Cleco Tools BTSE series System Handbook
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Cleco Tools BTSE series System Handbook

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System Handbook
P2077SB/EN
2011-09
mPro400GC-DGD-intelligent-spindle
BTSE series
For additional product information visit our Web site at http://www.apextoolgroup.com

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  • Page 1 System Handbook P2077SB/EN 2011-09 mPro400GC-DGD-intelligent-spindle BTSE series For additional product information visit our Web site at http://www.apextoolgroup.com...
  • Page 2 Notes on System Handbook This System Handbook is the original system handbook – and • provides important information on safe, correct and efficient operation of the system. • describes the function and operation of the components. • serves as a lexicon for technical data. •...

  • Page 3: Table Of Contents

    Contents Safety Warnings and notes ............... 7 Basic requirements for safe working practices ........7 Operator training................... 8 Personal protective equipment ............. 8 Designated use..................8 Ambient conditions ................9 EMC (Electromagnetic compatibility)............ 9 Noise....................10 Transport / Storage System description Components ..................
  • Page 4 Gearing Motor 10.1 Technical data ..................35 10.2 Electrical Data..................36 10.3 Thermal data..................36 10.4 Pin configuration motor connector ............. 37 Power distribution box PDB-CPS… 11.1 Brief function description ..............39 11.2 General technical data................ 40 11.3 Electrical Data..................40 11.4 Installation...................
  • Page 5 Disposal P2077SB/EN 2011-09 P2077SB-EN_2011-09_m-Pro-400S-DGD-IS_BTSEIVZ.fm, 06.09.2011...
  • Page 6 P2077SB/EN 2011-09 P2077SB-EN_2011-09_m-Pro-400S-DGD-IS_BTSEIVZ.fm, 06.09.2011...

  • Page 7: Safety

    Safety Safety Warnings and notes WARNING! A symbol combined with the word WARNING warns of a potentially dangerous situation for the health of personnel, If this warning is not observed, death or serious injury may occur. CAUTION! A symbol combined with the word CAUTION warns of a potentially harmful situation for the health of personnel or damage to property or the environment.

  • Page 8: Operator Training

    Safety CAUTION! Work area ➔ Close all safety devices. ➔ Ensure that there is enough space in the work area. ➔ Keep the work area clean. Electrical safety tightening system ➔ Only operate the indoors. ➔ Observe the safety notes on the DGD-IS. Safe working with and around fastening tools ➔...

  • Page 9: Ambient Conditions

    Safety • Secure the DGD-IS to an electroconductive mounting plate. • Only cable types approved by DGD may be used. • Only accessory parts approved by DGD may be used. • Unauthorized alterations, repairs and modifications are prohibited for reasons of safety and product liability.

  • Page 10: Noise

    Transport / Storage NOTE Equipment from EMC limit class value A, DIN EN 55 0081-2. This equipment may cause radio interference in residential areas. Should this occur, you may request that the operator pay for and implement relevant EMC measures. Noise DGD-IS dB(A)

  • Page 11: System Description

    System description System description The system design is determined by the size and quantity of DGD-IS used and always varies depending on the individual situation. These components can be combined with one another in various sizes. This chapter includes a brief description of the components. Each respective chapter contains separate technical details.
  • Page 12 System description 3.1.1 DGD-IS The DGD-IS is available in sizes 1B(U)TSE…, 2B(U)TSE…, 3B(U)TSE… and 4B(U)TSE…. for a torque range of 2 to 1600 Nm. 3.1.2 Nutsetter control unit Power and logic are supplied via the power distribution box PDB-CPS…. This is controlled by the nutsetter control unit mPro400GC-M. •...

  • Page 13: First Operation

    First Operation First Operation For initial commissioning, the mPro400GC programming instructions must also be read and applied. Position components of the DGD-IS so that they interlock at toothed interfaces, see Service Manual: Turn size 1 in 15° increments. Turn sizes 2 to 4 in 10° increments. Connect all components, see (Chapter "3.1"Components starting on page 11).
  • Page 14 First Operation Blank page P2077SB/EN 2011-09 77d_Inbetriebnahme_bedingt-en.fm, 06.09.2011...

