernet Page 5-14 T-38324-A 39-30-38324 Editing VSMain.ini fo r an Ethernet N etw ork When you a r e using the E ther ne t link, you must also change VSMain.ini manually . In the f ollowing exam ple, show n in Figure 5- 16, VSMain.ini is configured to talk to four Tool Control Modules (TCMs) at IP address es 10.1.100.16[...]

Chapter 5. Setting Up the Ethernet May 2002 T-38324-A Page 5-15 Use Procedure 5-3 to m ake the n ecessary ch anges to VSMain.ini . Procedure 5-3. Editing VSMain.ini for an Ethernet N etwork 1. Open VSMain.ini using Notepa d. a. Click the Start m enu on the W indow s NT desk top. b. From the Start m enu, selec t Progr ams . c. From the Pr ogram s m [...]

CS4000 Mini Controller with Ethernet Page 5-16 T-38324-A 39-30-38324 4. Repeat Step 3 for each controller you are connecting to the Ethernet network. Each device has its own section in VSMain.ini . The s ample below shows s ettings for the second contr oller added to VSMain.ini . [Comm2Devices] #Devices=1 Device1=DCM Device1IPAddress=[IP address of[...]

Chapter 5. Setting Up the Ethernet May 2002 T-38324-A Page 5-17 Ethernet cables are in serted into the Ethe rnet connector on th e bottom panel of each CS4000 Mini Controller w ith Ethern et. T he other end of the Eth ernet cable is connected to a n etwork h ub. To conne c t the co mputer r unning Visual Super vi sor t o the net work, inser t one e[...]

CS4000 Mini Controller with Ethernet Page 5-18 T-38324-A 39-30-38324 2. Enter a name t o identif y this connection an d select the Hyperterminal ico n you want to use fo r it. See Figure 5- 17. a. Enter a m eaningful nam e f or the Hyperterminal connec tion in the Name: field. b. Select the shor tcut Icon: for the Hyperterm inal connection and c li[...]

Chapter 5. Setting Up the Ethernet May 2002 T-38324-A Page 5-19 3. Select the c ommunications port you want to use for the Hyperter minal connection. See Figure 5-18. This is the com m unications por t to which the null modem cable is attached. Usually COM1 is the com m unications port selection but you may choose any comm unications port on the co[...]

CS4000 Mini Controller with Ethernet Page 5-20 T-38324-A 39-30-38324 4. Specify the commu nications po rt setting s. See Figure 5-19. a. Set the Bits per se cond: field to 115200. b. Set the Data bits: field to 8. c. Set the Parity: f ield to None. d. Set the Stop bits: field to 1. e. Set the Flow Control: f ield to Hardware. f. C lick OK . Figure [...]

Chapter 5. Setting Up the Ethernet May 2002 T-38324-A Page 5-21 5. Hit the ENT ER key on the compu ter keyboard to v iew th e login promp t: ‘T INI login.’ See Fig ure 5-20. Figure 5-20. Hy perterminal Window Show ing Ethernet Interface Card (TINI) Login Prompt NOTE: If the Hyperter minal window does not appear when you hit the ENTER key, mak e[...]

CS4000 Mini Controller with Ethernet Page 5-22 T-38324-A 39-30-38324 7. Enter ping follow ed by the IP address o f the comp uter or cont roller on the Ethernet ne twork tha t you want to test. NOTE: The IP addres s of the Ethernet interface c ard is the same as the IP address of the c omputer or contr oller to which it is attac hed. For exam ple, i[...]

Chapter 5. Setting Up the Ethernet May 2002 T-38324-A Page 5-23 Use Procedure 5-5 to test th e Ethernet netw ork from th e host compu ter. NOTE: There is an alternative to the method desc ribed in Procedure 5- 5. You can use the Telnet applic ation, if it is installed on the Windows operating system of the host computer. Telnet es tablishes a conne[...]

CS4000 Mini Controller with Ethernet Page 5-24 T-38324-A 39-30-38324 2. Enter ping follow ed by the IP address o f the comp uter or cont roller on the Ethernet ne twork tha t you want to test. NOTE: The IP addres s of the Ethernet interface c ard is the same as the IP address of the c omputer or contr oller to which it is attac hed. For exam ple, i[...]

May 2002 T-38324-A Page 6-1 6. Setting Up the 485 Network The CS4000 Mini Controller w ith Ethernet can be connected to a L ocal Area Netw ork (LA N) usin g a 485 netw ork link and a s pecial Sy nchronou s Data Li nk Cont rol (SDLC) card. This chapter describes the steps you m ust take to set up the LA N: • Installin g the SDLC card in the comput[...]

CS4000 Mini Controller with Ethernet Page 6-2 T-38324-A 39-30-38324 Editing VSMain.ini for a 485 Netw ork When y ou are us ing a 485 netw ork, you m ust also chan ge VSMain.ini m anually. In the followin g exam ple, show n in Figu re 6-1, VSMain.ini is configur ed t o talk t o four TCM s using a single SDLC channel. Figure 6-1. VSM ain.ini configur[...]

