Instruction Manual
P2043BA/EN
2009-07
Station controller m-Pro-400SE mini
Order No. S961450-015
For additional product information visit our website
at http://www.cooperpowertools.com
Notes on this instruction manual
This instruction manual is the – translation of the original Instruction Manual –
• It provides important instructions for safe and effective operation.
• It describes the function and operation of the station controller m-Pro-400SE
(hereinafter referred to simply as m-Pro-400SE).
• It serves as a reference work for technical data and service intervals.
• It points out options.
Additional information for operation can be found in:
• Programming manual of software for tightening controller station, No. P2044PA
• Reference manual of software for tightening controller station, No. P2045RH
In the text:
➔
Identifies instructions to be followed.
•
Identifies lists.
In graphics:
Identifies movement in a direction.
Identifies function and force.
Disclaimer:
Cooper Tools reserves the right to modify, supplement or improve this document or the product without prior
notice.
2
P2043BA/EN 2009-07
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Contents
1
Safety
5
1.1
1.2
1.3
1.4
1.5
Symbols ................................................................................................
Safety instructions ................................................................................
Intended use .........................................................................................
EMC measures .....................................................................................
Operator training...................................................................................
5
5
6
6
6
2
General information
7
2.1
2.2
2.3
2.4
2.5
2.6
Overview...............................................................................................
Description............................................................................................
Field of application................................................................................
Ambient conditions ...............................................................................
Maintenance .........................................................................................
Transport and storage ..........................................................................
7
7
7
8
8
8
3
Mechanical data
9
3.1
3.2
3.3
Size....................................................................................................... 9
Installation guidelines ........................................................................... 9
Connections........................................................................................ 10
4
Electrical Data
4.1
4.2
System data........................................................................................ 11
Power supply
................................................................................. 12
5
Maintenance
12
6
Technical data
13
6.1
6.2
6.3
Connections........................................................................................ 13
Storage access, portable memory ..................................................... 18
MAC address ...................................................................................... 19
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11
P2043BA/EN 2009-07
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4
P2043BA/EN 2009-07
P2043BA-EN_2009-07_m-Pro-400SE-mini-HWIVZ.fm, 29.09.2009
Safety
1
Safety
Do not operate the m-Pro-400SE mini unless you have carefully read and fully understood the following
safety instructions and the instruction manual for your model.
We do not claim that these safety notes are complete.
Read and observe all applicable, general and local safety and accident prevention rules.
1.1
Symbols
The purpose of the following notes is to guarantee preservation of personal safety as well as to protect the
station controller m-Pro-400SE from damage.
The symbols defined below highlight safety notes and warnings in this instruction manual, which alert to
hazards endangering health and life of maintenance staff and causing property damage.
DANGER!
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 consequence.
WARNING!
A symbol combined with the word WARNING warns of a potentially dangerous situation for the health of
personnel, which, if not avoided, could result in death or serious injury.
CAUTION!
A symbol combined with the word CAUTION warns of a potentially harmful situation for the health of personnel or damage to property or the environment. If this warning is not observed, injuries, property or environmental damage may occur.
This sign warns of a possibly damaging situation.
ATTENTION! If the note is not adhered to, the product or parts of it may be damaged.
NOTE
This symbol indicates a general instruction.
General instructions include application tips and special useful information, but no warnings against
dangers.
1.2
Safety instructions
The station controller described in this instruction manual m-Pro-400SE mini was developed, manufactured,
inspected and documented according to the relevant safety standards. Therefore, the m-Pro-400SE mini
does not normally represent a danger to property or persons as long as the handling instructions and safety
notes are adhered to during installation and first operation.
• The company operating the product must make this instruction manual available to operators and must
ensure that operators have read and understood it.
• Do not attempt to repair possible faults on the m-Pro-400SE mini by yourself if you do not have the
required knowledge!
Inform the local repair center or your Cooper Tools representative.
• Follow a safety-conscious maintenance program which takes into account the local regulations for maintenance and servicing in all phases of operation of the tightening controller.
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P2043BA/EN 2009-07
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1
1
Safety
1.3
Intended use
The station controller m-Pro-400SE mini may be used only under the following conditions:
• Industrial environment EMC limit class A (EN 55011).
• Enclosed housing IP54.
• Only ARCNET cables of types authorized by Cooper Tools may be used.
• Furthermore, only accessory parts authorized by Cooper Tools may be used.