  • Page 15: Dgd Intelligent Spindles

    DGD intelligent spindles DGD intelligent spindles General technical data • torque measurement with integrated pre-amplifier, resulting in greater signal noise spacing • reverse voltage protected supply • short-circuit proof outputs • low voltage monitor • watchdog for processor • noise-protected input and output circuit Features Data Protection category...

  • Page 16: Catalogue Data

    DGD intelligent spindles Catalogue data 5.2.1 Size 1 – 1× transducer Designation Order No. Torque Speed Spring min. Length Weight Spring travel axis chuck distance max. min. + flange 1BTSE-1B012A-1M3B-1ZB 947626A6 1921 1BTSE-1B035A-1M1B-1ZB 947632A8 S308434 1BTSE-1B060A-1M2B-1ZB 947638A2 922325 1BTSE-1B012A-1VM3B 947627A5 1825 1BTSE-1B035A-1VM1B 947633A7...
  • Page 17 DGD intelligent spindles 5.2.2 Size 2 – 1× transducer Designation Order No. Torque Speed Spring min. Length Weight Spring travel axis chuck distance max. min. + flange 2BTSE-2B110A-2M1B-2ZB 947644A4 1/2" S308435 2BTSE-2B200A-2M3B-2ZB 947650A6 3/4" 910609 2BTSE-2B110A-2VM1B 947645A3 1/2" S308438 2BTSE-2B200A-2VM3B 947651A5 3/4"...
  • Page 18 DGD intelligent spindles 5.2.3 Size 3 – 1× transducer Designation Order No. Torque Speed Spring min. Length Weight Spring travel axis chuck distance max. min. + flange 3BTSE-3B300A-3M2B-3ZB 947656A0 14.1 S308436 910613 3BTSE-3B300A-3VM2B 947657A9 15.2 S308439 3BTSE-3B300A-3WM2B 947658A8 17.8 – 929065 3/4"...
  • Page 19 DGD intelligent spindles 5.2.4 Size 4 – 1× transducer Designation Order No. Torque Speed Spring min. Length Weight Spring travel axis chuck dis- tance max. min. + flange 4BTSE-4B500A-4M2B-4ZA 947662A2 3/4" 916643 4BTSE-4B660A-4M3B-4ZA 947668A6 1" 916642 – 4BTSE-4B360A-4M1B-4Z1250A 947676A6 1250 1"...

  • Page 20: Component Overview

    DGD intelligent spindles Component overview 5.3.1 Size 1 / 1× transducer DGD-IS 1BTSE-1B012A-1M3B-1ZB 947626A6 1B012A 927346 1M3B 934288PT 1BTSE-1B035A-1M1B-1ZB 947632A8 1B035A 927344 1M1B 934286PT 927222 KMAW 961089-002 1BTSE-1B060A-1M2B-1ZB 947638A2 1B060A 927345 1M2B 934287PT 947627A5 1B012A 927346 1VM3B 935863PT 1BTSE-1B012A-1VM3B 1BTSE-1B035A-1VM1B 947633A7 1BT 935560 TSE 961446PT 1B035A 927344...
  • Page 21 DGD intelligent spindles 5.3.2 Size 2 / 1× transducer DGD-IS 2BTSE-2B110A-2M1B-2ZB 947644A4 2B110A 935548 2M1B 934295PT 927227 KMAW 961089-002 2BTSE-2B200A-2M3B-2ZB 947650A6 2B200A 935549 2M3B 934294PT 2BTSE-2B110A-2VM1B 947645A3 2B110A 935548 2VM1B 934336PT 2BT 935561 TSE 961446PT KMAG 961088-004 2BTSE-2B200A-2VM3B 947651A5 2B200A 935549 2VM3B 934335PT –...
  • Page 22 DGD intelligent spindles 5.3.4 Size 4 / 1× transducer DGD-IS 4BTSE-4B500A-4M2B-4ZA 947662A2 4B500A 935780 4M2B 934319PT 927236 4BTSE-4B660A-4M3B-4ZA 947668A6 4B660A 935781 4M3B 936496PT KMAG 961069-002 4BTSE-4B360A-4M1B-4Z1250A 947676A6 4B360A 929541 4M1B 934318PT 4Z1250A S976950 4BTSE-4B500A-4M2B1-4Z1600A 947678A4 4B500A 935780 4M2B1 4Z1600A S976951 4BTSE-4B500A-4VM2B 947663A1 3/4BT 935562 TSE 961446PT...

