SPX CS4000 Mini Technical Reference Manual
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SPX CS4000 Mini Technical Reference Manual

Mini controller with ethernet
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CS4000 Mini Controller
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Technical Reference Manual

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  • Page 1 CS4000 Mini Controller with Ethernet Technical Reference Manual...

  • Page 2: Technical Support

    24-Hour Technical Support Toll Free: 1-877-224-7377 ® SPX GSE tech-motive tool manufactures products under the GSE and tech-motive tool brand names.
  • Page 3 Please Note: has a new name. We are now This change of name is not yet reflected in the documentation for this product where you will still find the old logo and company name. The new address is: SPX GSE tech-motive tool 42860 Nine Mile Road, Novi MI 48375-4122 The toll free service number remains the same: 1-877-224-7377.

  • Page 4: Limited Warranty

    LIMITED WARRANTY 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 year from the date of shipment from the manufacturing facility.
  • Page 5 Acknowledgments Special thanks are extended to the following SPX GSE tech-motive tool management, software and hardware engineers who provided value information in the development and review of this manual. Jim Grenier Tom Jozwiak Ken Lehoczky Larry Piggins Rick Szwast Steve Urbanski Bill Welch Karen R.

  • Page 6: Preface

    This Preface provides conventions and abbreviations used throughout this manual. If you have never used a CS4000 Mini Controller with Ethernet, read this manual entirely. The first three chapters will help you become familiar with safety requirements, the location of components, software and features.
  • Page 7 CS4000 Mini Controller with Ethernet If you want to use the CS4000 Mini Controller with Ethernet with a network or laptop computer, refer to Chapter 5. Setting Up the Ethernet, Chapter 6. Setting Up the 485 Network and Chapter 7. Setting Up the RS-232 Link that describe the methods by which you can connect the CS4000 Mini Controller to a network or laptop computer.

  • Page 8: Abbreviations

    Preface Abbreviations Some of the most common abbreviations used throughout this manual include the following: Application Program Interface GFCI Ground Fault Circuit Interrupter Input/Output IEEE Institute of Electrical and Electronic Engineers Internet Protocol kbps kilo-bits per second kilovolt-ampere Local Area Network Light Emitting Diode mbps million bits per second...
  • Page 9 CS4000 Mini Controller with Ethernet (This page is left blank intentionally.) Page T-38324-A 39-30-38324...

  • Page 10: Table Of Contents

    Using a 485 Network using SDLC ................1-4 Example of a “Permanent” (Embedded) 485 Network ..........1-5 (Using CS4000 KDM and Mini Controllers with SDLC)..........1-5 Using the RS-232 Serial Port ..................1-6 Using an Interbus-S Digital I/O Module ..............1-6 Using the Siemens 3964R Barcode Protocol.............
  • Page 11 Interbus-S Module....................3-16 Ground Fault Circuit Interrupter ................3-18 Fuses ........................3-18 4. Installing the CS4000 Mini Controller with Ethernet..........4-1 Mounting the CS4000 Mini Controller with Ethernet ..........4-1 Power and Connection-Requirements ............... 4-3 Meeting the AC Input Power Requirements .............. 4-4 Grounding ........................
  • Page 12 Contents 7. Setting Up the RS-232 Link..................7-1 Setting Up Visual Supervisor ..................7-1 Using RS-232 Cables....................7-1 8. Maintenance/Troubleshooting ..................8-1 Replacement Parts ....................... 8-1 Replacing Main Power Fuses ..................8-2 Replacing Backplane Fuses ..................8-2 Cleaning the Enclosure Window................. 8-2 Troubleshooting ......................
  • Page 13 Figure 3-2. Top Panel View....................3-3 Figure 3-3. Bottom Panel View..................3-4 Figure 3-4. Components Inside the Enclosure of the CS4000 Mini Controller with Ethernet ....................3-7 Figure 3-5. Front View of the TCM..................3-8 Figure 3-6. Rear View of the TCM and Location of the Servo Amplifier Fuse ....3-9 Figure 3-7.
  • Page 14 Figure 9-1. CS4000 Mini Controller with Ethernet Wiring of Standard Ethernet and Interbus-S Module................... 9-3 Figure 9-2. CS4000 Mini Controller with Ethernet Wiring of Standard Ethernet ....9-5 Tables Table 3-1. Description of Ethernet Interface Card LEDs..........3-15 Table 3-2.
  • Page 15 CS4000 Mini Controller with Ethernet (This page is left blank intentionally.) Page T-38324-A 39-30-38324...

