Home

mPro400GC-DGD-intelligent-spindle

1. Pin configuration motor Connector Power distribution box PDB CPS Brief function description General technical data El ctncal Data u a X 7 Supply module D General technical datl u uuu uu ES Cables High Flex quality suitable for flexible cable ducts Instructions on laying cables Function description Torgue 2 _ Troubleshooting Acknowledgment of Errors Maus asa qua Tightening module CPS3 power distribution box PDB CPS Tightening module 444222 Nutsetter control unit mPro400GC M Maintenance Service Disposal 47 47 51 53 53 P2077SB EN 2010 11 P2077SB EN 2010 11 m Pro 400S DGD IS BTSEI
2. 5 2 3 Size 3 1x transducer Designation Order No Torque Speed Spring e min Length Weight Spring travel axis chuck Nm distance max min RPM mm mm mm kg flange 3BTSE 3B300A 3M2B 3ZB 947656A0 453 81 589 14 1 5308436 3BTSE 3B300A 3VM2B 94765749 421 59 584 15 2 5308439 3BTSE 3B300A 3WM2B 94765848 437 25 678 17 8 929065 3BUTSE 3B300A 3M2B 3ZB 947659A7 y 453 id 417 16 1 5308436 3BUTSE 3B300A 3VM2B 947660A4 421 59 412 17 2 5308439 3BUTSE 3B300A 3WM2B 947661A3 437 25 81 506 19 8 929065 1 request Smallest scribed circle diameter Quantity Attachment DGD IS Centric Offset Angle head 2 81 59 81 3 94 69 94 4 116 84 116 5 139 102 139 6 164 122 164 7 189 138 189 16 P2077SB EN 2010 11 770 IntelligenteSpindel en fm 16 12 2010 DGD DGD intelligent spindles 5 2 4 Size 4 1x transducer Designation Order No Torque Speed Spring e min Length Weight Spring travel axis chuck Nm dis tance max min RPM mm mm mm kg flange 4BTSE 4B500A 4M2B 4ZA 947662 2 500 100 254 3 4 Bi Aa 916643 4BTSE 4B660A 4M3B 4ZA 947668 6 660 130 174 1 916642 4BTSE 4B360A 4M1B 4Z1250A 947676 6 1250 320 86 1 N 5976956 4BTSE 4B500A 4M2B 4Z1600A 947678 4 1600 400
3. PE Gelb Gr n Gelb Gr n 1 Gelb Gr n Gelb Gr n Rot Rot 380 1 Schwarz Schwarz J Rot Rot 2 Schwarz J Schwarz i 2 24 VDC A Braun Braun 24V gt Weis g Enable G gt Schwarz Schwarz DATAA C gt WeiR Griin Weift Gr n C Weif Rot X WeiR Rot DATAB D Y D 4 380 VDC 0 VDC 24 VDC 0 VDC 24 V Enable DATA A DATA B 12 2 Instructions on laying cables Preparation gt Unrollthe cable from the cable drum at least 4 hours before installation gt Donotkink the cable or allow loops to form when unrolling gt When cutting the cable to length remember that a strain relief clamp and compression set must be incorporated within the bending radius Strain relief clamp gt Formoving cables Position the strain relief clamp in front of the DGD IS plug connector The plug connector must not be subjected to alternating forces gt Position the strain relief clamps so that the cables have maximum freedom of movement gt Only secure cables with strain relief clamps designed for the corresponding cable diameter Use screw on cable clips if possible N Avoid crushing individual wires or subcomponents We recommend applying a clamping force around the entire circumference of the cable V v x Only secure the cables at the strain relief clamp A secure strain relief clamp prevents the cable from shi
4. 5 3 1 Size 1 1x transducer DGD IS B G H J 1 2 1 2 1 2 1 2 1 2 1 2 1 2 2 1BTSE 1B012A 1M3B 1ZB 947626 63 18012 927346 1M3B 934288PT 1BTSE 1B035A 1M1B 1ZB 947632 8 1B035A 927344 1M1B 934286PT 178 927222 961089 002 1BTSE 1B060A 1M2B 1ZB 947638 2 18060 927345 1M2B 934287PT 1BTSE 1B012A 1VM3B 947627 53 18012 927346 1VM38 935863PT 1BTSE 18035A 1VM1B 947633407 1 935560 TSE 961446 18035 927344 1VM1B 935865 961088 004 1BTSE 1B060A 1VM2B 947639 13 1B060A 927345 1VM28 935864PT 1BTSE 1B012A 1WM3B 947628 43 1 012 927346 1WM3B 9 SMAG 1BTSE 1B035A 1WM1B 947634 63 1 035 927344 1WMiB 9 961088 003 18TSE 1B060A 1WM2B 947640 83 1B060A 927345 1WM2B 3 1BUTSE 1B012A 1M3B 1ZB 947629A3 1B012A 927346 1M3B 934288PT 1BUTSE 1B035A 1M1B 1ZB 947635 53 1B035A 927344 1M1B 934286PT 128 927222 KMAG 961088 004 1BUTSE 1B060A 1M2B 1ZB 947641 73 1B060A 927345 1M2B 934287PT 1BUTSE 1B012A 1VM3B 947630A09 1 012 927346 1VM38 935863PT 7 1BUTSE 1B035A 1VM1B 947636 43 1807 936321 TUSE 961447PT 1B035A 927344 1VM1B 935865 1BUTSE 1B060A 1VM2B 947642 63 1B060A 927345 1VM28 935864PT 1 1 012 1 947631 93 1 012 927346 1WM3B 9 1BUTSE 1B035A 1WM1B 947637 39 1 035 927344 1WM1B 3 18UTSE 1B060A 1WM2B 947643 53 1B060A 927345 1WM2B 3 1 Code 2 Part no 3 On request Fit as spac
5. Pin Signal designation Wire colors in motor Motor type BT Motor type BUT Motor 1 4 PE Green yellow 1 Phase S green green 2 Phase R Black Red 3 Phase T red black Resolver 2 1 Resolver R1 Red white 2 Resolver R2 Yellow white 3 Resolver S1 Red 4 Resolver S3 Black 5 Resolver S2 Yellow Blue 6 Resolver S4 Blue Yellow Temperature sensor 3 1 0V 2 Signal Red 77g Komponenten en fm 16 12 2010 P2077SB EN 2010 11 35 Motor 36 P2077SB EN 2010 11 77g Komponenten en fm 16 12 2010 Power distribution box PDB CPS 1 1 11 Power distribution box PDB CPS 1 5 4 3 2 Designation 1 Rotary switch 2 Seal 3 Supply module CPS3 integrated 4 Ready indicator i 5 Emergency stop i 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 These switch the inter mediate circuit voltage for the DGD IS on and off The integrated emergency stop safety relay PNOZ X3P activates and monitors two relays The relays activate the supply voltage 77h PowerDistributionBox en fm 16 12 2010 P2077SB EN 2010 11 37 Power distribution box PDB CPS DGD 1
6. 2 gt 24 VDC A gt Schwaz 0 VDC 24 8 Schwarz Enable o gt Schwarz DATAA C gt Gtin n Sin DATAA DATAB m N X X Rn s DATA B 270 Schwarz 1 01 24V Out Schwarz2 0V Schwaz3 2 Enable SV 12 1 4 Use DGD IS DGD IS Order No 961299 xxx xxx cable length in dm Socket T J yellow green ES T yellow green PE yellow green yellow green a 380 VDC ox A 24 5 1 380 JA A red 2 lack 0 black 1 2 brown brown 24 VDC 2 1 A 24 VDC 24 v B gt White white p 0 VDC 24 V Enable G black black G Enable DATAA C white green white green DATAA DATAB D white red white red p 771 Kabel en fm 16 12 2010 P2077SB EN 2010 11 49 Cables 12 1 5 12 1 6 Jumper cable type F Use DGD IS DGD IS Order No 961295 xxx xx
7. 0 1 5 ms No output signal 1 5 ms random Max rise delay 3 ms Max drop delay 16 ms Example of a DGD IS standard A 05 77 DGD IS BTSE e Offset version 1BTSE 1B012A 1VM3B Order no 947627A5 Speed 1824 RPM Torque max 12 Nm Kal Md 12 Nm 5V DC voltage 380 V DC 77k_Funktionsbeschreibung en fm 16 12 2010 P2077SB EN 2010 11 53 Function description This page has been left empty deliberately 54 P2077SB EN 2010 11 77 Funktionsbeschreibung en fm 16 12 2010 DGD Troubleshooting 14 DANGER NOTE 14 1 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 090 15 High leakage current Fatal electric shock could occur gt ltis 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 Always replace the CPS3 and the TSE TUSE completely Opening the CPS3 or TSE TUSE will void the warranty This does not include the service panel Observe the conditions for operation see 4 First Operation page 11 Acknowledgment of Errors gt Eliminate the malfunction and press the Reset button on the CPS3 or TSE TUSE The system is again operational The measuring board acknowledges faults pen
8. Motor Temperature NOK The motor temperature is gt 90 The temperature sensor in the motor measures a temperature gt 90 Check the motor temperature if gt 90 G gt ensure adequate ventilation of the motor Measuring cable in the motor is interrupted Check the thermosensor for breaks The resistance should be approx 1 at 20 gt Replace motor Measuring current is misdirected Check the wires in the DGD IS for breaks and short circuits gt Replace motor Measuring current is not mea sured Internal error gt Replace the TSE TUSE Motor is not connected gt Connect the motor Motor Pt monitoring NOK The monitor has measured excessive power on the DGD IS Motor power reguired is too high Check the motor temperature if 80 gt Shorten the fastening time by increasing the speed DGD IS is defective i e gear ing bearings Check the ease of movement of the gearing and motor on the DGD IS gt Replace the DGD IS or motor Motor Resolver NOK No resolver signals measured Signals are not present Check whether the motor is con nected gt Connect the motor Signal interruption Check the resolver wires in the DGD IS gt Replace motor Short circuit of signals Check the resolver wires in the DGD IS for short circuits gt Replace motor Supply to the resolver is defec tive Internal defect
9. 12 2 1 9 0 34 Mechanical time constants ms 2 1 1 3 1 41 torque 0 03 0 07 0 15 Rotor weight kg 0 36 0 79 1 54 Motor weight kg 1 6 3 1 6 5 Ball bearing A B side 6000 608 6200 6200 6202 6201 77g_Komponenten en fm 16 12 2010 P2077SB EN 2010 11 33 Motor DGD 10 2 Electrical Data Features Data 1B U T 2B U T 3 AB U T Intermediate circuit voltage V 380 380 380 Rated current A 2 1 6 8 7 Rated output W 260 500 940 Number of phases 3 3 3 Terminating resistance 2 Ohms 11 1 8 0 6 Inductance 2 mH 6 5 3 1 24 Voltage constants mV RPM 34 34 44 Torque constant 3 Nm A 0 28 0 28 0 36 Current at peak torque 1 11 44 59 14 20 54 73 Electrical time constants ms 0 59 1 7 4 1 Sine peak value 2 Measured between two phases 3 10 4 The values specified apply to operation within the temperature range of 0 40 C They may not be exceeded even for a short period of time since this would lead to the risk of a magnetic weakening 10 3 Thermal data without cooling Features Data 1B U T 2B U T 3 4B U T Insulation class F F F according to VDE 0530 Thermal time constants min 17 5 25 35 Temperature rise K W 1 30 1 05 0 75 34 P2077SB EN 2010 11 77g Komponenten en fm 16 12 2010 DGD Motor 10 4 Pin configuration motor connector
10. Code Part no Ratio Permissible load Lateral force at wrench head i on output shaft 25 50 sure 1 sion 1 Extended Retracted Retracted Nm N N N N N 1ZB 927222 53 1900 1500 1150 1350 1600 278 927227 ja 200 4500 3200 2450 2700 3250 3ZB 927233 i 300 6500 5000 3000 3500 4100 47 927236 660 9000 8800 4300 4800 5400 471250 976950 3 7368 1250 9000 8800 4300 4800 5400 4Z1600A 5976951 3 7368 1600 1 During continuous operation for long periods multiply the specified values 0 3 Offset attachment Range torque measurement Helical spur asa ap nut Crown gearing 800333 1 eps Code Part no Torgue Ratio Permissible load Lateral force at wrench head Calibration i on output shaft 25 50 sion Extended Retracted Retracted Nm N N N N N 1VM1B 935865PT 35 1VM2B 935864PT 60 1 0526 53 2300 2300 1510 1720 2000 1VM3B 935863PT 12 2VM1B 934336PT 110 110 1 0714 2500 2500 2300 2600 3100 2VM3B 934335PT 200 200 3VM2B 2 300 1 0769 260 3600 3600 2850 3250 3750 4VM2B 2 500 1 0667 660 4VM3B 2 660 6300 2100 4300 4800 5400 4VM4B 2 900 1 2857 900 1 During continuous operation for long periods multiply the specified values by 0 3 2 On request 77g Komponenten en fm 16 12 2010 P2077SB EN 2010 11 27 Attach