  • Page 23: Tightening Module Tse/Tuse

    Tightening module TSE/TUSE Tightening module TSE/TUSE Order no. 961446PT TUSE Order no. 961447PT Item Designation "XS1A" supply input "XS1B" supply output Service panel "XS3" transducer plug connector "Ready" LED, ready for operation (green) or fault (red) P2077SB/EN 2011-09 77f_Schraubmodul-en.fm, 06.09.2011...

  • Page 24: Description

    Tightening module TSE/TUSE Description The tightening module TSE/TUSE controls the DGD-IS. The servo amplifier (output section) and the measuring section (measuring board) are integrated in the tightening module. Both circuit boards are linked to the connections via cables and plug connectors. General technical data Features Data...

  • Page 25: Ready" Led

    Tightening module TSE/TUSE 6.2.3 Logic power supply The logic power supply in the tightening module generates all supply voltages (24 V from the nutsetter con- trol unit). Features Data Supply voltage 24 +10 % Rated supply current approx. 0.35 Power loss (standby) "Ready"...
  • Page 26 Tightening module TSE/TUSE 6.4.1 ARCNET address preset The ARCNET address is preset via the two 10-stage decode switch. Permitted settings 01 to 32. • Switch (x1) for units (00-09), • Switch (x10) for tens (00-30). NOTES • Always switch off the nutsetter control unit before making adjustments. •...

  • Page 27: Internal Assemblies

    Tightening module TSE/TUSE 6.4.5 DGD service interface (RS232) for servo NOTE only for DGD service • Connection to PC via special cable • Plug connector type: PS2 Signal Description ±10 V ±10 V 3.3 V ±2 % / 20 mA AMON Analog monitor, 0 V –...
  • Page 28 Tightening module TSE/TUSE 6.5.2 Motor end stage • Short-circuit proof: phase – phase, phase – PE, phase – temperature monitor. • Minimum losses due to IGBT end stage. Features Data Intermediate circuit voltage U 380 ±10 % Excess voltage shut-off >...

  • Page 29: Attachment

    Attachment Attachment Centric Attachment Illustration of 1ZB Code Part no. Ratio Permissible load Lateral force at wrench head on output shaft Pres- Ten- 25 mm 50 mm sure sion Extended Retracted Retracted 927222 1900 1500 1150 1350 1600 927227 4500 3200 2450 2700...

  • Page 30: Angle Head Attachment

    Attachment 7.2.1 Pin configuration of offset attachment Type: 12-pin circular connector Lumberg SGR 120, Binder series 680 no. 09-0331-90-12 with locking connector in accordance with DIN 45 321 Color Signal Description – – Brown – green Torque output Yellow 0 VA 0 V torque reference connection gray 0 V supply...

  • Page 31: Spring Collet - Optional

    Attachment 7.3.1 Pin configuration angle head attachment Type: 12-pin circular connector Lumberg SGR 120, Binder series 680 no. 09-0331-90-12 with locking connector in accordance with DIN 45 321 Color Signal Description – – Brown – green Torque output Yellow 0 VA 0 V torque reference connection gray 0 V supply...
  • Page 32 Attachment Size 4Z.. Part no. Permissible load on output shaft Lateral force at wrench head Pres- Ten- Weight sure sion 25mm 50 mm Extended Retracted Retracted 916643 3/4" 1.21 4Z.. 9000 8800 4300 4800 5400 916642 1" 1.24 1) During continuous operation for long periods, multiply the specified values by 0.3 7.4.2 For angle head including flange housing Stroke of spring: 25 mm...