• Unauthorized alterations, repairs and modifications are prohibited for reasons of safety and product
liability.
• The temperature inside the control cabinet may not exceed 50 °C (122°F).
1.4
EMC measures
•
•
•
The filters and measures required to satisfy the EMC regulations are built into the design.
The enclosed metal housing provides substantial protection against irradiated and radiated interference.
The tool complies with the following EMC standards:
Emissions
- EN 55011:1998 + A1:1999 + A2:2002 Cl. A
Noise immunity
- EN 61000-4-2:1995 + A1:1998 + A2:2001
- EN 61000-4-3:2002 + A2:2002
- EN 61000-4-4:2004
- EN 61000-4-5:1995 + A1:2002
- EN 61000-4-6:1996 + A1:2001
- EN 61000-4-8:1993 + A1:2001
- EN 61000-4-11:2004
- EN 61000-6-2: 2005
Circuit feedback
- EN 61000-3-2:2000 + A2:2005
- EN 61000-3-3:1995 + A1:2001
•
This is a Class A device. The device may cause signal interference; in this case, the operator may be
required to implement suitable EMC measures.
Operation while the housing is open is prohibited, since the properties of the shielding would change and
the noise emission would increase.
WARNING!
•
1.5
Operator training
•
•
•
6
The station controller m-Pro-400SE mini may only be commissioned by personnel who have specialized
training (electrical/mechanical engineering).
The owner's operating and service personnel will be trained by qualified employees of Cooper Tools.
A repair is only permitted by Cooper Tools authorized personnel.
P2043BA/EN 2009-07
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General information
2
General information
2.1
Overview
Station controller
… for m-Pro-400SE mini
Additional internal serial interface for control
Two-line display
Order number
(without software)
Designation
Usable software
S961450-015
Controller SE,
basic with serial display interface
Standard, hand-held application S168851
Allowed range of numbers S168800 – S168899.
For more information, contact the Cooper Tools Sales & Service
Center.
2.2
Description
The station controller m-Pro-400SE mini includes the following functions:
• Communication with resource control (for example, digital I/O, Profibus, Interbus, etc.).
• Communication with computer networks (for example, Ethernet).
• Communication with the TM tightening modules via ARCNET high-performance fieldbus.
• Printer control
• Tightening process control
2.3
Field of application
•
•
The station controller m-Pro-400SE mini is used as the master computer, data concentrator and interface concentrator in conjunction with the TM and TMH tightening modules.
Communication with the TM tightening modules takes place using an ARCNET serial high-performance
fieldbus. A decentralized setup of the m-Pro-400SE and TMs at distances of up to 100 m can be
realized.
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P2043BA/EN 2009-07
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2
2
General information
2.4
Ambient conditions
Features
Data
Ambient temperature
0 – 50 °C (32 – 122 °F)
Storage temperature
-20 – 60 °C (-4 – 140 °F)
Cooling type
Convection (self-cooling)
Relative humidity
0 – 90 % non-condensing
Working height
Up to 3000 m (9,842.5 ft) above sea level1)
Dust, dirt
Required enclosure (IP20, without installation)
1) For use with TM modules: 1000 m (3,280.8 ft) above sea level
2.5
Maintenance
•
•
2.6
Transport and storage
•
•
•
8
Always replace the station controller m-Pro-400SE mini completely.
When the station controller is replaced for service, observe the software instruction manual.
Transport and store in suitable packaging only. If necessary, request packaging from Cooper Tools.
The packaging can be recycled.
Check the m-Pro-400SE mini for any visible damage if the packaging is damaged. Inform the transport
company, and, if applicable, Cooper Tools.
P2043BA/EN 2009-07
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Mechanical data
3
Mechanical data
3.1
Size
Features
Data
Weight
1,2 kg (2.6 lbs)
Mean time between failures (lamps)
Protection class
3.2
100.000 h
IP20, without installation
Installation guidelines
•
•
en03b421.fm, 29.09.2009
An enclosed housing made of sheet steel must be used.
Don’t cover the opening of the housing above and below the m-Pro-400SE mini with components (wireway e. g.).