  • Page 16: Overview

    You simply plug in the tool, power up the system, program the desired tightening parameters and begin production. A complete fastening system is made up of the CS4000 Mini Controller (with or without) Ethernet, a tech-motive tool nutrunner (46, 66 or 116 Series) and a standard tech-motive tool cable. The CS4000 Mini Controller with Ethernet houses one Tool Control Module (TCM), with fuses and ground fault circuit interrupt (GFCI) protection.

  • Page 17: Using Ethernet

    4.06 or higher installed on the controllers. The CS4000 Mini Controller with Ethernet also has an optional Application Program Interface (API) which you can have built into each controller. This allows you to collect rundown data and send it to a software application across the Ethernet network, other than Visual Supervisor.

  • Page 18: Example Of A "Permanent" (Embedded) Ethernet Network

    Example of a “Permanent” (Embedded) Ethernet Network (Using Mini Controllers with Ethernet) Pentium Class Computer running Windows 95, 98, 2000 CS4000 Mini Controllers with Ethernet or Windows NT, version 4.0 or above. It also has an installed Ethernet interface card. Each controller has an Ethernet connector.

  • Page 19: Using A 485 Network Using Sdlc

    CS4000 Mini Controller with Ethernet Using a 485 Network using SDLC In a 485 network, the controller is linked to a LAN, via cable between the first controller’s RS-485 connector and the port for the Synchronous Data Link Control (SDLC) card installed on the host computer.

  • Page 20: Example Of A "Permanent" (Embedded) 485 Network

    Chapter 1. Overview Example of a “Permanent” (Embedded) 485 Network (Using CS4000 KDM and Mini Controllers with SDLC) KDM based CS4000 Compact Controller (in read-only mode) contains one or two CS4000 Mini Controller each contains Pentium Class Computer running TCMs one Tool Control Module (TCM) Windows NT, version 4.0 or above, with an...

  • Page 21: Using The Rs-232 Serial Port

    CS4000 Mini Controller with Ethernet Using the RS-232 Serial Port In this configuration, a laptop PC loaded with the Visual Supervisor software is linked to the controller’s RS-232 serial port. See Figure 1-1 on page 1-3. Because the laptop can be disconnected from one Mini Controller and reconnected to another, VS is said to be operating in portable mode.

  • Page 22: Using The Siemens 3964R Barcode Protocol

    The following chapter describes the basic components of the controller so you can familiarize yourself with them before you install it. Chapter 4. Installing the CS4000 Mini Controller with Ethernet describes how to mount the controller and how to make sure you fulfill its power requirements.
  • Page 23 CS4000 Mini Controller with Ethernet (This page is left blank intentionally.) Page T-38324-A 39-30-38324...

  • Page 24: Think Safety First

    If you are an operator or service technician, you should become familiar with the contents of this manual before operating, servicing, or maintaining any part of the CS4000 Mini Controller with Ethernet, including the 66 Series fastening tools. Familiarization with all components of the system can minimize the possibility that an accident or injury might occur.

  • Page 25: General Machine Safety

    CS4000 Mini Controller with Ethernet General Machine Safety FOR YOUR OWN SAFETY READ THE INSTRUCTION MANUAL THOROUGHLY PRIOR TO OPERATING THE TOOL. DO NOT WORK IN A DANGEROUS ENVIRONMENT. Do not use power tools in a damp or wet location or expose them to rain, oils, or corrosive fluids.

  • Page 26: Electrical Safety

    Chapter 2. Think Safety First! MAINTAIN TOOLS IN TOP CONDITION. Keep tools properly lubricated and clean. If any wires become frayed or exposed, replace them immediately. Prevent dirt, grease or contaminants from getting into the tool. REDUCE THE RISK OF UNINTENTIONAL STARTING. Be careful how the tool is left unattended.
  • Page 27 CS4000 Mini Controller with Ethernet Always use fuses of a capacity smaller than or equal to the safe capacity of the line or the equipment it serves. Before you work on any circuit, check it with an appropriate testing device to be sure voltage is not present.

  • Page 28: Identifying The Components

    3. Identifying the Components The CS4000 Mini Controller with Ethernet houses all the standard functions of the standard CS4000 Mini Controller, but also has the ability to communicate across an Ethernet Local Area Network (LAN) using the standard Ethernet protocol, Transmission Control Protocol/Internet Protocol (TCP/IP).