  • Page 33: Transducer

    Transducer Transducer Evaluation electronics Range torque measurement Transducer …M… Code Part no. Capacity / calibration value 1M1B 934286PT 1M2B 934287PT 1M3B 934288PT 2M1B 934295PT 2M3B 934294PT 3M2B 934303PT 4M1B 934318PT 4M2B 934319PT 4M3B 936496PT P2077SB/EN 2011-09 77g_Komponenten-en.fm, 06.09.2011...

  • Page 34: Electrical Data

    Transducer Electrical Data Torque measurement features Data Nominal supply voltage Supply voltage limits +10.75...+12.5 Supply current Measured output voltage – nominal voltage -5…+5 Measured output voltage limits U ±5.000 ±0.5 % + U Permitted measuring range of rated torque ±10...±125 Zero voltage limit value U ±100 Nonlinearity / Torque measurement...

  • Page 35: Gearing

    Gearing Gearing Gearing …B… Code Part no. Ratio 1B012A 927346 5.7273 1B035A 927344 15.1364 1B060A 927345 25.7727 2B110A 935548 12.3595 2B200A 935549 21.9231 3B300A 935590 18.7500 4B360A 929541 26.3118 4B500A 935780 33.4219 4B660A 935781 48.9345 Motor 10.1 Technical data Features Data Code 1BUT...

  • Page 36: Electrical Data

    Motor 10.2 Electrical Data Features Data 1B(U)T 2B(U)T 3/4B(U)T Intermediate circuit voltage Rated current Rated output Number of phases Terminating resistance Ohms Inductance Voltage constants mV/RPM Torque constant Nm/A 0.28 0.28 0.36 Current at peak torque 1) 4) Max. peak current Electrical time constants 0.59 1) Sine peak value...

  • Page 37: Pin Configuration Motor Connector

    Motor 10.4 Pin configuration motor connector Signal designation Wire colors (in motor) Motor type BT Motor type BUT Motor (1) Green/yellow Phase S green green Phase R Black Phase T red/black Resolver (2) Resolver R1 Red/white Resolver R2 Yellow/white Resolver S1 Resolver S3 Black Resolver S2...
  • Page 38 Motor Blank page P2077SB/EN 2011-09 77g_Komponenten-en.fm, 06.09.2011...

  • Page 39: Power Distribution Box Pdb-Cps

    Power distribution box PDB-CPS… Power distribution box PDB-CPS… Item Designation Rotary switch Seal Supply module CPS3 (integrated) "Ready" indicator Emergency stop 11.1 Brief function description Power distribution box PDB-CPS… supplies the tightening module TSE/TUSE with 380 VDC (CPS3) and 24 VDC. The machine control unit transmits the signals Control on and Emergency stop.

  • Page 40: General Technical Data

    Power distribution box PDB-CPS… 11.2 General technical data Features Data PDB-CPS3 PDB-CPS6 PDB-CPS9 Weight Protection category IP54 Cooling type Convection (self-cooling) Service life, operating 40.000 Usability period if stored 100,000 (approx. 11 years) On/Off switching cycles 5.000.000 Safety requirements in accordance with Category 4 EN 964-1 11.3...

  • Page 41: Installation

    Power distribution box PDB-CPS… WARNING! Unplugging the system cable while still live may generate an electric arc and cause serious burns. The con- tacts may become damaged. ➔ Switch off the power supply to the PDB-CPS… before unplugging or inserting the system cable! 11.4 Installation ➔...

