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Manual SPX Cooling Technologies CS4000

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  • SPX Cooling Technologies CS4000 - page 1

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

  • SPX Cooling Technologies CS4000 - page 2

    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. ...

  • SPX Cooling Technologies CS4000 - page 3

    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. ...

  • SPX Cooling Technologies CS4000 - page 4

    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 ...

  • SPX Cooling Technologies CS4000 - page 5

    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 ...

  • SPX Cooling Technologies CS4000 - page 6

    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 ...

  • SPX Cooling Technologies CS4000 - page 7

    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 ...

  • SPX Cooling Technologies CS4000 - page 8

    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 ...

  • SPX Cooling Technologies CS4000 - page 9

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

  • SPX Cooling Technologies CS4000 - page 10

    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 ............. ...

  • SPX Cooling Technologies CS4000 - page 11

    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 ...

  • SPX Cooling Technologies CS4000 - page 12

    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 .................... ...

  • SPX Cooling Technologies CS4000 - page 13

    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 ...

  • SPX Cooling Technologies CS4000 - page 14

    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 ...

  • SPX Cooling Technologies CS4000 - page 15

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

  • SPX Cooling Technologies CS4000 - page 16

    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 ...

  • SPX Cooling Technologies CS4000 - page 17

    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 ...

  • SPX Cooling Technologies CS4000 - page 18

    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 ...

  • SPX Cooling Technologies CS4000 - page 19

    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 ...

  • SPX Cooling Technologies CS4000 - page 20

    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 ...

  • SPX Cooling Technologies CS4000 - page 21

    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 ...

  • SPX Cooling Technologies CS4000 - page 22

    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 ...

  • SPX Cooling Technologies CS4000 - page 23

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

  • SPX Cooling Technologies CS4000 - page 24

    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 ...

  • SPX Cooling Technologies CS4000 - page 25

    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 ...

  • SPX Cooling Technologies CS4000 - page 26

    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 ...

  • SPX Cooling Technologies CS4000 - page 27

    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 ...

  • SPX Cooling Technologies CS4000 - page 28

    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 ...

  • SPX Cooling Technologies CS4000 - page 29

    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 ...

  • SPX Cooling Technologies CS4000 - page 30

    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 ...

  • SPX Cooling Technologies CS4000 - page 31

    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 ...

  • SPX Cooling Technologies CS4000 - page 32

    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) • ...

  • SPX Cooling Technologies CS4000 - page 33

    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 ...

  • SPX Cooling Technologies CS4000 - page 34

    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 ...

  • SPX Cooling Technologies CS4000 - page 35

    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 ...

  • SPX Cooling Technologies CS4000 - page 36

    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 ...

  • SPX Cooling Technologies CS4000 - page 37

    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 ...

  • SPX Cooling Technologies CS4000 - page 38

    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 ...

  • SPX Cooling Technologies CS4000 - page 39

    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 ...

  • SPX Cooling Technologies CS4000 - page 40

    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 ...

  • SPX Cooling Technologies CS4000 - page 41

    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 ...

  • SPX Cooling Technologies CS4000 - page 42

    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 ...

  • SPX Cooling Technologies CS4000 - page 43

    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 ...

  • SPX Cooling Technologies CS4000 - page 44

    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 ...

  • SPX Cooling Technologies CS4000 - page 45

    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 ...

  • SPX Cooling Technologies CS4000 - page 46

    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 ...

  • SPX Cooling Technologies CS4000 - page 47

    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. ...

  • SPX Cooling Technologies CS4000 - page 48

    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 ...

  • SPX Cooling Technologies CS4000 - page 49

    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 ...

  • SPX Cooling Technologies CS4000 - page 50

    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 ...

  • SPX Cooling Technologies CS4000 - page 51

    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 ...

  • SPX Cooling Technologies CS4000 - page 52

    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 ...

  • SPX Cooling Technologies CS4000 - page 53

    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 ...

  • SPX Cooling Technologies CS4000 - page 54

    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 ...

  • SPX Cooling Technologies CS4000 - page 55

    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 ...

  • SPX Cooling Technologies CS4000 - page 56

    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 ...

  • SPX Cooling Technologies CS4000 - page 57

    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 ...

  • SPX Cooling Technologies CS4000 - page 58

    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 ...

  • SPX Cooling Technologies CS4000 - page 59

    CS4000 Mini Controller with Ethernet Page 4-14 T-38324-A 39-30-38324 (This page is left blank intentionally .) ...

  • SPX Cooling Technologies CS4000 - page 60

    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 ...

  • SPX Cooling Technologies CS4000 - page 61

    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 ...

  • SPX Cooling Technologies CS4000 - page 62

    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 ...

  • SPX Cooling Technologies CS4000 - page 63

    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 ...

  • SPX Cooling Technologies CS4000 - page 64

    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 ...

  • SPX Cooling Technologies CS4000 - page 65

    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 ...

  • SPX Cooling Technologies CS4000 - page 66

    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 ...

  • SPX Cooling Technologies CS4000 - page 67

    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 ...

