Cleco DGD mPro400GC Programming Manual
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Cleco DGD mPro400GC Programming Manual

Global controller
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Programming Manual
PL12EN-1001
2011-04
mPro400GC
Global Controller
For additional product information visit our website at http://www.apextoolgroup.com

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  • Page 1 Programming Manual PL12EN-1001 2011-04 mPro400GC Global Controller For additional product information visit our website at http://www.apextoolgroup.com...
  • Page 2 Identifies instructions to be followed Disclaimer: Cleco reserves the right to modify, supplement or improve this document or the product without prior notice. This document may not be reproduced in whole or in part in any way, shape or form, or copied to another natural or machine-readable language or to a data carrier, whether electronic, mechanical, optical or other- wise, without the express permission of Cleco.

  • Page 3: Table Of Contents

    Contents Set-Up Guide Controller description................6 General Information ................7 Checking your unit ................7 Software....................7 Installing the Unit .................. 7 Mounting the Controller ................ 8 Making Connections to the Controller........... 9 Accepting a Corded Tool ..............10 Accepting a LiveWire Tool ..............12 1.10 Programming a Basic Fastening Strategy ..........
  • Page 4 PL12EN-1001 2011-04 PL12EN-1001_2011-04_mPro400GC_V1.0IVZ.fm, 07.04.2011...
  • Page 5 Workplace safety symbols Warning notes are identified by a signal word and a pictogram: • The signal word describes the severity and the probability of the impending danger. • The pictogram describes the type of danger. Observe these notes and proceed with special care in the situations described. Pass all safety instructions on to other operators.

  • Page 6: Set-Up Guide

    Set-Up Guide Set-Up Guide Controller description The mPro400GC product line consists of three controllers; Master, Primary and Secondary. • Primary - Controls up to sixteen (16) tools. This unit includes a servo. One (1) standard corded hand- held or fixtured tool could directly connect. For further corded tools / fixtured spindles are Secondary controllers required.

  • Page 7: General Information

    Set-Up Guide General Information It is mandatory that national, state and local safety and wiring standards be followed during installation. These standards take precedence over any information presented in this section. CAUTION! To avoid the hazard of electrical shock or burn, the following instructions must be adhered to. Failure to fol- low these instructions may also cause damage to your unit and void existing warranties.

  • Page 8: Mounting The Controller

    Set-Up Guide • Location of printer • Attachment of a data collection unit, if desired. • Attachment of remote annunciators, socket nest, or remote parameter select. • Attachment of the unit in a network to a computer. • Operation convenience/safety – keep cables off the floor or dangling in operator areas. 1.5.3 Power source The controller requires a power supply connection of:...

  • Page 9: Making Connections To The Controller

    Set-Up Guide Making Connections to the Controller Connect the cable to the tool. Connect the other end of the cable to the controller. The connector at the controller is an Air-LB con- nector and utilizes a push-pull style connector. Before attempting to attach the cable verify that the collar on the controller connector is pushed towards the controller.

  • Page 10: Accepting A Corded Tool

    Set-Up Guide Accepting a Corded Tool Fig. 1-2 Run Screen When the controller has finished booting up it should advance to the Run screen. The screen is a touch screen. At the lower right corner of the screen press <Navigator>. Fig.
  • Page 11 Set-Up Guide Fig. 1-4 Tool Setup – Tool List Touch the horizontal bar indicating the Primary tool to highlight it. Touch <Tool Settings>. Fig. 1-5 Tool Setup Tool Settings Verify that the tool shown is the tool connected. Check the Model number and Serial Number. If the tool is correct press <Accept>.

  • Page 12: Accepting A Livewire Tool

    Set-Up Guide Accepting a LiveWire Tool Live wire communication requires three items; Tool, Controller, and Access point. Each item will require an IP address. All the IP addresses will be similar in structure such as 192.168.0.100, 192.168.0.110, 192.168.0.120, etc. The access point will also have a SSID name, which will need to be entered in the con- troller.
  • Page 13 Set-Up Guide 1.9.2 RF (Radio Frequency) Settings Setting Up the LiveWire Tool Fig. 1-7 Tool Setup – RF Settings Select Navigator Menu > Tool Setup > RF Settings > IRDA Serial. Correct port depending on the port connected to at the base of the controller. (CON 1 and CON 2 are X4 and X5 respectively at the con- troller.) If serial connectivity has been made the SSID, Encryption, and remaining fields will become avail- able for programming.
  • Page 14 Set-Up Guide Fig. 1-9 Tool Setup – Install Press <+ Install> and select the LiveWire w/WLAN choice from the popup screen that appears. Enter the Live Wire IP Address for the tool. Without DHCP this should be the same address as entered in Step 2, 1.9.2 RF (Radio Frequency) Settings, page 13.