11. System Handbook P2077SB EN 2010 11 For additional product information visit our Web site at http www apextoolgroup com DGD mPro400GC DGD intelligent spindle BTSE series Notes 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 It points out options Secondary information P1908E Tightening torques Assembling the DGD intelligent spindle components P2074BA Operating instructions for telemetry system P2075EL Data sheet Transducer P1913E Spare parts sheet Gearing P2080EL Spare parts sheet Transducer P1914E Spare parts sheet Motor P2085EL Tightening module spare parts sheet TSE TUSE P2076EL Spare parts sheet Offset attachment P2086MA DGD intelligent spindle assembly instructions P2078MA Tightening module assembly instructions TSE TUSE P1919E Supply module assembly instructions CPS3 PL12DE 1001 Programming ManualmPro400GC PL12DE 1004 Quick Start mPro400GC P2079WA DGD intelligent spindle service manual Symbols in text gt Identifies instructions to be followed Identifies lists italics Indicates menu items such as Diagnostics in software descriptions lt gt Identifies ele
12. Voltage 12 V The 12 V supply to the measur ing board and the transducer is outside the limits of 11 4 V 12 6 V 12 V short circuiting in the KMAG KMAW or DGD IS Check the mPro400GC M in the Diagnosis Voltages menu If values are outside permissible limits check the KMAG KMAW cables transducer TSE TUSE espe cially the 12 V and 0 V wires gt Replace the cable gt Replace the transducer or DGD IS Internal power adapter defective gt Replace the TSE TUSE Measurement card Voltage 24 V The 24 V supply of the TSE TUSE is outside the limits of 20 4 27 6 V Supply is overloaded Check the mPro400GC M in the Diagnosis Voltages menu If values are outside permissible limits gt Check the load Voltage on power adapter in PDB CPS is incorrect gt Setthe power adapter to 26 0 V Measurement card Temperature NOK The temperature on the measur ing board is gt 80 The temperature sensor in the TSE TUSE measures a tempera ture gt 80 gt ensure adequate ventilation of the DGD IS Internal error DGD IS is ventilated sufficiently gt Replace the DGD IS Transducer Connected NOK The signals from the transducer are not OK The connection to the trans ducer is interrupted Check the KMAG KMAW cable transducer TSE TUSE for breaks gt Replace the cable gt Replace the transduce
13. IP monitoring NOK also displayed in the rundown data table Overload If a current higher than the maxi mum permissible current is required for fastening the servo amplifier switches off automati cally motor position tracing i e resolver cable nutsetter cable gt Replace the nutsetter cable and check the resolver wires in the nutsetter cable for breaks Replace the DGD IS or motor Error in the motor circuit i e motor does not attain the required torque gt Check motor for short circuit to PE and phase resistances 1BT approx 11 O 2BT approx 2 O 3 4 approx 0 6 W Replace motor Incorrect programming Check programming in mPro400GC M Spindle constants Calibration values Fastening process sequence Parameter set Targets Servo Intermediate circuit voltage too high The voltage in the intermediate power circuit is 440 VDC Constant error See CPSS troubleshooting no error CPS3 gt Replace the TSE TUSE The error is triggered during braking i e when the DGD IS stops See CPS3 troubleshooting no error 53 gt Replace the TSE TUSE Sporadically the voltage is tem porarily too high See CPSS troubleshooting no error CPS3 gt Replace the TSE TUSE Servo Intermediate circuit voltage too low The voltage in the intermediate power circuit is 190 VDC Constant error See C
14. fails no measuring shaft rotor present rotor electronics defective between rotor and stator antenna too large Supply voltage voltage under low supply voltage limit gt Send the transducer to DGD for repair recalibration After an operation error the transducer remains in the operation error state until one of the following events occurs the operating voltage of the transducer is disconnected the transducer receives a calibration signal via the CAL input pin K the error bit in the operating memory is reset via the RS422 RS422 interface 56 P2077SB EN 2010 11 77 Fehlersuche en fm 16 12 2010 DGD Troubleshooting 14 3 Tightening module CPS3 in power distribution box PDB CPS 14 3 1 Ready LED Error Possible causes Measures and remedies Description Ready LED does not light up 24 V supply is unavailable gt Check the 26 V voltage at XS3 terminals 1 and 4 PDB CPS is disconnected from gt Check the mains supply the power supply 24 V power adapter is discon gt Check the fuse nected from the power supply Fuse in the CPS3 is gt Check the 26 V voltage at high resistance XS4 terminals 1 and 4 gt Switch off the PDB CPS and switch back on again after a minute gt Replace the CPS3 14 3 2 EM stop LED emergency stop Error Possible causes Measures and remedies Description EM stop lights up CPS3 is in Emer
15. the same ARCNET address addresses Dup ID gt Set different addresses The same ARCNET addresses are preset Measurement card ARCNET terminator missing 3 Plug in the ARCNET termina ARCNET communication Recon The ARCNET is temporarily disrupted tor No power supply to the ARCNET terminator gt Switch on the power supply for the last device Error in cabling Plug in all cables and lock Error in potential equalization Connect potential equaliza tion cable Internal error Replace the TSE TUSE Measurement card Initialization NOK Initialization error in measuring board Internal error gt Replace the TSE TUSE gt Inform DGD service Measurement card Flash image NOK Flash image in the measuring board is not OK The incorrect program has been transmitted by mPro400GC M gt Check the program version The program transfer was interrupted gt Repeat the program transfer Internal error Replace the TSE TUSE Measurement card Voltage 3 3 V NOK The 3 3 V supply to the measur ing board is outside the limits of 3 24 V 3 53 V The power adapter for the inter nal supply to the measuring board is overloaded or defective Internal error Replace the TSE TUSE P2077SB EN 2010 11 771 Fehlersuche en fm 16 12 2010 DGD Troubleshooting Error Description Possible causes Measures and remedies Measurement card
16. 380V0C lt Rot VA Rot gt 27 Schwar E LI Schwaz 2 24 VDC a x Schwarz 1 Lat Schwarz 1 24 0 24 B Schwarz 2 Schwaz 0V 24V Enable G gt Sehwarz 3 Schwar 3 Enable DATAA Grin c DATAA DATAB D gt VeilRot Y i v Rit op pATAB 12 1 2 System cable type C Use Connection PDB CPS DGD IS cable type A Order No 961109 xxx xxx cable length in dm 3 PE 2 1 380V0C 1 Rot Schwarz Rot 2 Z5 waz 1 24V Out 24 VDC A Schwarz 1 3 OV 0 VDC 24 V p Schwarz 2 2 Enable SV Enable G Schwarz 3 DATAA Srin C 8 DATAA okt OSI 3 DATAB I 48 P2077SB EN 2010 11 771 Kabel en fm 16 12 2010 DGD Cables 12 1 3 System cable type Use Connection PDB CPS DGD IS Order No 961294 xxx cable length in dm xxx in dm 7 8 8 000 sos 8 12 1314 Schwaz 2 ZK Rot PE p Schwarz elb Griin 0 a a 238 m Rot 380 VDC Rot
17. 5000 2850 3250 3750 1 80 1 During continuous operation for long periods multiply the specified values by 0 3 77g Komponenten en fm 16 12 2010 P2077SB EN 2010 11 29 Attachment DGD Size 4Z For Part no Permissible load output shaft Lateral force at wrench head Pres Ten Weight 1 A TQ sure sion 25mm 50 mm Extended Retracted Retracted Nm N N N N N kg 916643 3 4 460 1 21 47 9000 8800 4300 4800 5400 916642 1 630 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 For Part no Permissible load Lateral force at wrench head a on output shaft TQ Pres Ten 25mm sure sion Extended Retracted Nm N N N N 1W 929041 3 8 53 1700 6800 1800 2100 a 929053 1 2 110 1850 6800 2500 3000 7 929061 3 4 200 3800 7800 3000 3450 3VV 929065 3 4 300 3800 7800 3000 3450 929077 3 4 500 4VV 12000 13000 4300 5050 929089 1 660 1 During continuous operation for long periods multiply the specified values by 0 3 30 P2077SB EN 201 0 1 1 77g Komponenten en fm 16 12 2010 DGD Transducer 8 Transducer Range 3 5 torgue measurement Evaluation electronics T
18. IS is designed for stationary operation only and is intended exclusively for fastening and loosening thread connections Do not use as a hand held tool Only use the DGD IS in conjunction with the power distribution box PDB CPS and the nutsetter control unit mPro400GC M The DGD IS must be fully assembled Insert and lock all connecting cables 6 P2077SB EN 2010 11 77b Sicherheit bedingt en fm 16 12 2010 DGD Safety NOTE 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 Only operate the tightening system indoors Always remove the complete DGD IS from a unit gt Arepair is only permitted by DGD authorized personnel If repair is required send the complete DGD IS to Sales amp Service Center see backside Do not open the transducer offset attachment or angle head attachment as this will void the warranty A repair is only permitted by DGD authorized personnel If repair is required send the complete component to Sales amp Service Center Do not open the TSE TUSE or CPS3 as this will void the warranty This does not include the service panel A repair is only permitted by DGD authorized personnel If repair is required send the complete component to Sales amp Service Center
19. Replace the TSE TUSE Measurement Task monitoring Error at the program execution end of the measuring board Internal error gt Replace the TSE TUSE gt Inform DGD service Measurement card RAM Insufficient RAM available in the measuring board Internal error gt Replace the TSE TUSE gt Inform DGD service 771 Fehlersuche en fm 16 12 2010 P2077SB EN 2010 11 65 Troubleshooting DGD Error Description Possible causes Measures and remedies Measurement card Sampling clock from servo NOK The system clock from the servo amplifier is missing Internal error gt Replace the TSE TUSE Measurement card Servo type correct NOK The selected servo amplifier type is incorrect Error in programming gt Check the system program ming Self identification of transducer is not OK Check the transducer gt Replace the transducer Internal error gt Replace the TSE TUSE Measurement card Servo par matching servo NOK The parameter set selected from the measuring board is not present in the TSE TUSE Error in programming gt Check the system program ming Self identification of transducer is not OK Check the transducer gt Replace the transducer Internal error gt Replace the TSE TUSE Measurement card Several TSE TUSE are preset to Check the preset ARCNET ARCNET communication