  • Page 29: Front Panel

    CS4000 Mini Controller with Ethernet Front Panel Figure 3-1 shows the front panel components of the CS4000 Mini Controller with Ethernet. AC Power Cord Display Access Screws CS4000 mini SYSTEM CONTROLLER Parameter Select Switch 4 5 6 Figure 3-1. Front Panel View NOTE: The AC power cord is described in the Top and Bottom Panel section later in this chapter.

  • Page 30: Parameter Set Switch

    Figure 3-2. Top Panel View AC Power Cord A power cord connection is available on the top of CS4000 Mini Controller with Ethernet. The power cords it accepts are the 6-ft American style 20A, 240V AC power cord (part number 299250-32835) or the 2.5-m European style 10A, 240V power cord (part number 22-30-1021).

  • Page 31: I/O Connector

    (part number 23-10-5200). The mating connector enables connection of your own remote control and/or monitoring devices, such as external annunciator lamps or remote cycle-on contacts. Refer to I/O Wiring in Chapter 4. Installing the CS4000 Mini Controller with Ethernet for pinout details. Tool Connector The 37-position connector is the interface between the 46, 66 and 116 Series nutrunner cable and control electronics.

  • Page 32: Rs-422 Connector

    The RJ-45 Ethernet connector enables the controller to communicate and send data to and from a host device on the same Local Area Network (LAN) using standard Ethernet protocols (Transmission Control Protocol/Internet Protocol, TCP/IP). Refer to Chapter 4. Installing the CS4000 Mini Controller with Ethernet for details.

  • Page 33: Fuses

    Fuse 1 and Fuse 2 are 15A, 250V, SLO-BLO fuses, Littelfuse 326015 or equivalent (part number 13-10-1015). Enclosure Interior The enclosure interior for the CS4000 Mini Controller with Ethernet includes the following components and sub-components: Tool Control Module (TCM), that includes:...

  • Page 34: Figure 3-4. Components Inside The Enclosure Of The Cs4000 Mini Controller With Ethernet

    Exterior Wall Ethernet Interface Card Power Supply Backplane Figure 3-4. Components Inside the Enclosure of the CS4000 Mini Controller with Ethernet NOTE: The AC power cord is described in Top and Bottom Panel earlier in this chapter. May 2002 T-38324-A...

  • Page 35: Tool Control Module

    The TCM and its attached tool are referred to as a spindle. The TCM houses both the servo amplifier and Device Control Module (DCM). For the location of the TCM inside the CS4000 Mini Controller with Ethernet, see Figure 3-4 on page 3-7.

  • Page 36: Figure 3-6. Rear View Of The Tcm And Location Of The Servo Amplifier Fuse

    Chapter 3. Identifying the Components The TCM has a small four-digit display, a column of nine indicator LEDs, and two potentiometers. The LEDs provide status and condition information about the connected nutrunner. The indicator LEDs are labeled: READY ANGLE HI GOOD ANGLE LOW SPINDLE FAULT...

  • Page 37: Servo Amplifier

    The Device Control Module (DCM) is an electronic circuit board that contains powerful 80186EA processor. It is paired with the servo amplifier inside the TCM. The DCM is the brain of the CS4000 Controller with Ethernet. It receives signals from the nutrunner control switches, the set point inputs, the nutrunner torque sensor, and remote control inputs and generates the appropriate outputs to the servo amplifier control inputs, the status output relays, and the nutrunner status LEDs.

  • Page 38: Backplane

    (DCM) Fuse, F4 Jumpers, JP1 to JP8 Address Switch, Jumper, JP9 SW-1 +24VDC Input Fuse, F3 +24VDC Fuse to Tool, F2 +24V Input, J8 I/O Board, J2 Figure 3-8. CS4000 Mini Controller with Ethernet Backplane May 2002 T-38324-A Page 3-11...

  • Page 39: Backplane Fuses

    CS4000 Mini Controller with Ethernet Backplane Fuses Fuse F4 is Littelfuse 239001, 5x20 mm, 1A, SLO BLO (SB) 250V (part number 13-10-61001). Fuse F4 protects the DCM board inside the TCM. Fuses F2 and F3 are Littelfuse 255.500, subminiature 0.5A (part number 13-10-4050). Fuse F2 protects the 24VDC to the tool, and Fuse F3 protects the 24VDC used with the discrete I/O circuits.

  • Page 40: I/O Board

    Chapter 3. Identifying the Components I/O Board The I/O board shown in Figure 3-9 is inserted into a connector, J2, on the backplane. It interfaces to all of the connectors available on the bottom of the controller, see Figure 3-3 on page 3-4. On the top side of the I/O board are some diagnostic connections (J19 and J20) for digital I/O.