  • Page 15: Programming A Basic Fastening Strategy

    Set-Up Guide 1.10 Programming a Basic Fastening Strategy Fig. 1-11 Tool Application Fastening Strategy Select Navigator Menu > Basic and the Basic Application Builder screen with appear. Verify that the Tool and Application are correct. Select a Fastening strategy, Torque Control/Angle Monitor or Angle Control/Torque Monitor.

  • Page 16: Manual Programming

    Set-Up Guide Fig. 1-13 Torque Control/Angle Monitor Select Navigator Menu > Basic > Auto Progr…. Enter the desired final stage torque value using the virtual keypad. Press <Enter> to close the keyboard. Press <OK> from the Auto Program screen. Lim- its of ±15% will be provided.
  • Page 17 Set-Up Guide Fig. 1-15 Manual Programming Touch the Torque High Limit field and a keyboard will appear. Enter the desired High Torque value. Whole numbers do not require decimal points. They will be added automatically. Use the Tab key on the keyboard to move the keyboard to the next field.

  • Page 18: Controller Specifications

    Controller specifications Controller specifications Fig. 2-1 System Overview PL12EN-1001 2011-04 en02d441_bedingt.fm, 07.04.2011...
  • Page 19 Controller specifications Position Description Position Description System Bus Connector Serial Connector #2 Tool Connector Anybus Fieldbus Power Connection Serial Connector #1 Mounting Bracket Screw 11 USB ports (2) Mounting Bracket Screw 12 Ethernet Connector #2 I/O Connectors Ethernet Connector #1 Anybus Fieldbus Fig.
  • Page 20 Controller specifications 10.38" (263 mm) 4× 1.315" 4× 7.750" (33.4 mm) (197 mm) 1.825" (46.4 mm) 2× 1.250" (31.8 mm) 2× 12.500" 14.88" (318 mm) (378 mm) 0.075" (1.9 mm) 10×.270“ (6.86 mm) 10×.503“ (12.8 mm) 10×.313“ (1.95 mm) Fig. 2-3 Mounting Information PL12EN-1001 2011-04 en02d441_bedingt.fm, 07.04.2011...

  • Page 21: Technical Data

    Controller specifications Technical Data 2.1.1 Housing The Global Controller is factory sealed with external access to all connectors. The front of the unit has a USB and power switch. On the back of the enclosure is a cover plate that can be removed to access the Compact Flash card which contains all program data.
  • Page 22 Controller specifications Pin 24 Pin 12 Pin 13 Pin 1 Fig. 2-4 Primary / Master Pin Configuration Pin # Description Pin # Description GND2 GND2 Common GND Common GND Output O 03 Output O 07 Output O 02 Output O 06 Output O 01 Output...
  • Page 23 Controller specifications Note: The Primary configuration has an output connector only. The Secondary and Master configurations have both an input and output connector. AC power supply • 104–126 VAC or 207–253 VAC • 50–60 Hz single phase • 1 A Input current (rated), 16 A (peak) 2.1.3 Secondary Configuration Pin 24...
  • Page 24 Controller specifications System Bus Address Two rotary dials are used to manually set the address for System Bus Devices. Turn the dial until the desired number appears in the slot. The dial closer to the front of the unit is the most significant digit. The dial closer to the system bus connectors is the least significant digit.

  • Page 25: Programming

    Programming Programming Navigator Fig. 3-1 Navigator Menu Application Builder <Basic> Allows the user to graphically select and program a two-stage rundown for Torque Control/Angle Monitor (SEQ 11 + SEQ 30) or Angle Control/Torque Monitor (SEQ 11 + SEQ 50) for any of the 99 Applications. The user only enters Torque, Angle, and Speed parameters in one screen.