20. The rotor electronics are attached to the measuring shaft and are connected to the full strain gage bridge and the rotor antenna system The stator electronics are located in the transducer housing They incorporate the evaluation circuit the sta tor antenna system and the 12 pin system connector The torque is measured directly at the attachment Exception the angle of the angle head attachment is measured at the drive wheel Torque measurement is made symmetrically for right and left rotating torques tightening and loosening direction The measured torque values are transferred from the transducer to the measuring electronics via an amplified analog voltage 0 5 V Always use measuring devices that are galvanically isolated from the protective earth PE ground connec tion for measuring the torque signals directly on the transducer i e oscilloscope with isolation transformer When measuring ensure that both 0 V reference connections of the transducer 0 V torque Pin D and 0 V supply Pin E cannot be short circuited lgnoring this may result in failures or measuring errors from potential egualization currents between 0 V TQ and 0 V supply in the torque measurement circuit Calibration takes places in the rotor unit by means of a switched shunt resistor parallel to a strain gage mea suring bridge section The calibration signal has the following time characteristics Input pulse duration pin K Output signal delay pin C
21. could occur gt Always disconnect the power supply before performing maintenance work on the DGD IS and the mPro400GC M gt Always disconnect the system cable motor or motor cable from the mPro400GC M or DGD IS before making throughput resistance and short circuit measurements gt Do not attempt to repair possible faults on the fastening system by yourself if you do not have the required knowledge Please consult your local service agent or the responsible Sales amp Service Center see backside gt Establish a grounding connection PE to the nutsetter control unit mPro400GC M before taking into operation High temperature the motor on the DGD IS may heat up and cause burns during removal max engine temperature 90 Wear gloves Regular maintenance reduces operating faults repair costs and downtime Implement a safety related maintenance program that takes the local regulations for repair and maintenance for all operating phases of the tool into account Disposal Injuries and environmental damage from improper disposal Components of the DGD IS pose risks to the health and the environment gt The DGD IS contains components that can be reused as well as components that require special disposal Separate the components and dispose of them by segregating them clearly gt Catch auxiliary materials oils greases when drained and dispose of them properly gt Separate the components of the packing and dispos
22. data 5 2 1 Size 1 1x transducer Designation Order No Torque Speed Spring a Length Weight Spring travel axis chuck Nm distance max min RPM mm mm mm kg flange 1 5 1 012 1 3 128 947626 6 12 2 1921 1BTSE 1B035A 1M1B 1ZB 947632 8 35 5 727 43 486 4 8 5308434 1BTSE 1B060A 1M2B 1ZB 947638 2 53 15 427 1BTSE 1B012A 1VM3B 947627A5 12 2 1825 1BTSE 1B035A 1VM1B 947633A7 35 5 690 35 474 5 3 5308437 1BTSE 1B060A 1VM2B 947639A1 53 15 405 1BTSE 1B012A 1WM3B 947628A4 12 2 1801 1BTSE 1B035A 1WM1B 94763446 35 5 681 25 52 542 5 7 929041 1BTSE 1B060A 1WM2B 94764048 53 15 400 1BUTSE 1B012A 1M3B 12B 947629A3 12 2 1921 id 1BUTSE 1B035A 1M1B 1ZB 194763545 35 5 727 43 393 5 3 5308434 1BUTSE 1B060A 1M2B 1ZB 947641A7 53 15 427 1BUTSE 1B012A 1VM3B 947630A0 12 2 1825 mi 1BUTSE 1B035A 1VM1B 947636A4 35 5 690 35 382 5 8 5308437 1BUTSE 1B060A 1VM2B 94764246 53 15 405 1BTSE 1B012A 1WM3B 947631 9 12 2 1801 1BTSE 1B035A 1WM1B 947637A3 35 5 681 25 52 370 6 2 929041 1BUTSE 1B060A 1WM2B 94764345 53 15 400 1 On reguest Smallest scribed circle diameter in mm Ouantity Attachment DGD IS Centric Offset Angle head 2 43 35 52 3 54 40 60 4 61 50 74 5 81 58 89 6 99 70 105 7 116 85 120 14 P2077SB EN 2010 11 77 Intel
23. faulty Internal error gt Replace the TSE TUSE Servo Node guarding NOK The servo amplifier monitors the function of the measuring board watchdog Sporadic malfunction of the measuring board Internal error gt Replace the TSE TUSE Servo Flash NOK The flash memory in the servo amplifier indicates an error Internal error gt Replace the TSE TUSE Servo Program NOK Error in the program execution for the servo amplifier Internal error gt Replace the TSE TUSE gt Inform CPT Service Motor Motor cable NOK Motor wire in DGD IS is interrupted Cable break in TSE TUSE motor wires gt Check the motor wires for breaks and short circuits Motor phases interrupted gt Check motor for short circuit to ground and phase resis tances 1BT approx 11 O 2BT approx 2 O 3 4 approx 0 6 W Replace motor Test current for cable monitoring is misdirected Replace motor Internal error gt Replace the TSE TUSE P2077SB EN 2010 11 77 Fehlersuche en fm 16 12 2010 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 gt Replace motor motor circuit on the DGD IS In the TSE TUSE Internal error gt Replace the TSE TUSE
24. 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 Control on output relay relay for external relay 24 VDC max 0 3 A PWRon PWRon Power on output 24 VDC max 0 3 A 0 VDC 0 VDC 0 VDC 0 VDC 0 Vof24 V 0 VDC 0 VDC XS4 mPro400GC M Emergency stop signal from the mPro400GC M and Ready signal to the mPro400GC M Required connector type Phoenix Combicon IC2 5 4 STF 5 08 Order No 961178 Contact Signal Description 24 VDC 24 VDC Supply output 24 V max 2A EM stop Emergency Stop Emergency stop input from mPro400GC M Ready Ready for Ready output to the mPro400GC M 24 VDC operation 0 3 0 VDG 0 VDG OV X55 machine control Emergency stop signal from the machine control and Ready signal to the machine control Required connector type Phoenix Combicon MSTB2 5 4 STF 5 08 Order No 961179 Contact Signal Description Ready 1 Ready for Ready output relay contact 1 max 26 V operation max 100 mA Relay contact 1 Ready 2 Ready for Ready output relay contact 2 max 26 V operation max 100 mA Relay contact 2 CTR on Control on Control on or Emergency stop input 24 V 10 mA 0 VDC Ext 0 VDC Ext 0 V from input 56 ARCNET The CPS3 is not equippe
25. gt Read the following documents when replacing the DGD IS This System Handbook see 15 Maintenance Service page 69 Service Manual DGD IS Assembly instructions DGD IS Spare part sheets 1 6 Ambient conditions Do not operate the fastening system in an explosive atmosphere System components Ambient temperature Relative humidity Working height DGD IS mPro400GC M PDB CPS 0 to 40 C CP3 JH TSE TUSE Motor CPS3 0 to 70 0 to 90 96 no condensation up to 3000 m above sea level 1 7 EMC Electromagnetic compatibility The tool complies with the following applicable EMC standards DIN EN 61000 3 2 DIN EN 61000 3 3 DIN EN 61000 6 2 DIN EN 61000 6 4 The filters required to fulfill the EMC standards are integrated in the system components Shielded cables offer protection against irradiating and radiating interference All cable shields are connected to the shield terminals on the nutsetter control unit and the plug casing on the DGD IS 77b Sicherheit bedingt en fm 16 12 2010 P2077SB EN 2010 11 Transport Storage DGD NOTE Equipment from EMC limit class value A DIN EN 550081 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 1 8 Noise DGD IS dB A 1B U TSE 1B012A 72 1B U
26. too high Intermediate circuit voltage 480 VDC May also occur momentarily Braking chopper is defective gt Replace the CPS3 Excessive number of DGD IS is causing the braking chopper to overload gt Reduce the number of PDB CPS Intermediate circuit capacitors no longer have sufficient capacity Life span exceeded gt Replace CPS3 1 7 Intermediate circuit voltage is too low Intermediate circuit voltage 250 VDC Mains supply is not powerful enough Check the mains supply gt More powerful mains supply required Relay to the switch on current limiter is defective and perma nently open gt Replace the CPS3 Excessive number of DGD IS The voltage drops during fastening gt Reduce the number of PDB CPS 77 Fehlersuche en fm 16 12 2010 P2077SB EN 2010 11 59 Troubleshooting DGD play Error Description Possible causes Measures and remedies Dis 53 15 100 high or too low Temperature is outside of the 40 C to 85 C range Excessive number of DGD IS Constant overload of the CPS3 gt Reduce the number of PDB CPS Ambient temperature PDB CPS gt 40 C gt Improve the ambient condi tions PDB CPS is exposed to other heat sources i e sunlight gt Improve the ambient condi tions attach covers if nec essary Heat dissipation from the PDB CP
27. 0 Rated current A 3x7 Peak current momentary in RMS mode A 3x25 Rated output VA 3000 Peak power momentary in RMS mode VA 30 000 Output voltage of intermediate power circuit VDC 380 10 95 Nominal output current 380 VDC A 8 Output current maximum 5 s A 80 Control supply voltage VDC 24 10 Input current without external load A 0 5 Control voltage Output voltage VDC 24 10 Output current maximum 24 VDC A 8 77h PowerDistributionBox en fm 16 12 2010 P2077SB EN 2010 11 41 Power distribution box 5 11 5 4 Size S O N E gt 2 JA 5 2 ES dp 11 5 5 Indicators LED Signal LED CPS3 Green Ready Ready for operation Red EM stop Emergency stop or Control on signal unavailable The intermediate power circuit 380 VDC is deactivated 7 segment Status display Error indicators see 14 3 3 7 segment Status display page 58 11 5 6 lt Reset gt button Press the lt Reset gt button to acknowledge faults You will reguire a pointed object such as a ball point pen Pressing this button resets the processor and reconfigures all functions 42 P2077SB EN 2010 11 77h PowerDistributionBox en fm 16 12 2010 DGD Power distribution box PDB CPS 11 5 7 Plug connectors and configuration WARNING Unplugging the system cable while still live may gen