  • Page 41: Ethernet Interface Card

    The Ethernet interface card lets you connect individual controllers to a host device forming a LAN, using TCP/IP. The card comes with its own software and fits into the interior of the CS4000 Mini Controller with Ethernet, forming a connection with the Ethernet connector on the bottom panel of the controller.

  • Page 42: Table 3-1. Description Of Ethernet Interface Card Leds

    Ethernet Interface Flash Utility on a laptop connected to the Ethernet interface card, via J7. Refer to Chapter 4. Installing the CS4000 Mini Controller with Ethernet for further details. You can also obtain diagnostics information on the state of the Ethernet network through the Ethernet interface card using Hyperterminal.

  • Page 43: Interbus-S Module

    When it is included in the controller enclosure, it provides another I/O interface, usually to an external, remote PLC. The module is housed inside the CS4000 Mini Controller with Ethernet enclosure. See Figure 3-4 on page 3-7.

  • Page 44: Figure 3-12. Interbus-S Module Top View

    Chapter 3. Identifying the Components Table 3-2 describes the LEDs. Table 3-2. Description of LEDs on the Side of the Interbus-S Module LED Name Description Steady yellow light indicates the +24V power supply is connected to 24V Power Supply the Interbus-S module. Remote Bus Connected Steady green light indlicates the remote bus is connected.

  • Page 45: Ground Fault Circuit Interrupter

    CS4000 Mini Controller with Ethernet Ground Fault Circuit Interrupter The Ground Fault Circuit Interrupter (GFCI) is wired in series from the AC power input to the servo amplifier. It monitors both AC power leads to the servo amplifier, ensuring that current flowing in one lead is the same as the current flowing out the other lead.

  • Page 46: Installing The Cs4000 Mini Controller With Ethernet

    4. Installing the CS4000 Mini Controller with Ethernet This chapter shows you how to mount and wire the CS4000 Mini Controller with Ethernet. Mounting the CS4000 Mini Controller with Ethernet The CS4000 Mini Controller with Ethernet is installed vertically with the back flat against the mounting surface.

  • Page 47: Figure 4-1. Cs4000 Mini Controller With Ethernet Dimensions

    CS4000 Mini Controller with Ethernet NOTE: All dimensions are in inches with millimeters in square brackets. Figure 4-1. CS4000 Mini Controller with Ethernet Dimensions To mount the controller you require four 1/4-20-in bolts or screws. Page T-38324-A 39-30-38324...

  • Page 48: Power And Connection-Requirements

    WARNING! 230 VAC SINGLE PHASE INPUT ONLY. Internal capacitors store a high voltage charge and discharge slowly after external power is removed. Figure 4-2 shows the power supply and connection requirements of the CS4000 Mini Controller with Ethernet. Figure 4-2. Power/Connection Requirements...

  • Page 49: Meeting The Ac Input Power Requirements

    It is extremely important that you connect the CS4000 Mini Controller with Ethernet enclosure properly to an earth ground. The CS4000 Mini Controller with Ethernet has a ground prong on the power cord, (if supplied) but the AC outlet that will be used must be grounded properly, as well.

  • Page 50: I/O Wiring

    Chapter 4. Installing the CS4000 Mini Controller with Ethernet I/O Wiring The CS4000 Mini Controller with Ethernet is equipped with a 19-pin I/O connector for field I/O. The settings described in Table 4-1 are Visual Supervisor (VS) default settings. NOTE: The 14-shell, 19-pin strain relief mating connector for the I/O connector is part number 23-10-5200.
  • Page 51 After a fastening cycle has started, changing the state of these inputs Limit Set Select B2 input does not change which limit set the CS4000 Controller uses until the (Orange wire - internal) cycle on command (from either the nutrunner or the cycle on input or (White/Black wire - external)) both) is de-activated.
  • Page 52 Chapter 4. Installing the CS4000 Mini Controller with Ethernet Table 3-1. 19-Position Remote I/O Connector Pinout Signal Names and Descriptions (Continued) Signal Description This bi-directional signal is used for synchronizing two or more spindles Synchronization in/out in a multi-spindle fastening application. It is connected to both the...

  • Page 53: Figure 4-3. Remote Input Circuit Schematics

    CS4000 Mini Controller with Ethernet A remote input circuit schematic and remote I/O schematics for sourcing and sinking outputs are shown in Figure 4-3 through Figure 4-5. Figure 4-3. Remote Input Circuit Schematics To ensure that you operate the fastening system properly, refer to Table 4-2 for input requirements.