P2043BA/DE 2009-07
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3
3
Mechanical data
3.3
Connections
For technical data, siehe 6.1 Connections, Seite 13
On top
•
•
•
•
•
•
•
•
•
Inputs / Outputs
USB version 1.1
Ethernet1, RJ45
ARCNet system bus
CAN bus (currently without function)
Profibus slave (DP)
RS232 for auxiliary equipment
Supply
CF card
Schnittstelle zum 2-Zeilen-Display
Sidewards
Serial interfaces are not galvanically isolated. RS232-4_4 interface with 24 VDC on pin1 + 9: this interface
ATTENTION! can be used as the operating voltage for simple devices.
This may cause damage to a standard modem or a PC connected via a null modem cable!
10
P2043BA/DE 2009-07
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Electrical Data
4
Electrical Data
4.1
System data
Hardware
Nonvolatile
memory
1 CF card for system and application with 256 MB (internal)
Interfaces
ARCNET interface (system bus)
4 serial data interfaces RS232 incl. printer (CON3)
1 10/100 Base-T network interface on RJ45
1 Ethernet
Process interface
I/O (process) 16-bit inputs/outputs 24 V opto-decoupled
Profibus DP (slave)
CAN bus (not enabled)
System functions
RTC real-time clock with calendar
Watchdog: voltage monitoring
Battery
Varta CR2025: 170 mAh / 3.0 V or order No. 941555
Lithium battery
Display
Via two-line display, order No. S961787
Operating system
OS-9000 real-time operating system, bootable without mechanically moving
drives, no UPS required
HMI (human-machine
interface)
•
•
Data protection
User access authorization, configurable (remote program)
Window-oriented, graphical user interface via PC via remote program
Via two-line display
Parts to be dismounted
Optional
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ProfiNet, second Profibus port (more can be added on request)
P2043BA/EN 2009-07
11
4
5
Maintenance
4.2
Power supply
Attempting to operate the station controller m-Pro-400SE at a voltage other than 24 VDC (e. g. 15 VAC /
ATTENTION! 230 VAC) will result in immediate and irreparable total loss!
Features
Data
Order number
S961450-015
Nominal supply voltage
24 VDC
Nominal supply voltage limits
15 – 30 DC
Rated supply current
0.4 A
Internal fusing (slow blow)
2A
Power loss (standby)
9A
CAUTION!
The fuse on the power plug connector protects the lines in the m-Pro-400SE in the event of faults or an
oversized external fuse.
The fuse on the main board protects the conducting paths to the power adapter.
➔ Internal fuses may only be changed by Cooper Tools.
5
Maintenance
Interval
Measures
Annual
Battery change
The battery supplies the real-time clock with power and ensures data retention when
the power supply is switched off.
Type of battery:
Varta CR2025: 170 mAh / 3.0 V or order No. 941555
(typical duration for data retention = 1.4 years)
Lithium battery
➔ Replace the battery when the station controller is switched off. For battery location, see 3.4 Connections on the front panel, page 8.
NOTE
The battery change must be completed within 15 minutes, as continuous operation
without battery can trigger a RESET signal. Exceeding this limit will result in data loss
of parameters, counter readings and time of day.
➔ Have the replacement battery ready. If in storage, do not short-circuit the battery
or exceed the storage time.
➔ Provide access to the station controller in the interior. Open the control cabinet or
housing.
➔ Wait for a pause in production.
➔ Remove the battery using insulated tongs.
Caution: Do not cause a short-circuit or ground fault.
➔ Insert the new battery with the positive pole facing towards the battery compartment lid. The positive pole can be identified by the smaller contact area.
➔ Carry out a test with production monitoring.
12
P2043BA/EN 2009-07
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Technical data
6
Technical data
6.1
Connections
All connections are short-circuit proof.
6.1.1
Station controller inputs/outputs
The required signal circuits are connected to these input/output
connectors. The signal groups are not galvanically connected to
the power supply; galvanic isolation is required.
Type: DIO16 (10 pole MICRO Combicon RM2.5 on processing unit)
16-bit digital inputs/outputs, opto-isolated for 24V level / 0.5 A
Pin
DIO8-15
Pin
DIO1-7
11
+24 VDC
1
+24 VDC
12
I0 8
Bit 9
2
OK 0
Bit 1
13
OK 9
Bit 10
3
OK 1
Bit 2
14
OK 10
Bit 11
4
OK 2
Bit 3
15
OK 11
Bit 12
5
OK 3
Bit 4
16
OK 12
Bit 13
6
OK 4
Bit 5
17
OK 13
Bit 14
7
OK 5
Bit 6
18
OK 14
Bit 15
8
OK 6
Bit 7
19
OK 15
Bit 16
9
OK 7
Bit 8
20
GND
10
GND
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6
6
Technical data
Digital input/output
There are 16 available lines for 24V technology that can be programmed as inputs or outputs as desired.