28. 09 4B500A 935780 4WM2B 3 961069 003 4BTSE 4B660A 4WM3B 947670 23 48660 935781 4WM3B 3 4BUTSE 4B500A 4M2B 4ZA 947665493 4 500 935780 4M2B 934319 47 927236 4BUTSE 4B660A 4M3B 4ZA 947672403 4 660 1935781 4M3B 936496 4BUTSE 4B360A 4M1B 4Z1250A 1947677 53 4B360A 929541 4M1B 934318 421250 5976950 4BUTSE 4B500A 4M2B1 4Z1600A 947679 39 48500 935780 4M281 3 4Z1600A S976951 4BUTSE 4B500A 4VM2B 947666 8 3 4BUT 936323 TUSE 961447PT 4B500A 935780 4VM2B 3 961069 005 4BUTSE 4B660A 4VM3B 947673 93 4 660 935781 4VM3B 3 4BUTSE 4B660A 4VM4B 947675 73 4 660 935781 4VM48 3 4BUTSE 4B500A 4WM2B 947667 73 4 500 935780 4VVM28 3 4BUTSE 4B660A 4WM3B 947674 83 4 660 935781 4WM3B 3 1 Code 2 Part no 3 On reguest 20 P2077SB EN 2010 11 77e_IntelligenteSpindel en fm 16 12 2010 DGD Tightening module TSE TUSE 6 Tightening module TSE TUSE TSE 1 Order 961446 TUSE Order no 961447PT Item Designation 1 XS1A supply input 2 XS1B supply output 3 Service panel 4 XS3 transducer plug connector 7 Ready LED ready for operation green or fault red a N 77f_Schraubmodul en fm 16 12 2010 P2077SB EN 2010 11 21 Tightening module TSE TUSE DGD 6 1 Description The tightening module TSE TUSE controls the DGD IS The servo ampli
29. 1 2 General technical data Features Data PDB CPS3 PDB CPS6 PDB CPS9 Weight Ibs 125 140 155 Protection category IP54 Cooling type Convection self cooling Service life operating h 40 000 Usability period if stored h 100 000 approx 11 years On Off switching cycles 5 000 000 Safety requirements in accordance with Category 4 EN 964 1 11 3 Electrical Data Features Data PDB CPS3 PDB CPS6 9 Supply voltage VAC 3 x 480 10 Freguency Hz 50 60 Rated current A 3x4 3x8 3x12 Peak current momentary A 3x20 3x40 3x60 Rated output VA 3000 6000 9000 Peak power momentary VA 30 000 60 000 90 000 Output voltage of intermediate power circuit VDC 380 10 Nominal output current 380 VDC A 8 16 24 Output current maximum 5 s A 80 160 240 Circuit breaker 3 pin A 32 32 50 Tripping characteristic C D D Control voltage Output voltage VDC 24 10 Output current maximum 24 VDC A 5 10 20 11 3 1 Intermediate power circuit 380 VDC The intermediate power circuit supplies the DGD IS with 380 VDC A safety isolating transformer converts the supply voltage to 3x 270 VAC which is then supplied to the CPS3 The processor controls two integrated relays that limit the switch on current The main relay switches on after the system initializes The intermediate circuit capacitors are charged via a resistor until the inter mediate circuit voltage reaches approx 380 VDC The resistor is then bridged via a start up relay Energy is generated when the
30. 1 8 8 2 Transport Storage 8 System description 9 3 1 9 4 First Operation 11 5 DGD intelligent spindles 13 5 1 General technical data 13 5 2 Catalogue RO EC 14 5 3 18 6 Tightening module TSE TUSE 21 6 1 sre mec 22 6 2 General technical data 22 6 3 0 23 6 4 SEVICE Panele 23 6 5 Internal 40 25 7 Attachment 27 7 1 Centric M 68 L 27 7 2 Offset attachment e 27 7 3 Angle head Ferr ette eec eee etie obesse bius 28 7 4 Spring Collet Optional eruere iiir tanen tnnt nennen 29 8 Transducer 31 8 1 Electrical 32 8 2 Pin configuration of transducer 32 P2077SB EN 2010 11 m Pro 400S DGD IS BTSEIVZ fm 16 12 2010 P2077SB EN 2010 11 3 DGD 10 10 1 10 2 10 4 11 11 1 11 2 11 3 11 4 11 6 11 7 12 12 1 12 2 13 13 1 14 14 1 14 2 14 3 14 4 14 5 15 16 Gearing Motor Technical Electrical Data
31. 12 2010 DGD 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 Pin Color Signal Description A nc B Brown nc C green TQ Torque output oen E D Yellow 0 VA 0 V torque reference connection D F E gray 0 V supply G F Pink 12 V Supply L M G Blue H Red RxD interface A K J Y Black RxD interface K Violet CAL Input calibration voltage L Gray pink TxD interface M Red blue TxD interface Housing PE Shield connection 7 4 Spring collet Optional 7 4 1 For centric offset attachment 1 4 Part Permissible load output shaft Lateral force at wrench head Pres Ten Weight TQ sure sion Extended Retracted Retracted Nm N N N N N kg 1Z 1V 922325 3 8 53 2300 1500 1510 1720 2000 0 33 27 2V S 4500 3200 2300 2600 3100 935553 3 4 200 0 48 3Z 3V 910613 3 4 300 6500 5000 2850 3250 3750 0 67 PER 912106 3 4 500 9000 8800 4300 4800 5400 0 87 912147 1 750 9000 8800 4300 4800 5400 0 90 including flange housing 12 5308434 3 8 53 2300 1500 1510 1720 2000 0 65 27 5308435 1 2 110 4500 3200 2300 2600 3100 1 05 37 5308436 3 4 300 6500
32. 188 Canada Tel 905 501 4785 Fax 905 501 4786 China Cooper China Co Ltd a company of Apex Tool Group LLC 955 Sheng Li Road Heqing Pudong Shanghai China 201201 Tel 86 21 28994176 Fax 86 21 51118446
33. 68 50 11 2 lt 2 5308441 4BTSE 4B500A 4VM2B 947663A1 500 100 238 3 4 912106 4BTSE 4B660A 4VM3B 947669A5 660 130 163 i 76 684 22 5 S308440 4BTSE 4B660A 4VM4B 947671A1 750 160 135 1 4BTSE 4B500A 4WM2B 947664A0 500 100 245 3 4 929077 4BTSE 4B660A 4WM3B 947670 2 660 130 167 25 1 N 929089 4BUTSE 4B500A 4M2B 4ZA 947665A9 500 100 254 3 4 546 916643 4BUTSE 4B660A 4M3B 4ZA 947672 0 660 130 174 1 916642 4BUTSE 4B360A 4M1B 4Z1250A 947677A5 1250 320 86 1 N 5976956 4BUTSE 4B500A 4M2B 421600A 947679A3 1600 400 68 50 11 2 SER 5308441 4BUTSE 4B500A 4VM2B 947666 500 100 238 3 4 912106 4BUTSE 4B660A 4VM3B 947673 9 660 130 163 1 76 512 5308440 4BUTSE 4B660A 4VM4B 947675A7 750 160 135 1 24 5 4BUTSE 4B500A 4WM2B 947667 7 500 100 245 3 4 i 558 28 6 _ 929077 4BUTSE 4B660A 4WM3B 947674A8 660 130 167 1 28 7 929089 1 On request Smallest scribed circle diameter in mm Quantity Attachment DGD IS Offset Angle head 2 91 76 112 3 122 88 130 4 130 108 160 5 174 130 192 6 217 153 224 7 246 180 263 77e_IntelligenteSpindel en fm 16 12 2010 P2077SB EN 2010 11 17 DGD intelligent spindles DGD 5 3 Component overview
34. B 947656A0 3M2B 934303PT 37 927233 961088 002 3BTSE 3B300A 3VM2B 947657 93 3 4BT 935562 TSE 961446 3VM2B 3 KMAG 961088 004 3BTSE 3B300A 3WM2B 947658 83 3WM2B 3 961088 003 3B300A 935590 3BUTSE 3B300A 3M2B 3ZB 947659 73 3M2B 934303PT 378 1927233 3BUTSE 3B300A 3VM2B 947660443 3 4BUT 936323 TUSE 961447PT 3VM2B 3 KMAG 961088 004 3BUTSE 3B300A 3WM2B 947661 433 3WM2B 3 1 Code 2 Part no 3 On reguest 77e IntelligenteSpindel en fm 16 12 2010 P2077SB EN 2010 11 19 DGD intelligent spindles 5 3 4 Size 4 1x transducer DGD IS B L 1 2 Diala a i 2 1 i 2 4BTSE 4B500A 4M2B 4ZA 947662A2 48500 935780 4M2B 934319 47 927236 4BTSE 4B660A 4M3B 4ZA 947668469 4B660A 935781 4M3B 936496 961069 002 4 5 4 360 4 1 421250 947676 63 4B360A 929541 4M1B 934318 421250 5976950 4 5 4 500 4 2 1 421600 947678A4 4B500A 935780 4 2 1 3 421600 5976951 4BTSE 4B500A 4VM2B 947663A1 3 4BT 935562 TSE 961446 4B500A 935780 4VM2B 3 4BTSE 4B660A 4VM3B 947669459 4B660A 935781 4VM38 3 961069 004 4BTSE 4B660A 4VM4B 947671A1 48660 935781 4VM48 3 4BTSE 4B500A 4WM2B 9476648
35. Description A nc B Brown nc C green TQ Torque output D Yellow 0 0 V torque reference connection D F E gray 0V 0 V supply G F Pink 12 V Supply L M G Blue H H Red RxD Interface A K J Y Black RxD Interface K Violet CAL Input calibration voltage L Gray pink TxD Interface M Red blue TxD Interface Housing PE Shield connection 32 P2077SB EN 2010 11 779 Komponenten en fm 16 12 2010 DGD Gearing 9 Gearing 8 Part Ratio 1 1B012A 927346 5 7273 1B035A 927344 15 1364 1B060A 927345 25 7727 2 2B110A 935548 12 3595 2B200A 935549 21 9231 3 3B300A 935590 18 7500 4 4B360A 929541 26 3118 4B500A 935780 33 4219 4B660A 935781 48 9345 10 Motor 10 1 Technical data Features Data Code 1BT 1BUT 2BT 2BUT 3 4BT 3 4BUT Part no 935560 935563 935561 935564 935562 935565 Speed maximum RPM 11000 11000 8500 Operating mode according to 51 51 51 VDE 0530 Enclosure type according to IP54 IP54 IP54 DIN 40050 Sense of rotation Reversible Reversible Reversible Design B14 B14 B14 Connection type Plug connector Plug connector Plug connector Mass moment of inertia x 107 0 017 0 06 0 25 Rated torque Nm 0 55 1 60 3 Permanent torque maximum Nm 0 61 1 8 4 at a stop Peak torque Nm 2 8 10 5 18 3 Speed change per torque rpm
36. PSS troubleshooting no error 53 gt Check system cable for interruptions Replace the system cable System cable OK gt Replace the TSE TUSE During fastening error is trig gered during the fastening pro cess See CPS3 troubleshooting no error CPS3 gt Replace the TSE TUSE Sporadically the voltage is tem porarily too low See CPS3 troubleshooting no error CPS3 gt Check the mains power sup ply for voltage drops 77 Fehlersuche en fm 16 12 2010 P2077SB EN 2010 11 63 Troubleshooting DGD Error Possible causes Measures and Description remedies Servo The temperature sensor in the Check temperature if gt 80 C Temperature output section TSE TUSE measures a tempera gt ensure adequate ventilation too high ture gt 80 C of the DGD IS The temperature in the TSE TUSE output section is gt 80 DGD IS is ventilated sufficiently gt Replace the TSE TUSE Servo Driver supply output section NOK The power adapter for the inter nal supply to the output section is overloaded or defective Internal error gt Replace the TSE TUSE Servo Offset of current measurement NOK The zero point of the integrated motor current measurement has moved Internal error gt Replace the TSE TUSE Servo SSIO communication NOK The communication interface between the servo amplifier and the measuring board is
37. S is inadequate due to external conditions gt Ensure that air can circulate through the cooling fins Housing openings on the CPS3 are covered gt Clear the housing openings 2 1 Switch on relay contact does not open Relay for switch on current limitation in the CPS3 is Stuck Detection only occurs when switching on The relay contact is closed during operation Subsequent error a different fault destroyed the relay gt Replace the CPS3 Maximum number of switch on cycles exceeded gt Replace the CPS3 2 2 Intermediate circuit 380 VDC discharge not possible The intermediate circuit can not be discharged Subsequent error a different fault destroyed the relay Main relay Q4 or Q5 in PM does not open gt Replace the main relay or Q5 Braking chopper in the CPS3 is defective gt Replace the CPS3 Braking resistor is highly resis tive or burnt through gt Replace the CPS3 2 3 24V supply 24 V supply is not within the range 21 5 V 27 3 V gt Measure the voltage at XS3 terminals 1 and 6 24 V power adapter in PDB CPS is defective gt Replace the power adapter Power adapter T2 in PDB CPS is overloaded gt Checkthe maximum load 8 A on the CPS3 Voltage on power adapter in PDB CPS is incorrect gt Setthe voltage on the power adapter to 26 0 V Fuse thermal 24 V in the CPS3 is highly resist