  • Page 54: Figure 4-4. Example Of Cs4000 Controller Remote I/O Wiring Sourcing Outputs

    Chapter 4. Installing the CS4000 Mini Controller with Ethernet Figure 4-4 is an example of the remote I/O wiring scheme using the defaults (voltage source) for the jumpers. It shows one of the many ways the remote I/O feature of the controller can be used. To ensure that you operate the fastening system properly, refer to Table 4-2 for output requirements.

  • Page 55: Figure 4-5. Example Of Cs4000 Controller Remote I/O Wiring Sinking Outputs

    2 and solder in place a jumper between pins 2 and 3 to take the I/O pin to ground. NOTE: JP9 ties discrete output 8 to discrete input 6 for spindle synchronization. Figure 4-5. Example of CS4000 Controller Remote I/O Wiring Sinking Outputs 4-10 Page...

  • Page 56: Connector Pinout Definitions

    Chapter 4. Installing the CS4000 Mini Controller with Ethernet Connector Pinout Definitions Pinout definitions are provided for the tool, I/O, RS-422, TCM network, RS-232, printer/barcode and Interbus-S connectors. Tool Connector Pin Designation Wire Color (Ref) Function POWER PHASE 1 POWER PHASE 2...

  • Page 57: Rs-422 Connector

    CS4000 Mini Controller with Ethernet RS-422 Connector Pin Designation Wire Color (Ref) Function BRN/WHT TXD+ OUT WHT/BRN TXD- OUT ORN/WHT RXD+ IN WHT/ORN RXD- OUT GRN/WHT Not used WHT/GRN Not used BLU/WHT SHIELD COMMON SHIELD Tool Control Module (TCM) Network Connector...

  • Page 58: Interbus-S "Out" Connector

    Chapter 4. Installing the CS4000 Mini Controller with Ethernet Interbus-S “OUT” Connector Pin Designation Wire Color (Ref) Function GND1 Not DO2 Not DI2 RBST May 2002 T-38324-A Page 4-13...
  • Page 59 CS4000 Mini Controller with Ethernet (This page is left blank intentionally.) 4-14 Page T-38324-A 39-30-38324...

  • Page 60: Setting Up The Ethernet

    5. Setting Up the Ethernet The CS4000 Mini Controller with Ethernet can be connected to an Ethernet Local Area Network (LAN). This chapter describes the steps you must take to set up the Ethernet LAN: Programming the Ethernet interface card...

  • Page 61: Procedure 5-1. Programming The Ethernet Interface Card

    The IP address consists of 32-bits (Internet Protocol version 4, IPv4) and is most often depicted in a dot address. This is the format in which you must enter IP addresses for the CS4000 Mini Controller with Ethernet software. It is called a dot address because the address is divided into four groups of decimal digits separated by a period.

  • Page 62: Figure 5-1. Message Upon Starting The Tini Ethernet Interface Flash Utility

    Chapter 5. Setting Up the Ethernet 4. Insert one of the female connectors on the null modem cable (part number 41-41-0109FN) into the 9-pin connector (J7) on the Ethernet interface card. See Figure 3-10 on page 3-14. As you open the enclosure door and look at the interior, the Ethernet interface card is mounted in the top left of the enclosure.

  • Page 63: Figure 5-2. Selecting The Com Port Menu

    CS4000 Mini Controller with Ethernet 9. Select the RS-232 serial communications port on your laptop that you will be using to send data to the attached Ethernet interface card. This is the communications port to which the null modem cable is attached.

  • Page 64: Figure 5-4. Establishing A Successful Connection Via Com1

    Chapter 5. Setting Up the Ethernet The TINI Ethernet Interface Flash Utility attempts to connect to the communications port you specified in Step 9. When the attempt is successful, the message shown in Figure 5-4 is displayed. Figure 5-4. Establishing A Successful Connection via COM1 When another utility or program is using the COM1 port, the attempt to establish a connection fails and the message shown in Figure 5-5 is displayed.

  • Page 65: Figure 5-6. Selecting The "Flash Tini..." Option

    CS4000 Mini Controller with Ethernet 10. Flash the application file to the Ethernet interface card. a. Click the Flash menu in the TINI Ethernet Interface Utility window. b. From the Flash menu, click Flash TINI…. Figure 5-6. Selecting the “Flash TINI…” Option 11.