  • Page 42: Supply Module Cps3

    Power distribution box PDB-CPS… 11.5 Supply module CPS3 11.5.1 Description The supply module CPS3 (Central Power Supply 3 KVA) is integrated in the power distribution box PDB-CPS: • 1× in PDB-CPS3 • 2× in PDB-CPS6 • 3× in PDB-CPS9 The CPS3 has the following functions: •...
  • Page 43 Power distribution box PDB-CPS… 11.5.2 General technical dataCPS3 Features Data Order No. 961112 Weight 3650 Protection category IP20 Cooling type Convection (self-cooling) Service life, operating 40.000 On/Off switching cycles 5.000.000 Usability period if stored 100,000 (approx. 11 years) 11.5.3 Electrical DataCPS3 Features Data Supply voltage power...
  • Page 44 Power distribution box PDB-CPS… 11.5.4 Size 11.5.5 Indicators Signal CPS3 Green "Ready" Ready for operation "EM stop" Emergency stop or Control on signal unavailable. The intermediate power circuit (380 VDC) is deactivated. 7-segment "Status" display Error indicators, see 15.3.3 7-segment "Status" display, page 66. 11.5.6 <Reset>...
  • Page 45 Power distribution box PDB-CPS… 11.5.7 Plug connectors and configuration WARNING! • Unplugging the system cable while still live may generate an electric arc and cause serious burns. • The contacts may become damaged. ➔ Switch off the power supply to the PDB-CPS… before unplugging or inserting the system cable! "XS1 Power in"...
  • Page 46 Power distribution box PDB-CPS… "XS3" Logic supply and control-on relay output 24 V supply for the CPS3 and control on relay connection for the power supply Required connector type: Phoenix Combicon MSTB2.5/6-STF-5.08 Order No. 961177 Contact Signal Description +24 V IN (1) +24 V IN Supply of the logic in the CPS3, 24 V +10 %...

  • Page 47: Transformer

    Power distribution box PDB-CPS… 11.6 Transformer Item Designation Connection to PDB-CPS… Bracket for mounting on wall / machine 11.7 General technical data Part no. Power Weight Protection Type Nominal category CP3-3750-JH Dry type, class AA, CP3-6750-JH IP54 encapsulated NEMA 1 CP3-9750-JH P2077SB/EN 2011-09 77h_PowerDistributionBox-en.fm, 06.09.2011...
  • Page 48 Power distribution box PDB-CPS… Dimensions / drilling pattern Transformer mm (") mm (") mm (") mm (") mm (") CP3-3750-JH3 387 (15.25) 314 (12.38) 229 (9.00) 286 (11.25)) 454 (8.50)) CP3-6750-JH6 CP3-9750-JH9 406 (16.00) 486 (19.12) 222 (8.75) 216 (8.50) 216 (17.88) NOTE ➔...

  • Page 49: Instructions On Laying Cables

    Instructions on laying cables Instructions on laying cables 12.1 General ➔ Don't bend cables while unrolling them. Don't create any loops or twists. ➔ Remember that a strain relief clamp and compression set must be incorporated within the bending radius. ➔...

  • Page 50: Strain Relief Clamp

    Instructions on laying cables 12.2 Strain relief clamp ➔ Generally all cable and hose components must be provided with traction reliefs at the beginning and NOTE! end of the sections so that no tensile stresses can occur at connectors, plugs and rundowns. Strain relief clamp Strain relief clamp Fig.

  • Page 51: Laying "High-Flex Quality" Cables In Cable Ducts

    Instructions on laying cables For this, use the following shield clamps: Cables Shield clamp Order No. Phoenix Phoenix Name Item number DGD-IS cable, BTS series S961062 SK14 30 25 17 6 Hand tool cable S961062 SK14 30 25 17 6 The shielding in the transducer line is connected to the connector housing.

  • Page 52: Wiring Of Robot Area »Superhighflex Quality

    Instructions on laying cables 12.5 Wiring of robot area »SuperhighFlex Quality« In order to achieve an optimal service life of cables in robotics applications, comply with the following points when laying the cables: ➔ Avoid using cable binders to fasten cables. ➔...