38. TSE 1B035A 72 1B U TSE 1B060A 67 2B U TSE 2B110A 71 2B U TSE 2B200A 67 3B U TSE 3B300A 66 4B U TSE 4B500A 66 4B U TSE 4B660A 66 Measured sound pressure level at idling speed no load clockwise rotation in accordance with ISO 3744 2 Transport Storage Transport only in the original packing If the package is damaged check the part for visible damage Inform the carrier or DGD if necessary System components Storage temperature Relative humidity DGD IS PDB CPS TSE TUSE condensation Motor CPS3 25 0 70 8 P2077SB EN 2010 11 776 Sicherheit bedingt en fm 16 12 2010 DGD System description 3 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 Special features of the fastening system mPro400GC DGD intelligent spindles In the mPro400GC DGD intelligent spindles fastening system the tightening modules are no longer installed in a control cabinet but directly on the built in nutsetter see system m Pro 400 tm with single cable solution The intermediate circuit voltage was increased from 320 VDC to 380 VDC compare
39. VZ fm 16 12 2010 DGD Safety 1 1 1 WARNING gt Safety Warnings and notes CAUTION gt DANGER gt 1 2 DANGER WARNING CAUTION A A symbol combined with the word WARNING warns of a potentially dangerous situation for the health of personnel II this warning is not observed death or serious injury may occur 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 If this warning is not observed injuries property or environmental damage may occur A symbol combined with the word DANGER warns of an impending health risk or risk of fatal injury to personnel If this danger note is not adhered to severest injury that may lead to the death of people is the conseguence This symbol indicates a general instruction General instructions include application tips and special useful information but no warnings against dangers Basic reguirements for safe working practices Only take the fastening system into service after you have read and completely understood the following safety instructions and this document Failure to observe the instructions below may result in electric shock fire and serious injuries High leakage current Fatal electric shock could occur gt gt Establish a protective earth PE ground connection to the PDB CPS before taking into operati
40. d to the TM tightening modules This increased the maximum speed of the built in nutsetter by 20 3 1 Components Item Designation 1 Nutsetter control unit mPro400GC M ARCNET cable Order no 960950 xxx length dm Mains cable 3x480 VAC Transformer CP3 JH Power distribution box PDB CPS DGD IS ARCNET terminator System cable type A System cable type C Z NI OD CI gt C2 N 77 system png Power cable 77c_Systembeschreibung en fm 16 12 2010 P2077SB EN 2010 11 9 System description DGD 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 torgue 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 Asingle system cable PDB CPS to the last DGD IS may have up to 16 DGD IS units connected depending on the size and number Asingle mPro400GC M can have up to 32 DGD IS units connected Available channel numbers Code Maximum number of DGD IS Quantity 1B U TSE 2B U TSE 3B U TSE 4B U TSE System cable PDB CPS3 16 6 6 6 1 PDB CPS6 32 12 12 12 2 PDB CPS9 18 18 18 3 The maximum number of DGD IS units per PDB CPS depends on load In order to guarantee the number stated the
41. d with ARCNET 44 P2077SB EN 2010 11 77h PowerDistributionBox en fm 16 12 2010 Power distribution box PDB CPS 1 1 11 6 Transformer Designation 1 Connection to PDB CPS 2 Bracket for mounting on wall machine 77 power disribution box fronLpng 11 7 General technical data Part no Power Weight Protection Type Nominal Ibs category KVA CP3 3750 JH 3 125 N Dry type class AA CP3 6750 JH 6 150 IP54 encapsulated NEMA 1 CP3 9750 JH 9 200 77 PowerDistributionBox en fm 16 12 2010 P2077SB EN 2010 11 45 Power distribution box 5 Dimensions drilling pattern Transformer A B D E 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 77 Masse png NOTE 9 gt When installing keep distance of 25 4 mm from voltage conducting components 46 P2077SB EN 2010 11 77h PowerDistributionBox en fm 16 12 2010 DGD Cables 12 CAUTION AN NOTE Cables There is a risk of tripping or falling over loose cables on the ground gt Lay all connected cables safely Remember that the maximum cable length is 50 m Close or lock all plug connectors The red ring around the outer diameter of plug connectors
42. ding in the TSE TUSE each time a spindle starts the failure is brief i e undervoltage the TSE TUSE becomes ready to operate automatically after the next acknowledgment signal All malfunctions in the DGD IS on in the 53 are archived in the mPro400GC M The error informa tion is displayed here during troubleshooting The error is permanent if the error mode cannot be acknowledged 771 Fehlersuche en fm 16 12 2010 P2077SB EN 2010 11 55 Troubleshooting DGD 14 2 14 2 1 DGD IS Error Description Possible causes Measures and remedies DGD IS does not turn Motor defective Gearing defective Tightening module TSE TUSE defective gt Replace the DGD IS Cable defective gt Replace the cable Loud noises Gearing wear gt Replace the DGD IS Transducer When an operating failure occurs the torque output is set to an output value of gt 6 5 V and an error bit is set in the operating data memory Error Description Possible causes Measures and remedies Output signal is not linear Measuring hub was over stretched Offset voltage is too high Measuring hub was over stretched No output signal Pre amplifier is defective Torque output is set to an output value gt 6 5 V Error bit is set in the operating data memory CPU NOK internal transmission to D A converter fails HF section NOK HF telemetry transmission
43. e Center 2630 Superior Court Auburn Hills 48326 Tel 248 391 3700 Fax 248 391 7824 Seattle WA Apex Tool Group Sales amp Service Center 2865 152nd Avenue N E Redmond WA 98052 Tel 425 497 0476 Fax 425 497 0496 England Cooper Power Tools a company of Apex Tool Group LLC Unit G Quinn Close Seven Stars Industrial Estate Whitlet Coventry CV3 4LH England Tel 44 2476 3089 60 Fax 44 2476 3089 69 Brazil Houston TX Apex Tool Group Sales amp Service Center 6550 West Sam Houston Parkway North Suite 200 Houston TX 77041 Tel 713 849 2364 Fax 713 849 2047 York PA Apex Tool Group Sales amp Service Center 3990 East Market Street York PA 17402 Tel 717 755 2933 Fax 717 757 5063 France Cooper Power Tools SAS a company of Apex Tool Group LLC Zone Industrielle BP 28 Avenue Maurice Chevalier 77831 Ozoir la Ferri re Cedex France Tel 011 33 1 64 43 22 00 Fax 011 33 164401717 Cooper Tools Industrial Ltda a company of Apex Tool Group LLC Av Liberdade 4055 Zona Industrial Iporanga 18087 170 Sorocaba SP Brazil Tel 011 55 15 238 3929 Fax 011 55 15 228 3260 PLxx xxxx Printed in USA 00 2010 Copyright Apex Tool Group LLC Lexington SC Apex Tool Group 670 Industrial Drive Lexington SC 29072 Tel 800 845 5629 Tel 803 359 1200 Fax 803 358 7681 Canada Apex Tool Group Sales amp Service Center 5925 McLaughlin Road Mississauga Ont L5R
44. e of them by segregating them clearly gt Follow the locally applicable regulations Observe generally valid disposal guidelines such as in Germany the Electrical and Electronic Equipment Act ElektroG gt Handin the DGD IS at your company collection point or return to Sales amp Service Center see back side 77m Wartung Entsorgung bedingt en fm 16 12 2010 P2077SB EN 2010 11 69 Sales amp Service Centers Note All locations may not service all products Please contact the nearest Sales amp Service Center for the appropriate facility to handle your service reguirements Dallas TX Apex Tool Group Sales amp Service Center 1470 Post amp Paddock Grand Prairie TX 75050 Tel 972 641 9563 Fax 972 641 9674 Los Angeles CA Apex Tool Group Sales amp Service Center 15503 Blackburn Avenue Norwalk CA 90650 Tel 562 926 0810 Fax 562 802 1718 Germany Cooper Power Tools GmbH amp Co OHG a company of Apex Tool Group LLC Postfach 30 D 73461 Westhausen Germany Tel 49 0 73 63 81 0 Fax 49 0 73 63 81 222 Mexico Cooper Tools de S A de a company of Apex Tool Group LLC Vialidad EI Pueblito 103 Parque Industrial Quer taro Quer taro QRO 76220 Tel 52 442 211 3800 Fax 52 442 103 0443 Apex Tool Group LLC 1000 Lufkin Road Apex NC 27539 Phone 919 387 0099 Fax 919 387 2614 www apextoolgroup com Detroit MI Apex Tool Group Sales amp Servic
45. er 18 P2077SB EN 2010 11 77e IntelligenteSpindel en fm 16 12 2010 DGD DGD intelligent spindles 5 3 2 Size 2 1x transducer DGD IS B L 1 2 1 9 2 1 2 1 2 1 2 1 2 2BTSE 2B110A 2M1B 2ZB 947644A4 2B110A 935548 2M1B 934295 2ZB 927227 KMAW 961089 002 2BTSE 2B200A 2M3B 27B 947650A6 2B200A 935549 2M3B 934294PT 2BTSE 2B110A 2VM1B 947645A3 2B110A 935548 2VM1B 934336PT 2BT 935561 TSE 961446 KMAG 961088 004 2BTSE 2B200A 2VM3B 947651A5 2B200A 935549 2VM3B 934335 2BTSE 2B110A 2WM1B 947646 23 2 110 935548 2VVM18 3 961088 003 2BTSE 2B200A 2WM3B 947652 43 2 200 935549 2WM3B 3 2BUTSE 2B110A 2M1B 2ZB 947647 13 28110 935548 2M1B 934295PT 278 927227 KMAG 961088 004 2BUTSE 2B200A 2M3B 2ZB 947653 33 2B200A 935549 2 934294 2BUTSE 2B110A 2VM1B 947648A03 2B110A 935548 2VM1B 934336PT 2BUT 936322 TUSE 961447 KMAG 961088 003 2BUTSE 2B200A 2VM3B 947648A0 2 200 935549 2VM3B 934335PT 2BUTSE 2B110A 2WM1B 947649493 2B110A 935548 2WM1B 3 KMAG 961088 004 2BUTSE 2B200A 2WM3B 947655 13 2B200A 935549 2WM3B 3 1 Code 2 Part no 3 On reguest 5 3 3 Size 3 1x transducer DGD IS B H 1 2 1 2 1 2 1 2 2 1 3 2 3BTSE 3B300A 3M2B 3Z
46. erate an electric arc and cause serious burns A The contacts may become damaged gt Switch off the power supply to the PDB CPS before unplugging or inserting the system cable XS1 Power in Required connector type Phoenix Power Combicon PC6 4 ST 10 16 Order No 961175 Contact Signal Description L1 L1 L2 L2 Supply voltage 3 x 270 VAC L3 L3 PE PE Earth conductor connection to housing XS21 Power out Power supply DGD IS 380 VDC Required connector type Phoenix Power Combicon IPC6 3 ST 10 16 Order No 961188 Contact Signal Description IC 380 VDC Intermediate circuit voltage 380 VDC 10 IC 0 VDC Intermediate circuit voltage 0 V PE PE Earth conductor connection to housing XS22 TSE TUSE 24 V supply and Enable servo signal end stage release signal to DGD IS Required connector type Phoenix Combicon MSTB2 5 3 STF 5 08 Part 5959935 Contact Signal Description 24 V 24 V Out Supply TSE TUSE 24 V 10 4 8 DGD IS Enab SV Enable servo Enable servo output End stage release Active when no errors or Emergency stop pending 24 VDC max 0 3 A 0VDC Supply TSE TUSE 0 V 77h PowerDistributionBox en fm 16 12 2010 P2077SB EN 2010 11 43 Power distribution box 5 DGD XS3 Logic supply and control on relay output 24 V supply for the CPS3 and control on relay connection