  • Page 26: Basic

    Programming <Archive> Chronological History are viewable from this screen. Data can be erased as well. <Diagnostics> Contains screens to determine if the system is functioning properly. <Utilities> Contains functions for upgrading or changing the system software. From the Utilities the user can update the mPro400GC application software, or install a new firmware version in the Tightening Module.
  • Page 27 Programming 3.2.1 Basic Application Builder Parameters Parameter Name Range Typical Fastening Strategy Torque Control/Angle Monitor Torque Control/Angle Monitor Fastening Strategy Angle Control/Torque Monitor Angle Control/Torque Monitor Trigger Torque [Nm] 0 to Tool Max 10% of Turnoff Torque Turnoff Torque Stage 1 [Nm] 0 to Tool Max As appropriate Threshold Torque [Nm]...

  • Page 28: Standard

    Programming application. When using Copy function from the Basic Application Builder, all stages of the selected applica- tion are copied. Multiple target applications may be specified by separating the application numbers with a comma. Ranges could specified with minus, e.g. 2,10–15, 99… Standard Fastening stage summary Spindle status summary...
  • Page 29 Programming 3.3.1 Fastening stages summary The summary shows which fastening stages are to be run, displayed and printed out. The functions are dis- played as active if they have already been activated for at least one spindle. Display and Print are only displayed if the stage is activated (green = activated, red = deactivated). 3.3.2 Spindle status summary The summary displays which spindles are installed and which of the installed spindles have been activated.
  • Page 30 Programming Fig. 3-3 Fastening Stages The headline shows the application and the spindle you are currently programming. In each application each spindle used (activated) must be programmed in this way. Various copy functions reduce the effort required when making inputs. Fastening stages shows which stages are activated and which sequences are processed by the spindle selected in which stage.
  • Page 31 Programming The target values for the releasing stage are stored permanently in the control unit. If the <Release> is acti- vated, the spindle automatically moves 3 degrees or 1/6 of the min torque of the last activated stage. The evaluation of the releasing stage is shown in the spindle monitor only. The rundown data of the releas- ing stage cannot be printed, even in the event of an error.
  • Page 32 Programming Number N The number N defines the rundown interval at which this stage is to be printed. The results for all spindles will be printed. If the stage is to be printed for every stage, N = 1 must be entered. NOK print This function prints all spindles in this stage with NOK results.
  • Page 33 Programming Fig. 3-6 Rundown Programming after pushing graphic button This summary shows the application with its identifier, the spindle, and the stage to be programmed. The sequence currently selected is displayed when you press <Sequences>; a different sequence can be selected here.
  • Page 34 Programming If a value is out of range or not plausible, the program displays an error message and returns to Rundown programming. Additional limitations result from process-related interdependencies of the parameters, e.g. minimum torque Tqmin must not be higher than maximum torque Tqmax. Both are also examined in a plausibility check when you exit Rundown programming.
  • Page 35 Programming Fig. 3-7 Fastening stage timing Range of values When Fastening stage timing is completed, the entered parameters are checked for agreement with the permitted value ranges. If a value is out of range, the program displays an error message and returns to Fastening stage timing. Parameters Explanation Fastening time...

  • Page 36: Advanced

    Programming 3.3.7 Extended NOK Strategy Touch up / Error handling The NOK strategy comprises touch up and error-handling. Another fastening stage may be started after a touch up, while error-handling leads to the end of the process. This allows joint backoffs in the touch up rou- tine and these can be retightened in the further fastening sequence to achieve an OK rundown.
  • Page 37 Programming 3.4.2 Inputs Each of the physical inputs 0–7 can be programmed to have one of the following definitions: Not Used Unused Tool Enable When active, allows the tool to run in conjunction with Tool Start. Tool Start Starts the tool. External Tool Start Allows external input to control the start of the tool.
  • Page 38 Programming 3.4.4 Linking Fig. 3-9 Linking Linking allows the user to automatically change from application to application for a predefined number of positions (cordless EC tools up to 40, corded tools up to 96). Each application is run when the start switch on the tool is activated in the order specified by its position.
  • Page 39 Programming 3.4.5 Controller Settings Fig. 3-10 Controller Settings Allows the user to assign a name to the controller. Name Allows the user to assign a number to the controller. Number Allows the user to change the units for the controller. Available units are Nm, FtLbs, Torque Units InLbs, dNm.
  • Page 40 Programming 3.4.6 Tool Settings Fig. 3-11 Tool Settings Allows the user to give the tool a name. This name will be displayed in all Tool drop Tool name down lists. Allows the user to enter the maximum number of rejects that will be permitted before a Max Number release signal is required.