6.1.2
Ethernet RJ45
Access is obtained internally or via cable bushings and connected directly to the processing unit.
10/100 BASE-T
14
Pin
Signal
1
TPOP
2
TPON
3
TPIP
4
nc
5
nc
6
TPIN
7
nc
8
nc
P2043BA/EN 2009-07
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Technical data
6.1.3
ARCNet system bus
An ARCNet cable can be connected to this interface. The station controller has an integrated bus termination; therefore, no external termination is necessary.
Access is obtained internally or via cable bushings and connected directly to the station controller.
Type: 9-pole D-Sub pin with slide lock
Pin
1
PE
2
nc
3
DATA-B (ARC L)
4
nc
5
GND (ARCNet)
6
+5 V (ARCNet) max. 100 mA
7
nc
8
DATA-A (ARC H)
9
nc
Housing
6.1.4
Signal
PE shield connection
CAN bus
Type: 9-pole D-Sub pin
Pin
Signal
1
–
2
CAN L
3
CAN GND
4
–
5
–
6
CAN GND2
(close LB22 for this)
7
CAN H
8
9
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CAN +5 V
Max. 100 mA
(close LB21 for this)
P2043BA/EN 2009-07
15
6
6
Technical data
6.1.5
Profibus slave (DP)
The Profibus of a higher-level unit can be connected to this interface.
Access is obtained internally or via cable bushings and connected directly to the processing unit.
Type: 9-pole D-Sub plug with screw lock
Pin
6.1.6
Signal
1
CHGND
2
nc
3
IO+ (PRO H)
4
nc
5
GND
6
+5 V max. 100 mA
7
nc
8
IO-(PRO L)
9
nc
Housing
PE
RS232 for auxiliary equipment
•
•
•
•
All outputs provide signals conforming to RS232.
The inputs allow voltages in the range from -15 V to +15 V.
- Voltages < 0.8 V correspond to a zero.
- Voltages > 2.4V are interpreted as a one.
- Open inputs are preset to zero using a pulldown resistor.
The power supply pins are connected directly to the main board power supply.
A consumer should not require current of more than 500 mA.
- Do not connect or tighten consumers during operation.
Doing so may result in a system reset!
A conventional barcode scanner, for example, can be connected to this interface (depending on the
software used). Access is obtained internally or via cable bushings and connected directly to the station
controller.
Type: 9-pole D-Sub pin with screw lock
Serial interfaces are not galvanically isolated. RS232-4_4 interface with 24 VDC on pin1 + 9: this interface
ATTENTION! can be used as the operating voltage for simple devices.
This may cause damage to a standard modem or a PC connected via a null modem cable!
D-Sub pin
16
RS232_1
RS232_2
RS232_3
RS232_4
1
–
2
RxD
PSC1_1
RxD
PSC2_1
RxD
3
TxD
PSC1_0
TxD
PSC2_0
TxD
4
–
–
–
–
5
GND
GND
GND
GND
–
–
P2043BA/EN 2009-07
+24V2.