  • SPX Cooling Technologies CS4000 - page 68

    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 ...

  • SPX Cooling Technologies CS4000 - page 69

    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 ...

  • SPX Cooling Technologies CS4000 - page 70

    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 ...

  • SPX Cooling Technologies CS4000 - page 71

    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 ...

  • SPX Cooling Technologies CS4000 - page 72

    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. ...

  • SPX Cooling Technologies CS4000 - page 73

    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 ...

  • SPX Cooling Technologies CS4000 - page 74

    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 ...

  • SPX Cooling Technologies CS4000 - page 75

    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 ...

  • SPX Cooling Technologies CS4000 - page 76

    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 ...

  • SPX Cooling Technologies CS4000 - page 77

    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 ...

  • SPX Cooling Technologies CS4000 - page 78

    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 ...

  • SPX Cooling Technologies CS4000 - page 79

    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 ...

  • SPX Cooling Technologies CS4000 - page 80

    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 ...

  • SPX Cooling Technologies CS4000 - page 81

    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 ...

  • SPX Cooling Technologies CS4000 - page 82

    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 ...

  • SPX Cooling Technologies CS4000 - page 83

    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 ...

  • SPX Cooling Technologies CS4000 - page 84

    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 ...

  • SPX Cooling Technologies CS4000 - page 85

    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 ...

  • SPX Cooling Technologies CS4000 - page 86

    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 ...

  • SPX Cooling Technologies CS4000 - page 87

    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 ...

  • SPX Cooling Technologies CS4000 - page 88

    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 ...

  • SPX Cooling Technologies CS4000 - page 89

    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 ...

  • SPX Cooling Technologies CS4000 - page 90

    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 ...

  • SPX Cooling Technologies CS4000 - page 91

    CS4000 Mini Controller with Ethernet Page 6-8 T-38324-A 39-30-38324 (This page is left blank intentionally .) ...

  • SPX Cooling Technologies CS4000 - page 92

    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 ...

  • SPX Cooling Technologies CS4000 - page 93

    CS4000 Mini Controller with Ethernet Page 7-2 T-38324-A 39-30-38324 (This page is left blank intentionally .) ...

  • SPX Cooling Technologies CS4000 - page 94

    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 ...

  • SPX Cooling Technologies CS4000 - page 95

    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 ...

  • SPX Cooling Technologies CS4000 - page 96

    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 ...

  • SPX Cooling Technologies CS4000 - page 97

    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 ...

  • SPX Cooling Technologies CS4000 - page 98

    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. ...

  • SPX Cooling Technologies CS4000 - page 99

    CS4000 Mini Controller with Ethernet Page 9-2 T-38324-A 39-30-38324 (This page is left blank intentionally .) ...

  • SPX Cooling Technologies CS4000 - page 100

    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 ...

  • SPX Cooling Technologies CS4000 - page 101

    CS4000 Mini Controller with Ethernet Page 9-4 T-38324-A PRELIMINAR Y DRAFT 39-30-38324 (This page is left blank intentionally .) ...

  • SPX Cooling Technologies CS4000 - page 102

    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 ...

  • SPX Cooling Technologies CS4000 - page 103

    CS4000 Mini Controller with Ethernet Page 9-6 T-38324-A PRELIMINAR Y DRAFT 39-30-38324 (This page is left blank intentionally .) ...

  • SPX Cooling Technologies CS4000 - page 104

    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 ...

  • SPX Cooling Technologies CS4000 - page 105

    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 ...

  • SPX Cooling Technologies CS4000 - page 106

    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 ...

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All of them are important, but the most important information from the point of view of use of the device are in the user manual SPX Cooling Technologies CS4000.

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A manual, also referred to as a user manual, or simply "instructions" is a technical document designed to assist in the use SPX Cooling Technologies CS4000 by users. Manuals are usually written by a technical writer, but in a language understandable to all users of SPX Cooling Technologies CS4000.

A complete SPX Cooling Technologies manual, should contain several basic components. Some of them are less important, such as: cover / title page or copyright page. However, the remaining part should provide us with information that is important from the point of view of the user.

1. Preface and tips on how to use the manual SPX Cooling Technologies CS4000 - At the beginning of each manual we should find clues about how to use the guidelines. It should include information about the location of the Contents of the SPX Cooling Technologies CS4000, FAQ or common problems, i.e. places that are most often searched by users in each manual
2. Contents - index of all tips concerning the SPX Cooling Technologies CS4000, that we can find in the current document
3. Tips how to use the basic functions of the device SPX Cooling Technologies CS4000 - which should help us in our first steps of using SPX Cooling Technologies CS4000
4. Troubleshooting - systematic sequence of activities that will help us diagnose and subsequently solve the most important problems with SPX Cooling Technologies CS4000
5. FAQ - Frequently Asked Questions
6. Contact detailsInformation about where to look for contact to the manufacturer/service of SPX Cooling Technologies CS4000 in a specific country, if it was not possible to solve the problem on our own.

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