  • Page 41: Run Screen

    Programming Run Screen Fig. 3-12 Run Screen From the Run Screen the user sees rundown data as it occurs. The Torque and Angle readings are dis- played with a background color corresponding to the status of each. The background is red if the value is too high, yellow if it is too low, and green if it is within limits. The current tool model number, station name, and indicator labels are also displayed.
  • Page 42 Programming Input Status Indicates whether or not a new Part ID can be entered (screen above). Data function Status Yellow Accepting Part ID input A new Part ID may be entered. Not Accepting Part ID input A new Part ID may not be entered. A new Part ID may not be entered when the tool trigger is active.

  • Page 43: Communications

    Programming 3.5.2 Oscilloscope The Oscilloscope function displays a Torque curve after each complete rundown in the tightening direction. The curve is colored in alternating red (pink) and blue lines to indicate the different stages. A green box is also displayed on the trace to indicate the torque and angle limits. There is a data point for each degree of angle rotation.
  • Page 44 Programming Serial Protocol None, AVIS, PFCS Port COM1, COM2 Baud Rate 2400, 4800, 9600, 14400, 19200, 38400, 57600, 115200 Data Bits 7, 8 Parity None, Odd, Even Stop Bits 1, 2 Flow Control None, Hardware Ethernet Protocol None, Standard, Standard Plus, WinSPC, CooperNet, PFCS The Ethernet settings are •...
  • Page 45 Programming Settings Defines the level of functionality of the Part ID Enabled • No: The Part ID interface is completely disabled. No Part ID information is present on the Run Screen. • Yes: The Part ID interface is enabled and is present on the Run Screen. A valid part ID is NOT REQUIRED to run the tool.
  • Page 46 Programming Allows the tool functionality to be automatically controlled based on the Part ID. Special • Disabled: The Part ID characters have no control over the tool functionality. Function Note: Setting this option to Disabled does NOT cause Configure Data table entries to be lost.
  • Page 47 Programming 3.6.3 Network Settings Fig. 3-16 Network Settings The Network settings tab is used to configure how the controller will communicate over a network. The Ethernet settings are • Default Gateway • Domain Suffix • Primary DNS • Secondary DNS •...

  • Page 48: Tool Setup

    Programming Tool Setup For accepting a tool see 1.8 Accepting a Corded Tool, page 10 and 1.9 Accepting a LiveWire Tool, page 12. 3.7.1 Tool List Fig. 3-17 Tool List The Tool List displays installed tools, and gives a user the ability to install, edit and uninstall tools. Tool List Table: Displays the associated tool's number.
  • Page 49 Programming <RF Settings> <RF Settings> button brings up the LiveWire configuration application. • Communication With Tool IRDA off: IR communication with LiveWire tool is turned off IRDA Serial: IR communication with LiveWire tool is set-up through the selected IRDA Gateway IP: IR communication with LiveWire tool made through a Ethernet gateway. •...

  • Page 50: Archive

    Programming Archive Fig. 3-19 Archive In the archive, all rundown data is saved in a ring buffer. The number of entries it can hold depends on the number and scope of the individual archived rundown sequences. Approx. 400 rundown sequences with no archived graphics or 100 rundown sequences with archived graphics can be saved.

  • Page 51: Diagnostics

    Programming Diagnostics Fig. 3-20 System Test 3.9.1 Inputs/Outputs <Data Transmission> Allows the user to analyse Serial and Ethernet data transmission. <System Bus> A Map of all available Arcnet users is displayed by node, status, ID, serial number, and software version. <I/O-Level>...
  • Page 52 Programming <Angle Encoder> The button <Start> starts the spindle with a speed of 30% of the maximum. After one revolution of the out- put shaft (set angle 360 deg), measured with the tool resolver, it is stopped. During a permanently set dwell time of 200ms any further angle pulses occurring are traced.