47. eration For initial commissioning the mPro400GC programming instructions must also be read and applied 1 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 2 Connect all components see Chapter 3 1 Components starting on page 9 Risk of tripping or falling over loose cables on the ground Lay all connected cables safely 3 Close all plug connectors and lock The red ring around the outer diameter of plug connectors with a slide lock should not be visible Always terminate the ARCNET with an ARCNET terminator at the bus end i e at the last DGD IS order no 961127 This terminator is permanently installed in the nutsetter control unit mPro400GC M start of bus 4 Connect the mains cable to the nutsetter control unit High leakage current Fatal electric shock could occur Establish a protective earth PE ground connection to the nutsetter control unit before taking into opera tion 5 Preset the ARCNET address on each DGD IS under the service panel see 6 4 1 ARCNET address preset page 24 Each address can be used only once in the system Close the service panel Close the protective devices i e safety grilles Switch on the machine control unit PLC SPS Switch on the nutsetter control unit If there are no faults pending after switching on the unit the Ready LED on the DGD IS lights up
48. ew bits retained securely gt Wedonotclaim that these safety notes are complete Read and observe all applicable general and local safety and accident prevention rules gt Follow a safety conscious maintenance program which takes into account the local regulations for maintenance and servicing in all phases of operation of the fastening electronics Operator training The fastening system may only be operated by personnel that have been trained and instructed correspondingly and authorized by the operator The tightening system must only be serviced by persons who have been instructed by qualified representatives of DGD The operator must make sure that all new operating and maintenance personnel are instructed in the operation and maintenance of the fastening system to the same extent and with the same care and attention Personnel who are being trained may only work on the fastening system under the supervision of an experienced operator Personal protective equipment When working Wear the protective goggles to protect against spurting metal splinters Danger of injury by being wound up in and caught by machinery Wear close fitting clothing Do not wear jewelry 1 5 Designated use The owner is responsible for using the machine according to its designated use The fastening system may be used only under the following conditions Industrial environment EMC limit class value A DIN EN 550081 2 The DGD
49. fier 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 6 2 General technical data Features Data Weight TSE 14800 TUSE 1500 g Protection category is attained IP54 when all connectors are plugged in and the service panel is closed Cooling type Convection self cooling Service life operating 40 000 h Usability period if stored 100 000 h approx 11 years Acceleration of each axis max 100 m s 6 2 1 Power loss Low loss components generate minimal heat Extremely good heat dissipation Overall housing serves as a cooling element Standby 9A Operation max 40 W WARNING High temperature the tightening module TSE TUSE may heat up and cause burns during removal max temperature 70 C Wear gloves 6 2 2 Power supply 380 VDC Intermediate power circuit 380 VDC and logic power 24 VDC are supplied separately by the PDB CPS In the event of an emergency stop the intermediate power circuit is switched off separately by the PDB CPS The logic section remains connected to the power Performance data DGD IS different Features Data 1B U TSE 2B U TSE 3B U TSE 4B U TSE Supply voltage VDC 380 10 Rated supply current A 0 5 1 Peak supply current A 6 15 15 15 22 P2077SB EN 2010 11 77t Schraubmodul en fm 16 12 2010 DGD Tightening m
50. following settings are to be made Maximum speed at 20 of maximum torque for 18TSE 2BTSE 3BTSE and 4BTSE Final tightening up to 500 Nm Maximum speed 50 rpm at maximum torque for 1BTSE 2BTSE 3BTSE and 4BTSE 4 500 e Final tightening above 500 Nm Maximum speed 20 rpm at maximum torque for 4BTSE 4B660A 4BTSE 4B660A 4VK4MS 4BTSE 4B360A 4Z1250A and 4BTSE 4B460A 4Z1600A If settings above those stated are selected the number of channels must be reduced If using different types of spindle on one control unit these must be individually defined Please consult your Sales amp Service Center see backside 3 1 3 Cables From PDB CPS to the last DGD IS 50 maximum length 3 1 4 ARCNET System bus Communication between the mPro400GC M and the DGD IS is achieved via the serial high performance field bus ARCNET based on RS485 cable is connected between mPro400GC M and PDB CPS e ARCNET cables are integrated in the system cable between PDB CPS DGD IS and between DGD IS and DGD IS Several system wiring harnesses meet at PDB CPS6 and PDB CPS9 An ARCNET bus amplifier module ARCNET HUB 1E3A order no 961237 is installed for this purpose The module allows a star shaped bus topology 10 P2077SB EN 2010 11 77c Systembeschreibung en fm 16 12 2010 DGD First Operation CAUTION gt C 2 DANGER gt O ON O First Op
51. fting inside the flexible cable duct Position the cable sleeve about 100 mm above the clamp in the fixed area Lay insulated wires in small loops in order to avoid a tensile load on the clamp We recommend running some motion cycles after the first installation of the cables Then the cable layout should be checked again and if necessary optimized 77i Kabel en fm 16 12 2010 P2077SB EN 2010 11 51 Cables Laying High Flex cables in cable ducts In order to achieve an optimal service life of cables in flexible cable ducts comply with the following points when laying the cables gt V v v The cables should lay straight in the drag chain Insert the cables into the cable ducts one by one Separate the cables using cut off bridges Lay a maximum of 2 cables per partition Never lay cables with different diameters gt 3 mm together in the same partition 52 P2077SB EN 2010 11 77i Kabel en fm 16 12 2010 DGD Function description 13 13 1 NOTE Function description 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 e individual assemblies cannot be replaced
52. gency stop status Intermediate power circuit 380 VDO is deactivated No signals at the inputs Emer gency stop 54 terminal 2 or Control on XS5 terminals 3 and 4 gt Check voltage 24 V at CPS3 Plug connector XS4 Terminals 2 and 4 Plug connector XS5 Terminals 3 and 4 Check voltage 24 V at CP Plug connector XS3 Terminals 2 and 6 Plug connector XS2 Terminals 5 and 6 Conclusion the signals are not generated by external controls 77 Fehlersuche en fm 16 12 2010 P2077SB EN 2010 11 57 Troubleshooting DGD 14 3 3 7 segment Status display Encoded errors are displayed in 7 segment display on the CPS3 The display alternates between the first and second digit at brief intervals Display Duration Pause 1st digit 0 55 0 25 2nd digit 0 55 15 1st digit 0 55 0 2 5 period in the display means NO error If several errors occur the error with the highest priority is displayed i e with the lowest number No information about faults and malfunctions that are detected by the CPS3 is transmitted to the mPro400GC M by ARCNET and displayed in the screen there Error Possible causes Measures and C Description remedies 2 0 0 Error loading the inter Short circuit in the intermediate gt Replace the CPS3 mediate circuit capacitors after switching on circuit CPS3 Cables gt Check the cables for short circu
53. green Otherwise please refer to 14 Troubleshooting page 55 troubleshooting Ready LED 10 Enter parameters for torque angle of rotation setting via the mPro400GC M The mPro400GC M is programmed by DGD technical staff during commissioning The first time the nutsetter control unit is switched on the parameters for controlling fastening sequences must be read in via the keyboard or a valid parameter file For process programming of the nutsetter control unit see Programming Manual mPro400GC M 77d Inbetriebnahme bedingt en fm 16 12 2010 P2077SB EN 2010 11 11 First Operation This page has been left empty deliberately 12 P2077SB EN 2010 11 77d Inbetriebnahme bedingt en fm 16 12 2010 DGD DGD intelligent spindles 5 DGD intelligent spindles 5 1 General technical torque measurement with integrated pre amplifier resulting in greater signal noise spacing reverse voltage protected supply Short circuit proof outputs low voltage monitor e watchdog for processor e noise protected input and output circuit Features Data Protection category 54 Service life operating 40 000 h Load cycles min at maximum torque 1 000 000 then recalibration Mechanical overload capacity of the mea suring shaft 100 77e_IntelligenteSpindel en fm 16 12 2010 P2077SB EN 2010 11 13 DGD intelligent spindles DGD 5 2 Catalogue
54. he converter is 80 kHz Supply Generated Maximum voltage current V A Internal servo section logic 3 3 3 2 3 4 0 5 Internal servo section analog 5 0 4 9 5 1 0 5 Internal servo section analog 15 0 14 25 15 75 0 12 Internal measuring section logic 1 9 1 78 2 02 1 Internal measuring section analog 2 5 2 4 2 6 1 Internal measuring section analog 3 3 3 2 3 4 0 5 Internal measuring section analog 12 0 11 4 12 6 0 5 Transducer 12 0 11 8 12 2 0 6 ARCNET output stage 5 0 4 8 5 2 0 2 774 Schraubmodul en fm 16 12 2010 P2077SB EN 2010 11 25 Tightening module TSE TUSE DGD 6 5 2 6 5 3 NOTE Motor end stage Short circuit proof phase phase phase PE phase temperature monitor Minimum losses due to end stage Features Data Intermediate circuit voltage U VDC 380 10 Excess voltage shut off VDC gt 480 Low voltage shut off VDC lt 160 Rated output at 50 VA 1000 Peak power momentary VA 8000 Peak current maximum A 65 Current controlled shut off short circuit A 100 Efficiency approx 98 Pulse freguency of the PWM KHz 10 Measuring board The measuring board is a component of the tightening module and should not be replaced separately Separate processors for measuring and communication tasks A measuring channel for torgue reco