  • Page 53: Cable

    Cable Cable 13.1 HighFlex Quality, suitable for cable ducts Thermal properties Ambient temperature °C -20…+80 Flammability Flame-retardant and self-extinguishing in accordance with EN 50265-2-1, IEC 60332-1 and UL1581 Chemical properties of the coating Coating material PUR, low-adhesion, resistant to hydrolysis and microbes, UV-resistant, abrasion-resistant, tear-resistant, cut-resistant, notch-resistant Oil resistance...
  • Page 54 Cable 13.1.2 System cable, type I Nutrunner control unit – DGD-IS Order No. 961294-××× (…-××× = cable length in dm) 13.1.3 System cable, type J Nutrunner control unit – DGD-IS Order No. 961289-××× (…-××× = cable length in dm) 13.1.4 System cable, type A Intermediate plug position –...
  • Page 55 Cable 13.1.5 Jumper cable, type E DGD-IS – DGD-IS Order No. 961299-××× (…-××× = cable length in dm) 13.1.6 Jumper cable, type F DGD-IS – DGD-IS Order No. 961295-××× (…-××× = cable length in dm) 13.1.7 Jumper cable, type G DGD-IS –...
  • Page 56 Cable 13.1.8 Jumper cable, type H DGD-IS – DGD-IS Order No. 961297--××× (…-××× = cable length in dm) 13.1.9 Jumper cable, type K DGD-IS – DGD-IS Order No. 961292-××× (…-××× = cable length in dm) 13.1.10 Jumper cable, type L DGD-IS –...
  • Page 57 Cable 13.1.11 Jumper cable, type M DGD-IS – DGD-IS Order No. 961296--××× (…-××× = cable length in dm) 13.1.12 Wiring diagram P2077SB/EN 2011-09 17i_Kabel en.fm, 06.09.2011...

  • Page 58: Super Highflex, Suitable For Robots

    Cable 13.2 Super Highflex, suitable for robots Thermal properties Ambient temperature °C -20…+90 Flammability Flame-retardant and self-extinguishing in accordance with EN 50265-2-1, IEC 60332-1 and UL1581 Chemical properties of the coating Coating material PUR, low-adhesion, resistant to hydrolysis and microbes, UV-resistant, abrasion-resistant, tear-resistant, cut-resistant, notch-resistant Oil resistance...
  • Page 59 Cable 13.2.3 Jumper cable, type H DGD-IS – DGD-IS Order No. 961397--××× (…-××× = cable length in dm) 13.2.4 Wiring diagram P2077SB/EN 2011-09 17i_Kabel en.fm, 06.09.2011...
  • Page 60 Cable Blank page P2077SB/EN 2011-09 17i_Kabel en.fm, 06.09.2011...

  • Page 61: Function Description

    Function description Function description 14.1 Torque measurement The transducer is equipped with a telemetry system and therefore has no slip rings. The transducer is either installed in the DGD-IS as a component or integrated in an offset attachment or angle head attachment. All components of the transducer (measuring shaft, antenna system, rotor electronics and stator electron- ics) belong together as one unit, i.
  • Page 62 Function description Blank page P2077SB/EN 2011-09 77k_Funktionsbeschreibung-en.fm, 06.09.2011...

  • Page 63: Troubleshooting

    Troubleshooting Troubleshooting The following displays will help you to troubleshoot • Nutsetter control unit mPro400GC-M • Supply module CPS3 (in PDB-CPS…) • Tightening module TSE/TUSE (on DGD-IS) . DANGER! High leakage current – Fatal electric shock could occur! ➔ It is essential for the system cable or motor cable to be disconnected from the PDB-CPS… or DGD-IS before making throughput, resistance and short circuit measurements.

  • Page 64: Dgd-Is

    Troubleshooting 15.2 DGD-IS Error Possible causes Measures and remedies Description DGD-IS does not turn Motor defective ➔ Replace the DGD-IS Gearing defective Tightening module TSE/TUSE defective Cable defective ➔ Replace the cable Loud noises Gearing wear ➔ Replace the DGD-IS 15.2.1 Transducer When an operating failure occurs, the torque output is set to an output value of >...