  • Page 66: Figure 5-8. Error Message Displayed When The Attempted Connection Fails

    Chapter 5. Setting Up the Ethernet The TINI Ethernet Flash Utility connects to the Ethernet interface card, via the COM port you specified in Step 9. When the communications connection is successful, the yellow LED (LED6 on the Ethernet interface card) stops blinking and the flash utility begins flashing the application file to the Ethernet interface card.

  • Page 67: Figure 5-11. Confirming The Ip Address, Subnet Mask And Default Gateway

    CS4000 Mini Controller with Ethernet There are three possible reasons that a flash fails: The null modem cable has been inserted into the 9-pin connector (J7) on the Ethernet interface card incorrectly. The jumper (J1) labeled ‘Prog’ on the Ethernet interface card has been installed incorrectly.
  • Page 68 From the Flash menu, select Com Port. c. From the Com Port menu, select Close COM Port. 14. Close the CS4000 Mini Controller with Ethernet enclosure door. 15. Turn OFF power to the controller. 16. By hand, install the access screws back into place in the enclosure door, turning them clockwise to tighten them.

  • Page 69: Updating Application Settings

    CS4000 Mini Controller with Ethernet Updating Application Settings After you have flashed an application file to the Ethernet interface card, you may want to update settings without re-flashing the entire application file again. To do this, the TINI Ethernet Flash Utility has a menu option that allows you to update the IP address, subnet mask and default gateway values, and enable or disable application functions for the Ethernet network and RS-422 link.

  • Page 70: Figure 5-13. Viewing The Application Settings Window - General Info Tab

    Chapter 5. Setting Up the Ethernet The Application Settings window, shown in Figure 5-13, opens to display the General Info tab. This window shows you details of the last successful flash of an application file to the Ethernet interface card. You cannot change this information; it is automatically updated by the TINI Ethernet Flash Utility whenever a successful flash occurs.

  • Page 71: Figure 5-15. Selecting The Application Settings Window - Comm Options Tab

    CS4000 Mini Controller with Ethernet 4. To change the IP address, subnet mask and/or default gateway: a. Click on the IP Address:, Subnet Mask: or Default Gateway: field. b. Enter the new value. c. Repeat Steps a) and b) for all the fields you want to change.

  • Page 72: Setting Up Visual Supervisor For An Ethernet Network

    Chapter 5. Setting Up the Ethernet d. Click on the drop-down menu next to 3964R Baud Rate to change the baud rate used for communications to and from the barcode scanner attached to the RS-422 port. You can select from the following baud rates: 1200 19200 2400...

  • Page 73: Editing Vsmain.ini For An Ethernet Network

    CS4000 Mini Controller with Ethernet Editing VSMain.ini for an Ethernet Network When you are using the Ethernet link, you must also change VSMain.ini manually. In the following example, shown in Figure 5-16, VSMain.ini is configured to talk to four Tool Control Modules (TCMs) at IP addresses 10.1.100.167 through 10.1.100.170.

  • Page 74: Procedure 5-3. Editing Vsmain.ini For An Ethernet Network

    Chapter 5. Setting Up the Ethernet Use Procedure 5-3 to make the necessary changes to VSMain.ini. Procedure 5-3. Editing VSMain.ini for an Ethernet Network 1. Open VSMain.ini using Notepad. a. Click the Start menu on the Windows NT desktop. b. From the Start menu, select Programs. c.

  • Page 75: Using Ethernet Network Cables

    Visual Supervisor. Using Ethernet Network Cables The type of Ethernet cable you need to connect the CS4000 Mini Controller with Ethernet to the Local Area Network (LAN) is known as 10Base-T. The name is an Institute of Electrical and Electronics Engineers (IEEE) standard identifier for this type of cable.

  • Page 76: Testing The Ethernet Network

    Chapter 5. Setting Up the Ethernet Ethernet cables are inserted into the Ethernet connector on the bottom panel of each CS4000 Mini Controller with Ethernet. The other end of the Ethernet cable is connected to a network hub. To connect the computer running Visual Supervisor to the network, insert one end of an Ethernet cable into the RJ-45 socket on the computer and the other end into the same network hub that the controllers are attached to.

  • Page 77: Figure 5-17. Select The Icon And Enter A Name For The Hyperterminal Connection

    CS4000 Mini Controller with Ethernet 2. Enter a name to identify this connection and select the Hyperterminal icon you want to use for it. See Figure 5-17. a. Enter a meaningful name for the Hyperterminal connection in the Name: field.