55. he transducer gt Replace the transducer Internal error gt Replace the TSE TUSE Transducer CRC of service memory NOK Could not read in the data for self identification correctly The data cables are interrupted Check the KMAG KMAW cable transducer TSE TUSE for breaks especially the signal wires for data transfer RS422 Replace the cable short circuiting with another signal Check the KMAG KMAW cable transducer TSE TUSE for short circuits gt Replace the cable Error in the transducer gt Replace the transducer Communication was disrupted when the transducer was plugged in gt Unplug and plug in again Transducer Tool identification NOK The data for self identification of the transducer are not verified by the mPro400GC M Data communication failed Copy data to mPro400GC M see Programming Manual mPro400GC gt Acknowledge the TSE TUSE with Reset Data communication not completed yet Copy data to mPro400GC M see Programming Manual mPro400GC gt Acknowledge the TSE TUSE with Reset P2077SB EN 2010 11 771 Fehlersuche en fm 16 12 2010 DGD Maintenance Service 15 DANGER WARNING AN 16 CAUTION A z Maintenance Service Only trained personnel are permitted to perform maintenance Please refer to the Service Manual DGD IS High leakage current Fatal electric shock
56. iting between contacts 1 and 2 on the plug connec tors and replace if neces sary TSE TUSE gt Replace the TSE TUSE Mainrelay Q4 or Q5 in PM does not switch gt Check the main relay replace if necessary 0 1 Faulty supply 3 x 270 VAC Phases missing gt Check phases gt Check mains supply Safety relay PNOZ 2 in the power module has triggered an emergency stop gt Check the emergency stop circuit gt Read the operating instructions for the PNOZ type X3P Relay 2 or has not switched gt Check the relay replace if necessary Supply voltage is too high U phase phase gt 300 VAC too low U phase phase lt 240 VAC gt Check the supply voltage gt Check mains supply 0 2 Excess current or short circuit on braking chopper Braking current gt 200 A Short circuit in the braking resistor gt Replace the CPS3 0 4 Braking chopper overload Braking resistor is overloaded The braking power is gt 100 Excessive number of DGD IS gt Reduce the number of mPro400GC M DGD IS is powered externally gt Check the mechanics of the fastening station 58 P2077SB EN 2010 11 771 Fehlersuche en fm 16 12 2010 DGD Troubleshooting play Error Description Possible causes Measures and remedies A Dis 4 Excessive voltage between artificial neutral point of the power supply a
57. ive gt Switch off the PDB CPS and switch back on again after a minute gt Check the maximum load replace the CPS3 60 P2077SB EN 2010 11 77 Fehlersuche en fm 16 12 2010 DGD Troubleshooting E Error Possible causes Measures and C Description remedies 2 2 5 5 V supply internal Internal voltage external check not possible Internal 5 V supply Power adapter in the CPS3 is defective gt Replace the CPS3 is not within the 4 5 V 5 5 V range Power adapter in the CPS3 is overloaded gt Replace the CPS3 2 7 Error in 15 V driver supply for the braking chopper The internal 15 V supply is 12 5 V Internal voltage can not be checked externally Power adapter in the CPS3 is defective gt Replace the CPS3 Power adapter in the CPS3 is overloaded gt Replace the CPS3 3 3 Initialization or program error Internal program error no extern al actions possible Error during program initializa tion 3 Inform DGD service gt Switch the PDB CPS off and on again Communication error with a service PC gt Reconnect PC to CPS3 Checksum error gt Inform DGD service gt Switch the PDB CPS off and on again 77 Fehlersuche en fm 16 12 2010 P2077SB EN 2010 11 61 Troubleshooting DGD 14 4 14 4 1 14 5 14 5 1 Tightening module TSE TUSE Ready LED Error Descripti
58. ligenteSpindel en fm 16 12 2010 DGD DGD intelligent spindles 5 2 2 Size 2 1x transducer Designation Order No Torque Speed Spring e min Length Weight Spring travel axis chuck Nm distance max min RPM mm mm mm kg flange 2BTSE 2B110A 2M1B 22B 1 947644 4 110 25 890 1 2 56 528 7 6 5308435 2BTSE 2B200A 2M3B 2ZB 1 947650 6 200 40 502 m 3 4 2BTSE 2B110A 2VM1B 94764543 110 25 831 1 2 44 551 9 2 5308438 2BTSE 2B200A 2VM3B 947651A5 200 40 468 3 4 2BTSE 2B110A 2WM1B 94764642 110 25 838 1 2 25 59 581 8 7 929053 2BTSE 2B200A 2WM3B 94765244 200 40 472 3 4 2BUTSE 2B110A 2M1B 2ZB 947647A1 110 25 890 1 2 56 367 8 6 5308435 2BUTSE 2B200A 2M3B 2ZB 947653 200 40 502 58 3 4 2BUTSE 2B110A 2VM1B 947648A0 110 25 831 1 2 44 390 10 2 5308438 2BUTSE 2B200A 2VM3B 947648A0 200 40 468 3 4 2BUTSE 2B110A 2WM1B 94764949 110 25 838 1 2 25 59 421 9 7 929053 2BUTSE 2B200A 2WM3B 947655A1 200 40 472 3 4 1 On reguest Smallest scribed circle diameter in mm Ouantity Attachment DGD IS Centric Offset Angle head 2 56 44 59 3 75 50 68 4 80 62 86 5 106 74 101 6 130 89 118 7 151 102 137 77e IntelligenteSpindel en fm 16 12 2010 P2077SB EN 2010 11 15 DGD intelligent spindles DGD
59. ment DGD 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 Pin Color Signal Description A nc B Brown nc C green TQ Torque output ue E D Yellow 0 VA 0 V torque reference connection D F E gray OV 0 V supply C G F Pink 12 L M G Blue H H Red RxD interface A K J Y Black RxD interface K Violet CAL Input calibration voltage L Gray pink TxD interface M Red blue TxD interface Housing PE Shield connection 7 3 Angle head attachment Helix toothed Cap nut bevel wheels Crown gearing IL H torque measurement i Code Part no Torque Ratio Permissible load Lateral force Calibration i on output shaft on square TQ Pres Ten 1 sion 1 1WM1B 2 35 1WM2B 2 60 1 0667 53 1700 3400 3100 1WM3B 2 12 2WM1B 2 110 110 1 0625 1850 3900 4200 2WM3B 2 200 200 3WM2B 2 300 1 0385 300 3800 4800 5100 4WM2B 2 500 1 0370 660 1200 6500 5900 4WM3B 2 660 1 During continuous operation for long periods multiply the specified values by 0 3 2 On request 28 P2077SB EN 2010 11 77g Komponenten en fm 16
60. ments that have to be selected or deselected such as buttons or control boxes i e lt F5 gt Courier Indicates the name of paths and files e g setup exe backslash between two names indicates the selection of an item from the menu e g file print Abbreviations DGD IS DGD intelligent spindles PDB CPS Power distribution box mPro400GC M Nutsetter control unit TSE TUSE Tightening module CP3 JH Transformer CPS3 Supply module Copyright protection DGD 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 otherwise without the express permission of DGD DGD and Cooper Power Tools GmbH amp Co are trademarks and internal designations of Apex Tool Group Division 2 P2077SB EN 2010 11 77a Deckblatt fm 16 12 2010 DGD Contents 1 Safety 5 1 1 Warnings 5 1 2 Basic requirements for safe working practices 5 1 3 Operator training o mE 6 1 4 Personal protective 6 1 5 Designated USC E sve 6 1 6 Ambient conditions eem 7 1 7 EMC Electromagnetic compatibility 7
61. motor brakes which causes the voltage to increase The braking chopper with braking resistor integrated in the CPS3converts the excess energy into heat When the circuit is switched off the intermediate circuit capacitors is discharged via the braking resistor 38 P2077SB EN 2010 11 77h PowerDistributionBox en fm 16 12 2010 DGD Power distribution box PDB CPS WARNING AN 11 4 11 4 1 NOTE Unplugging the system cable while still live may generate an electric arc and cause serious burns The con tacts may become damaged gt Switch off the power supply to the PDB CPS before unplugging or inserting the system cable Installation gt Secure the PDB CPS to the machine using 4 x 8 8 8 screws 25 Nm Guidelines The PDB CPS is ventilated by a natural convection system an active fan is not required Warm air must not enter below the housing gt No objects are allowed to obstruct the air flow below and above the housing see hatching in the graphic Dimensions drilling pattern page 39 gt The PDB CPS should not be exposed to direct sunlight Dimensions drilling pattern egoon Power distri A B D mm mm mm PDB CPS3 PDB CPS6 584 23 00 686 27 00 356 14 00 724 28 50 330 13 00 PDB CPS9 ee F A 77 power distribution box Masse png 77h Powe
62. nal Activity LED lights up Data transfer to the ARCNET LED flashes reconfiguration transfer is disrupted LED off Internal fault no power available lt Reset gt button Press the lt Reset gt button to acknowledge faults You will reguire a pointed object such as a ball point pen Pressing this button resets the processor and reconfigures all functions DGD service interface RS232 for measuring board MC only for DGD service Connection to PC via special cable Plug connector type PS2 Pin Signal Description 1 RxD 10 V 2 TxD 10 V 3 VCC 3 3 V 2 20 4 5 6 Housing GND OV 24 P2077SB EN 2010 11 77 Schraubmodul en fm 16 12 2010 DGD Tightening module TSE TUSE 6 4 5 DGD service interface RS232 for servo NOTE Q only for DGD service Connection to via special cable Plug connector type PS2 Pin Signal Description 1 RxD 10 V 2 TxD 10 V 3 VCC 3 3 V 2 20 mA 4 AMON Analog monitor 0 V 3 3 V 5 AIN Analog preset 0 V 3 3 V 6 START Start signal to servo 0 V start 3 3 V Housing GND 0V 6 5 Internal assemblies 6 5 1 Power adapters The internal power adapters supply power to all electronic assemblies in the tightening module All generated voltages are short circuit proof e Galvanic isolation of ARCNET output stage from all other power supplies Pulse frequency of t
63. nd PE or the center of the intermediate circuit approx 190 VDC and PE Voltage gt 100 V Short circuit between gt Check connection of inter IC and PE mediate circuit voltage 380 VDC and 0 VDC to PE CPS3 gt Check CPS3 Replace System cable gt Replace the system cable TSE TUSE Replace the TSE TUSE Motor Replace the motor or DGD IS 1 2 Excessive current or short circuit in the intermediate circuit Current gt 250 A Check the system cable between the 380 VDC and 0 V wires for short circuiting System cable short circuit gt Replace the cable e Short circuit TSE TUSE gt Replace the TSE TUSE Temperature of the cooling element is too high Temperature of CPS3 cooling element is gt 90 Constant overload CPS3 Excessive number of DGD IS gt Reduce the number of PDB CPS Ambient temperature PDB CPS 40 C gt Improve the ambient condi tions PDB CPS is exposed to other heat sources i e sunlight gt Improve the ambient condi tions attach covers if nec essary Heat dissipation from the PDB CPS is inadequate due to external conditions gt Ensure that air can circulate through the cooling fins Pt Error in intermediate circuit The intermediate circuit is over loaded Excessive number of DGD IS gt Reduce the number of PDB CPS 1 6 The intermediate circuit voltage is