  • Page 53: Utilities

    Programming 3.10 Utilities 3.10.1 Installed Versions Fig. 3-21 Utilities, Installed Versions Displays the installed controller software version. 3.10.2 Software Update Fig. 3-22 Utilities, Software Update Allows to update the controller software and the tightening module software. PL12EN-1001 2011-04 en03d441.fm, 07.04.2011...

  • Page 54: Administration

    Programming 3.10.3 System Settings Fig. 3-23 System Information <System information> displays information pertaining to the controller. It allows the user to select specific information or display all information. 3.11 Administration Fig. 3-24 Administration PL12EN-1001 2011-04 en03d441.fm, 07.04.2011...
  • Page 55 Programming 3.11.1 Counters Fig. 3-25 Counters The counter allows the user to count the number of OK and NOK rundowns. This data will be displayed on the Run Screen. 3.11.2 Print Fig. 3-26 Print Parameters Selecting the <File> option saves the selected print data in a file. The file name should have a maximum of 8 characters, not including the file extension.
  • Page 56 Programming 3.11.3 Date / Time Fig. 3-27 Date / Time Each parameter that the mPro400GC saves with the date or time refers to the realtime clock. This is the case e.g. for the rundown process time. The setting must therefore be checked regularly. Date and time must be entered in the required format.
  • Page 57 Programming 3.11.6 Users Fig. 3-29 Users Access to the functions and parameters can be protected by registering users and allocating access rights. Ten different users can be registered. Password protection is deactivated if no users are registered. A password prompt will not appear for any function.
  • Page 58 Programming 3.11.8 Save Parameters Fig. 3-31 Save Parameters All settings and parameters are saved during the data backup. The backup can be performed for all or only for individually selected parameters and settings. The data can be saved on the internal data storage facility (CF card) or a connected USB drive.

  • Page 59: Troubleshooting

    Troubleshooting Troubleshooting Problem Possible cause Corrective Action General ➔ No parameter is dis- Rundown sequence Use Standard Application Builder to display played in the Basic other than two-stage and edit the parameter. Application Builder. SEQ 11/30 or SEQ 11/ 50 is programmed. Not all or none of data Filter active.
  • Page 60 Troubleshooting Problem Possible cause Action Infrared data communication between controller and tool ➔ No infrared data Wrong port is selected Check the port settings for infrared (IRDA) communication for connection with the communication in Communication > Tool between controller and controller.
  • Page 61 Troubleshooting Problem Possible cause Action Barcode scanner on tool Barcode scanner does Parameter for Part ID is ➔ In the Communication > Part ID screen of the not activate when the not set to Enable Inter- controller, check that the Enable parameter is start switch is pressed.
  • Page 62 Troubleshooting PL12EN-1001 2011-04 en04d441.fm, 07.04.2011...

  • Page 63: Glossary

    Glossary Glossary Term Description Accepted Data Data that fall within the acceptable limits in a fastening strategy. Angle Angle that is to be reached at the end of the fastening sequence (also final angle, rated angle, or nominal angle). Angle Capability Indexes Measure of acceptable variation of final angle values in a fastening process.
  • Page 64 Glossary Term Description Fastening Strategy Strategy used to control or monitor a fastening process Final Angle Final angle desired in a fastening process Histogram Printout generated from statistical data output If NOK go to stage Gives the control system direction if the stage is NOK Internal Transducer Transducer physically located inside the tool LCD Screen...
  • Page 65 Glossary Term Description Sequence 11 High speed rundown Sequence 16 Depth sensor, Angle Control with Angle and Torque Monitoring Sequence 30 Torque control/angle monitor Sequence 41 Angle controlled backoff Sequence 50 Angle control/torque monitor Speed Nominal speed of nutrunner during a stage Standard Deviation (s) Measurement of the scatter of the population around a mean Start Delay Time (ms)
  • Page 66 Glossary Term Description Transducer Rated Torque Torque calibration value that must be set at rated torque of the trans- (torque calibration) ducer Trigger Torque (Nm) Torque to start collecting oscilloscope data Turn Off Angle Angle at which a tool is shut-off Turn Off Torque Torque at which a tool is shut-off PL12EN-1001 2011-04...
  • Page 68 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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