  • Page 78: Figure 5-18. Select Communications Port

    Chapter 5. Setting Up the Ethernet 3. Select the communications port you want to use for the Hyperterminal connection. See Figure 5-18. This is the communications port to which the null modem cable is attached. Usually COM1 is the communications port selection but you may choose any communications port on the computer.

  • Page 79: Figure 5-19. Setting The Communications Port Settings

    CS4000 Mini Controller with Ethernet 4. Specify the communications port settings. See Figure 5-19. a. Set the Bits per second: field to 115200. b. Set the Data bits: field to 8. c. Set the Parity: field to None. d. Set the Stop bits: field to 1.

  • Page 80: Figure 5-20. Hyperterminal Window Showing Ethernet Interface Card (Tini) Login Prompt

    Chapter 5. Setting Up the Ethernet 5. Hit the ENTER key on the computer keyboard to view the login prompt: ‘TINI login.’ See Figure 5-20. Figure 5-20. Hyperterminal Window Showing Ethernet Interface Card (TINI) Login Prompt NOTE: If the Hyperterminal window does not appear when you hit the ENTER key, make sure the jumper, J1, labeled “Prog”...
  • Page 81 CS4000 Mini Controller with Ethernet 7. Enter ping followed by the IP address of the computer or controller on the Ethernet network that you want to test. NOTE: The IP address of the Ethernet interface card is the same as the IP address of the computer or controller to which it is attached.

  • Page 82: Figure 5-21. Opening The Command Prompt Window

    Chapter 5. Setting Up the Ethernet Use Procedure 5-5 to test the Ethernet network from the host computer. NOTE: There is an alternative to the method described in Procedure 5-5. You can use the Telnet application, if it is installed on the Windows operating system of the host computer.

  • Page 83: Testing Ethernet Network Cables

    CS4000 Mini Controller with Ethernet 2. Enter ping followed by the IP address of the computer or controller on the Ethernet network that you want to test. NOTE: The IP address of the Ethernet interface card is the same as the IP address of the computer or controller to which it is attached.

  • Page 84: Setting Up The 485 Network

    6. Setting Up the 485 Network The CS4000 Mini Controller with Ethernet can be connected to a Local Area Network (LAN) using a 485 network link and a special Synchronous Data Link Control (SDLC) card. This chapter describes the steps you must take to set up the LAN: Installing the SDLC card in the computer you want attached to the network.

  • Page 85: Editing Vsmain.ini For A 485 Network

    CS4000 Mini Controller with Ethernet Editing VSMain.ini for a 485 Network When you are using a 485 network, you must also change VSMain.ini manually. In the following example, shown in Figure 6-1, VSMain.ini is configured to talk to four TCMs using a single SDLC channel.

  • Page 86: Procedure 6-1. Editing Vsmain.ini For A 485 Network

    Chapter 6. Setting Up a 485 Network Use Procedure 6-1 to make the necessary changes to VSMain.ini. Procedure 6-1. Editing VSMain.ini for a 485 Network 1. Open VSMain.ini using Notepad. a. Click the Start menu on the Windows NT desktop. b.

  • Page 87: Assigning A Network Address

    CS4000 Mini Controller with Ethernet 4. When you are finished editing VSMain.ini, save your changes and exit Notepad. a. Click the File menu in Notepad. b. From the File menu, select Save. c. From the File menu, select Exit. VSMain.ini is now ready to support a 485 network. The new settings take effect the next time you start Visual Supervisor.

  • Page 88: Figure 6-2. Network Address Dip Switch Set For Address '5

    Chapter 6. Setting Up a 485 Network Table 6-2. Setting Address Switches (continued) To set the following Set these Address Keep these DIP address number: switches ON: switches OFF Address 7 1, 2, 3 4, 5, 6, 7, 8 Address 8 1, 2, 3, 5, 6, 7, 8 Address 9 1, 4...

  • Page 89: Procedure 6-2. Setting The Address For The Controller

    CS4000 Mini Controller with Ethernet Use Procedure 6-2 to set the address on the backplane of the controller. Procedure 6-2. Setting the Address for the Controller 1. Turn OFF power to the controller. WARNING! Make sure the power is OFF before you remove the TCM.

  • Page 90: Using 485 Network Cables

    Chapter 6. Setting Up a 485 Network Using 485 Network Cables The type of cable you need to connect the CS4000 Mini Controller with Ethernet to the LAN using the 485-link is the Bellden 8104 low capacitance computer cable or equivalent.
  • Page 91 CS4000 Mini Controller with Ethernet (This page is left blank intentionally.) Page T-38324-A 39-30-38324...