64. odule 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 V 24 410 96 Rated supply current A approx 0 35 Power loss standby VV 9 6 3 Ready LED The Ready LED indicates that the system is ready for operation Signal Tightening module Green Ready for operation Red Not ready for operation an error is pending see 14 Troubleshooting page 55 6 4 Service panel 2 1 3 4 5 Item Designation 1 ARCNET address preset Active LED lt Reset gt button DGD service interface RS232 for measuring board MC DGD service interface RS232 for servo G a00601 wmf 77t_Schraubmodul en fm 16 12 2010 P2077SB EN 2010 11 23 Tightening module TSE TUSE DGD 6 4 1 NOTES 6 4 2 6 4 3 6 4 4 NOTE 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 Always switch off the nutsetter control unit before making adjustments Each address can be used only once in the system Otherwise an error is triggered on the mPro400GC M Active LED The Active LED indicates which activities the ARCNET is performing Sig
65. on Possible causes Measures and remedies Ready LED lights up red Error in the TSE TUSE For fault description on the mPro400GC M display see 14 5Nutsetter control unit mPro400GC M Ready LED does not light up 24 V supply is unavailable the TSE TUSE is not connected to the power supply gt Measure the voltage 24 26 V at XS1B sockets A and B gt Check the error display for the PDB CPS on the CPS3 If error present go to 14 3 Tightening module CPS3 in power distribution box PDB CPS page 57 Replace the system cable TSE TUSE is defective Replace the TSE TUSE Nutsetter control unit mPro400GC M Display on the Control Unit All faults and malfunctions that the TSE TUSE fastening electronics detect are transmitted to the mPro400GC M via ARCNET and then displayed on the screen If a malfunction develops in the TSE TUSE or DGD IS during tightening the faults reported by the TSE TUSE in the rundown data table will appear IP FLT FMK FHW KAL1 KAL2 OFF1 OFF2 VLP AN2F In the bus map window system see Programming Manual mPro400GC all current errors are displayed in plain text in the system information and listed in the following table 62 P2077SB EN 2010 11 771 Fehlersuche en fm 16 12 2010 DGD Troubleshooting Error Possible causes Measures and Description remedies Servo Error in Check the resolver wires in the
66. on Always disconnect the power supply before performing maintenance work on the DGD IS and the PDB CPS Always disconnect the system cable or motor cable from the PDB CPS or DGD IS before making throughput resistance and short circuit measurements Do not attempt to repair possible faults on the fastening system by yourself if you do not have the required knowledge Please consult your local service agent or the responsible Sales amp Service Center see backside High temperature the motor on the DGD IS may heat up and cause burns during removal max engine temperature 80 gt Wear gloves Risk of flying parts Components of the spindle may rotate come loose and cause injury gt Avoid speed increases of over on all axes 776 Sicherheit bedingt en fm 16 12 2010 P2077SB EN 2010 11 5 Safety Work area A 1 3 gt Close all safety devices gt Ensure that there is enough space in the work area gt Keep the work area clean Electrical safety gt Only operate the tightening system indoors gt Observe the safety notes on the DGD IS Safe working with and around fastening tools gt Inspect screw bits and retaining ring for visible damage and cracks Replace damaged parts immediately gt Always disconnect the power supply to the DGD IS before changing screw bits Only use screw bits for machine controlled fastening tools gt Make sure that the scr
67. r short circuited Check the KMAG KMAW cable for short circuits gt Replace the cable gt Replace the transducer unavailable gt Connect the transducer Replace the cable Internal error Replace the TSE TUSE Transducer Calibration voltage NOK The calibration voltage is outside the permissible range of 4 85 V 5 15 V The calibration signal is inter rupted Check the KMAG KMAW cable for breaks especially the calibration signal wire The calibration signal is short cir cuiting with another signal Check the KMAG KMAW cable transducer TSE TUSE for short circuits gt Replace the cable Error in the transducer gt Replace the transducer Internal error gt Replace the TSE TUSE 771 Fehlersuche en fm 16 12 2010 P2077SB EN 2010 11 67 Troubleshooting DGD Error Possible causes Measures and Description remedies Transducer The torque signal is interrupted Check the mPro400GC M in test Offset value NOK The zero point voltage is outside the permissible range of 200 mV 200 mV mode Diagnosis Voltages If values are outside permissible limits Check the KMAG KMAW cable transducer TSE TUSE for breaks gt Replace the cable The torque signal is short circuit ing with another signal Check the KMAG KMAW cable transducer TSE TUSE for short circuits gt Replace the cable Error in t
68. rDistributionBox en fm 16 12 2010 P2077SB EN 2010 11 39 Power distribution box 5 DGD 11 5 11 5 1 Supply module CPS3 Description The supply module CPS3 Central Power Supply 3 KVA is integrated in the power distribution box PDB CPS 1x in PDB CPS3 2x in PDB CPS6 in PDB CPS9 The CPS3 has the following functions Rectification and smoothing of the intermediate circuit voltage to 380 VDC for the tightening module TSE TUSE Switch on current limiting Braking chopper Excess and low voltage monitoring with intermediate circuit shut off Short circuit and overcurrent monitoring Generation of Ready signal on the mPro400GC M and machine control Evaluation of signal Emergency stop a00639 wmf 40 P2077SB EN 2010 11 77h PowerDistributionBox en fm 16 12 2010 Power distribution box PDB CPS General technical dataCPS3 Features Data Order No 961112 Weight G 3650 Protection category IP20 Cooling type Convection self cooling Service life operating h 40 000 On Off switching cycles 5 000 000 Usability period if stored h 100 000 approx 11 years Electrical DataCPS3 Features Data Supply voltage power VAC 3x 270 10 Frequency Hz 50 6
69. ransducer g M calibration value 1 1 1 934286 35 1 2 934287 60 1M3B 934288 12 2 2M1B 934295PT 110 2M3B 934294PT 200 3M2B 934303PT 300 4M1B 934318 400 4M28 934319 500 4M3B 936496PT 660 77g Komponenten en fm 16 12 2010 P2077SB EN 2010 11 31 Transducer DGD 8 1 Electrical Data Torque measurement features Data Nominal supply voltage V 12 Supply voltage limits V 10 75 12 5 Supply current mA 80 Measured output voltage nominal voltage V 5 5 Measured output voltage limits Un V 5 000 0 5 Permitted measuring range of rated torque 10 125 Zero voltage limit value MV 100 Nonlinearity Torgue measurement of Un 0 25 Measuring accuracy of Un 0 5 Output current maximum MA 5 Internal resistance Ri torgue output Q lt 10 Limit frequency of the torque measurement 3dB 2 2 Measured output voltage calibration ON Ux V Un 0 25 Calibration voltage input ON V gt 3 5 Calibration voltage input OFF V lt 2 0 Calibration vollage maximum V 35 Calibration input impedance 5 8 2 Pin configuration of transducer 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 Pin Color Signal
70. rding 2 tracks Measuring software in FLASH memory The software is updated by the nutsetter control unit mPro400GC M via the ARCNET Press the button under the service panel to reset see 6 4 3 lt Reset gt button page 24 Torgue measuring accuracy 0 2 Resolution 12 bits at 6 6 V therefore approx 6 5 mV Measurement sampling rate 3300 measurements per second Analog filter for torgue signals 1 KHz Current redundancy possible by measuring the motor current transferred by the servo amplifier Measuring the motor angle signals transferred by the servo amplifier via the synchronous serial inter face SSIO These are generated from the resolver signals Communication between measuring board and servo amplifier synchronous serial interface SSIO provides a means of communication between the servo amplifier and the measuring board For safety reasons the start signal is transferred from the measuring board to the servo amplifier both via a separate input output and via the SSIO Communication between CPS3 and mPro400GC M The two units communicate via the ARCNET high performance field bus The transfer rate is 2 5 26 P2077SB EN 2010 11 77 Schraubmodul en fm 16 12 2010 DGD Attachment 7 7 1 7 2 Attachment Centric Attachment Illustration of 178 2 1 0ps 200332 1 9
71. with a slide lock should not be visible 12 1 High Flex quality suitable for flexible cable ducts Thermal properties Ambient temperature 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 Oil resistant in accordance with DIN VDE 0472 part 803 ASTM oil 1 to 3 and HD 505 2 1 Resistance to hydrolysis In accordance with VDE 0283 part 10 Color Orange RAL 2003 matt Mechanical properties Diameter mm approx 16 Bending radii mm 30 min Single bends 95 mm min flexing action Multiple bends 130 min alternate bending Torsional length mm 500 min 180 around separate central axis Max acceleration m s 100 77i Kabel en fm 16 12 2010 P2077SB EN 2010 11 47 1 2 Cables 12 1 1 System cable type Use Extension cable type C DGD IS Order No 961104 xxx xxx cable length in dm I Gelb Grin Li T 1 11 Gelb Grin 3 Gelb Grin Gelb Gr n PE Rot Al LA Rot 4380VDC 1 i ss
72. x cable length in dm Ansicht A B lt 84 A PE EE 1 380 vDC 1 ca 1 380V0C Ted EN Ted ovpc 2 m LI 1 2 24 VDC 1 24 VDC 0V0C 24V 1 0VDC 24 V Enable G gt 1 Enable DATAA gt White green white green AAA DATAB D white red white red 1 D DATAB Jumper cable type G Use DGD IS DGD IS Order No 961298 xxx xxx cable length in dm i sis e Rot Rot 380 VDC 1 E C 1 1 380 VDC ot A 0 0 VDC Doi C 2 0V9C 24 VDC Taun 24 VDC 0 VDC 24V B 0V0C 4V Enable G gt 20112 1 Enable DATAA C gt Weift Gr n C DATA A DATAB D Weift Rot g Y X Weik Rot D DATA B 50 P2077SB EN 2010 11 77i Kabel en fm 16 12 2010 DGD Cables 12 1 7 Jumper cable type H Use DGD IS DGD IS Order No 961297 xxx xxx cable length in dm

Download Pdf Manuals

Related Search

mPro400GC DGD intelligent spindle

mPro400GC-DGD-intelligent-spindle

Contents

Download Pdf Manuals

Related Search

Related Contents