  • Page 65: Tightening Module Cps3 In Power Distribution Box Pdb-Cps

    Troubleshooting 15.3 Tightening module CPS3 in power distribution box PDB-CPS… 15.3.1 "Ready" LED Error Possible causes Measures and remedies Description "Ready" LED does not light up 24 V supply is unavailable ➔ Check the 26 V voltage at "XS3" terminals 1 and 4 PDB-CPS…...
  • Page 66 Troubleshooting 15.3.3 7-segment "Status" display Encoded errors are displayed in a 7-segment display on the CPS3. The display alternates between the first and second digit at brief intervals: Display Duration Pause 1st digit 0.5 s 0.2 s 2nd digit 0.5 s 1st digit 0.5 s 0.2 s etc.
  • Page 67 Troubleshooting Error Possible causes Measures and Description remedies Excessive voltage Short circuit between ➔ Check connection of inter- between artificial neutral IC and PE: mediate circuit voltage point of the power supply +380 VDC and 0 VDC to and PE or the center of the intermediate circuit ➔...
  • Page 68 Troubleshooting Error Possible causes Measures and Description remedies Temperature in CPS3 is too Excessive number of DGD-IS. ➔ Reduce the number of high or too low Constant overload of the CPS3 PDB-CPS… Ambient temperature ➔ Improve the ambient condi- Temperature is outside of PDB-CPS…...
  • Page 69 Troubleshooting Error Possible causes Measures and Description remedies 5 V supply (internal) Internal voltage, external check not possible ➔ Power adapter in the CPS3 is Replace the CPS3 Internal 5 V supply defective is not within the Power adapter in the CPS3 is ➔...

  • Page 70: Tightening Module Tse/Tuse

    Troubleshooting 15.4 Tightening module TSE/TUSE 15.4.1 "Ready" LED Error Possible causes Measures and Description remedies "Ready" LED lights up red Error in the TSE/TUSE For fault description on the mPro400GC-M display, see 15.5Nutsetter control unit mPro400GC-M ➔ "Ready" LED does not light 24 V supply is unavailable, the Measure the voltage TSE/TUSE is not connected to...
  • Page 71 Troubleshooting Error Possible causes Measures and Description remedies Servo: Error in Check the resolver wires in the IP monitoring: NOK motor position tracing, nutsetter cable (also displayed in the rundown i.e. resolver cable ➔ Replace the nutsetter cable data table) and check the resolver wires Overload in the nutsetter cable for...
  • Page 72 Troubleshooting Error Possible causes Measures and Description remedies Servo: The temperature sensor in the Check temperature if > 80 °C Temperature output section: TSE/TUSE measures a tempera- ➔ ensure adequate ventilation too high ture > 80 °C of the DGD-IS The temperature in the DGD-IS is ventilated sufficiently TSE/TUSE output section is...
  • Page 73 Troubleshooting Error Possible causes Measures and Description remedies Motor: in the motor Check the motor for short circuits Short circuit surveillance: NOK (for phase impedances, see Motor short circuit monitoring above) There is a short circuit in the ➔ Replace motor motor circuit on the DGD-IS In the TSE/TUSE Internal error...
  • Page 74 Troubleshooting Error Possible causes Measures and Description remedies Measurement card: Internal error ➔ Replace the TSE/TUSE Sampling clock from servo: The system clock from the servo amplifier is missing Measurement card: Error in programming ➔ Check the system program- Servo type correct: NOK ming The selected servo amplifier type Self-identification of transducer is...
  • Page 75 Troubleshooting Error Possible causes Measures and Description remedies Measurement card: +12 V short circuiting in the Check the mPro400GC-M in the Voltage +12 V (…): NOK KMAG/KMAW or DGD-IS Diagnosis>Voltages menu. If The +12 V supply to the measur- values are outside permissible ing board and the transducer is limits, check the KMAG/KMAW outside the limits of...
  • Page 76 Troubleshooting Error Possible causes Measures and Description remedies Transducer: The torque signal is interrupted Check the mPro400GC-M in test Offset value: NOK mode Diagnosis>Voltages. The zero-point voltage is outside If values are outside permissible the permissible range of limits: -200 mV...+200 mV Check the KMAG/KMAW cable (transducer –...

  • Page 77: Maintenance / Service

    Maintenance / Service Maintenance / Service Only trained personnel are permitted to perform maintenance. Please refer to the Service Manual DGD-IS. DANGER! High leakage current – Fatal electric shock could occur! ➔ Always disconnect the power supply before performing maintenance work on the DGD-IS and the mPro400GC-M.
  • Page 78 Sales & Service Centers Note: All locations may not service all products. Please contact the nearest Sales & Service Center for the appropriate facility to handle your service requirements. Dallas, TX Detroit, MI Houston, TX Lexington, SC Apex Tool Group Apex Tool Group Apex Tool Group Apex Tool Group...

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