  • Page 92: Setting Up The Rs-232 Link

    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...
  • Page 93 CS4000 Mini Controller with Ethernet (This page is left blank intentionally.) Page T-38324-A 39-30-38324...

  • Page 94: Maintenance/Troubleshooting

    Ethernet network. Replacement Parts If, at any time, you need to replace or order new parts for your CS4000 Mini Controller with Ethernet you can select from any item in Table 8-1.

  • Page 95: Replacing Main Power Fuses

    Main Power F1 and F2 15A, 250V, SLO-BLO Littelfuse 313015 or equivalent (part number 13-10-1015) Refer to Figure 3-3 on page 3-4 to locate the main power fuses on the CS4000 Mini Controller bottom panel. Replacing Backplane Fuses Backplane F2 and F3 0.5A, 250V, subminiature PICO...

  • Page 96: Troubleshooting

    Hyperterminal or Telnet applications. Refer to Table 3-1 on page 3-15 for a list of LEDs that exist on the Ethernet interface card within the CS4000 Mini Controller. Use the TINI Ethernet Flash Utility to modify the Ethernet interface card application settings and disable unnecessary functions (the latter may help if the troubleshooting problem is related to thru-put performance.) To find out how to update the application settings, refer to Updating...

  • Page 97: Rs-422 (Siemens 3964R) Interface

    CS4000 Mini Controller with Ethernet RS-422 (Siemens 3964R) Interface If you encounter problems with the RS-422 (Siemens 3964R) interface, you can use Procedure 5-4 on page 5-17. Although this procedure describes how you test an Ethernet network from a laptop computer, you can use the same steps to test the RS-422 (Siemens 3964R) interface until you reach Step 7.

  • Page 98: Technical Information

    9. Technical Information Assembly Drawing The wiring diagrams for the CS4000 Mini Controller with Ethernet are shown in Figure 9-1 on page 9-3 and Figure 9-2 on page 9-5. May 2002 T-38324-A Page 9-1...
  • Page 99 CS4000 Mini Controller with Ethernet (This page is left blank intentionally.) Page T-38324-A 39-30-38324...

  • Page 100: Figure 9-1. Cs4000 Mini Controller With Ethernet Wiring Of Standard Ethernet And Interbus-S Module

    Chapter 9. Technical Information Figure 9-1. CS4000 Mini Controller with Ethernet Wiring of Standard Ethernet and Interbus-S Module May 2002 T-38324-A PRELIMINARY DRAFT Page 9-3...
  • Page 101 CS4000 Mini Controller with Ethernet (This page is left blank intentionally.) Page 9-4 T-38324-A PRELIMINARY DRAFT 39-30-38324...

  • Page 102: Figure 9-2. Cs4000 Mini Controller With Ethernet Wiring Of Standard Ethernet

    Chapter 9. Technical Information Figure 9-2. CS4000 Mini Controller with Ethernet Wiring of Standard Ethernet April 2002 T-38324-A Page 9-5...
  • Page 103 CS4000 Mini Controller with Ethernet (This page is left blank intentionally.) Page 9-6 T-38324-A PRELIMINARY DRAFT 39-30-38324...

  • Page 104: Index

    Index 10Base-T, 1-2, 5-16 Etherflash.exe, 5-3 485 network cable, 6-7 Ethernet, 1-7 Ethernet cable, 1-2, 5-1, 5-16 testing, 5-24 twisted-pair, 5-16 AC power, 4-4 Ethernet Connector, 3-5 AC Power Cord, 3-3 Ethernet Flash Utility, 5-2, 5-10 address switch, 3-6, 6-4 Ethernet interface card, 1-1, 3-6, 3-13–3-14, 5-1, 8-1 Address switches, 3-12 initialization, 3-15...
  • Page 105 CS4000 Mini Controller with Ethernet RS-232 port, 1-1, 3-5, 5-3 LED, 3-9, 3-15, 3-17 RS-232 cable, 7-1 LED display, 3-2 RS-422 Limit Selector Switch, 8-1 port, 1-7, 3-5 Local Area Network, 1-1, 1-4, 3-1, 3-5, 5-1, 6-7 RS-485 port, 1-1, 6-7...
  • Page 106 Part Number: 39-30-38324 SPX Corporation 42860 Nine Mile Road Novi, MI 48375-4122 USA Phone: (248) 596-0600 Toll free: (800) 795-7875 Fax: (248) 596-0601 Website: www.gsetechmotive.com © 2002 SPX Corporation. All rights reserved. 4/02...

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