Chapter 6. Setting Up a 485 Network May 2002 T-38324-A Page 6-3 Use Procedure 6-1 to m ake the n ecessary ch anges to VSMain.ini . Procedure 6-1. Editing VSMain.ini for a 485 Network 1. Open VSMain.ini using Notepa d. a. Click the Start m enu on the W indow s NT desk top. b. From the Start m enu, selec t Progr ams . c. From the Pr ogram s m enu, se[...]

CS4000 Mini Controller with Ethernet Page 6-4 T-38324-A 39-30-38324 4. When you are finished edit ing VSMain.ini , save your changes and exit Notepad. a. Click the File menu in Notepad. b. From the File m enu, selec t S ave . c. From the F ile menu, s elect Ex it . VSMain.ini is now ready to support a 485 netw ork. T he new settin gs take ef fect t[...]

Chapter 6. Setting Up a 485 Network May 2002 T-38324-A Page 6-5 Table 6-2. Setting A ddress Switches (continued) To set the follow ing address num ber: Set these Address switch es ON: Keep these DIP switch es OFF Address 7 1, 2, 3 4, 5, 6, 7, 8 Address 8 4 1, 2, 3, 5, 6, 7, 8 Address 9 1, 4 2, 3, 5, 6, 7, 8 Address 10 2, 4 1, 3, 5, 6, 7, 8 Address [...]

CS4000 Mini Controller with Ethernet Page 6-6 T-38324-A 39-30-38324 Use Procedure 6-2 to set th e address on the back plane of the con troller. Procedure 6-2. Setting the Address fo r the Controller 1. Turn OFF power to the controller. WARNING! Make sure the power is OFF before you remove the TCM . High voltag e when the p ower is ON can resu lt in[...]

Chapter 6. Setting Up a 485 Network May 2002 T-38324-A Page 6-7 Using 485 Netw ork Cables The type of cable you need to connect t he CS4000 Mini Controller w ith Ethernet t o the LA N using the 485-lin k is th e Bellden 8104 low capacitance com puter cable or equ ivalent. The comput er and controllers f orm a dais y chain wh en they are network ed [...]

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May 2002 T-38324-A Page 7-1 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 Super[...]

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May 2002 T-38324-A Page 8-1 8. Maintenance/Troubleshooting Mainten ance of th e CS4000 Mini C ontroller w ith Eth ernet consis ts of replacin g fus es and cleani ng the enclosu re win dow. The Troubles hooting section of this chapt er gives possible solu tions to problem s and describes how to locate a malf unction in the Ethern et network. Replace[...]

CS4000 Mini Controller with Ethernet Page 8-2 T-38324-A 39-30-38324 Replacing Ma in Pow er Fus es Mai n P owe r F1 and F2 = 15A, 250V, S LO-BL O Littelfu se 313015 or equiv alent (part num ber 13-10-1015) Refer t o Figure 3- 3 on page 3- 4 to locate the m ain pow er fus es on th e CS4000 Mini C ontroller bott om panel. Replacing Backplane Fu ses Ba[...]

Chapter 8. Maintenance/Troubleshooting May 2002 T-38324-A Page 8-3 T roubles hooting This section describes some of th e problems y ou m ay encou nter with the Ethernet n etwork, R S-422 (Siem ens 3964R) interf ace and the Application Program Interf ace (API), and giv es brief description s of how you migh t attempt to solve each problem. Ethernet [...]

CS4000 Mini Controller with Ethernet Page 8-4 T-38324-A 39-30-38324 RS-422 (Siemens 3964R) Interface If y ou encoun ter problems w ith the RS-422 (S iemens 3964R ) interface, y ou can us e Procedure 5-4 on page 5 -17 . Although thi s p ro c edur e de sc rib e s how you test an E t hernet ne twork fro m a lapto p compu ter, you can u se the sam e st[...]

May 2002 T-38324-A Page 9-1 9. Technical Information A ssemb l y Draw ing The w iring diag rams f or the CS4000 Min i Controll er wit h Ethernet are show n in Fi gure 9-1 on page 9- 3 and Figu re 9-2 on pag e 9-5.[...]

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Chapter 9. Technical Information May 2002 T-38324-A PRELIMINAR Y DRAFT Page 9-3 Figure 9-1. CS4000 Mini Controller with Ethernet Wiring of Standard Ethernet and Inter bus-S Module[...]

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Chapter 9. Technical Information April 2002 T-38324-A Page 9-5 Figure 9-2. CS4000 Mini Controller with Ethernet Wiring of Standard Ether net[...]

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May 2002 T-38324-A Index- 1 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 C Clear [...]

CS4000 Mini Controller with Ethernet Index-2 T-38324-A 39-30-38324 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 C alibration, 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 [...]

Part Number: 39-30-38324 SPX Corporation 42860 Nine M ile Road Novi, M I 48375-4122 USA Phone: ( 248) 596-0600 Toll free: (800) 795-7875 Fax: ( 248) 596-0601 Website: www.gsetechmotive.com © 2002 SPX Corpor ation. All rights reserved. 4/02[...]