500mA
PSC3_1
RxD
PSC6_0
PSC3_0
TxD
PSC6_2
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Technical data
D-Sub pin
6.1.7
RS232_1
RS232_2
RS232_3
RS232_4
6
–
7
RTS
PSC1_2
RTS
PSC2_2
RTS
PSC3_2
RTS
PSC6_3
8
CTS
PSC1_3
CTS
PSC2_3
CTS
PSC3_3
CTS
PSC6_1
9
–
–
–
–
–
–
GND
Supply
Type: 4-pole Mini Combicon
PHOENIX 1827 729
Order No. S961397
6.1.8
Pin
Signal
1
+24V
2
+24V
3
GND
4
GND
Mini display
Internal board
Type: 10-pole
female connector (P5200)
RS232-5 station controller housing
Type: 9-pole D-Sub pin
Male
IDE
connector
D-Sub
TTL mode
Pin 1
Pin 1
Input
Mode pin
(open or > 2.4V)
Input
Mode pin
(connected to GND)
Pin 2
Pin 6
Input
TTL IN3
Input
TTL IN3
Pin 3
Pin 2
Input
TTL IN1
Input
RxD
Pin 4
Pin 7
Input
TTL IN0
Output
RTS
Pin 5
Pin 3
Output
–
Output
TxD
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ISPL232 mode
P2043BA/EN 2009-07
17
6
6
Technical data
6.2
Male
IDE
connector
D-Sub
TTL mode
ISPL232 mode
Pin 6
Pin 8
Input
TTL IN2
Input
CTS
Pin 7
Pin 4
Supply
+5 V max. 500 mA
Supply
+5 V max. 500 mA
Pin 8
Pin 9
Input
TTL IN4
Input
TTL IN4
Pin 9
Pin 5
Supply
GND
Supply
GND
Pin 10
–-
Supply
+5 V max. 500 mA
Supply
+5V max. 500 mA
Storage access, portable memory
Interface
m-Pro-400SE mini
S961450-015
6.2.1
USB
×
Plug for compact flash
×
Empty compact flash slot
(internal)
–
USB (version 1.1)
Not intended for serial devices or networking. Only USB sticks can be used here. Only a limited number of
products can be used for this embedded PC.
USB sticks that can be used
Due to continuous product changes for commercial USB sticks, an advance performance test is required.
We recommend Cooper Tools stick, 1 GB, order No. S981007.
6.2.2
Plug for compact flash
Function for S961450-050 for operating system and application. A CF card (internal) is required for operation.
18
Type
Size
1
128 MB
2
256 MB
3
512MB
4
Up to 2 GB
P2043BA/EN 2009-07
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Technical data
6.3
MAC address
6.3.1
Network access
The MAC address (Media Access Control address) is
the hardware address of the station controller, which is
used for unambiguous identification of the device in the
Ethernet network.
The MAC address is on the rear side of the station controller, but can also be formed from the serial number.
MAC = 00.12.91.50.xx.xx.
xx.xx is determined by multiplying the last 4 digits of the serial number by 2 and converting the result into
hexadecimal format. Example:
Serial number A20035:
0035 × 2 = 70 = 0x0046 ➔ MAC = 00.12.91.50.00.46
Serial number A20080:
0080 × 2 = 160 = 0x00A0 ➔ MAC = 00.12.91.50.00.A0
A second Ethernet access is possible via the station controller's graphic card. The MAC address of this
interface is one higher than that of the first interface. Example:
Serial number A20035:
0035 × 2 = 70 = 0x0046 + 1 = 0x0047 ➔ MAC = 00.12.91.50.00.47
Serial number A20080:
0080 × 2 = 160 = 0x00A0 + 1 = 0x00A1 ➔ MAC = 00.12.91.50.00.A1
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P2043BA/EN 2009-07
19
6
Sales & Service Centers
Note: All locations may not service all products. Please contact the nearest Sales & Service Center for the
appropriate facility to handle your ser vice requirements.
Dallas, TX
Cooper Tools
Sales & Service Center
1470 Post & Paddock
Grand Prairie, TX 75050
Tel: (972) 641-9563
Fax: (972) 641-9674
Detroit, MI
Cooper Tools
Sales & Service Center
4121 North Atlantic Blvd.
Auburn Hills, MI 48326
Tel: (248) 391-3700
Fax: (248) 391-6295
Cooper Tools
P.O. Box 1410
Lexington, SC 29071-1410
USA
Phone: 800-845-5629
803-359-1200
Fax: 803-359-0822
Cooper Tools
4121 North Atlantic Blvd.
Auburn Hills, MI 48326
USA
Phone: (248) 391-3700
Fax: (248) 391-6295
Cooper Tools
5925 McLaughlin Road
Mississauga, Ontario
Canada L5R 1B8
Phone: (905) 501-4785
Fax: (905) 501-4786
Houston, TX
Cooper Tools
Sales & Service Center
6550 West Sam Houston
Parkway North, Suite 200
Houston, TX 77041
Tel: (713) 849-2364
Fax: (713) 849-2047
Lexington, SC
Cooper Tools
670 Industrial Drive
Lexington, SC 29072
Tel: (800) 845-5629
Tel: (803) 359-1200
Fax: (803) 358-7681
Cooper Tools
de México S.A. de C.V.
Libramiento La Joya No. 1
Bodega No. 2
Esq. Politécnico
Barrio San José
Cuautitlán, Edo de México
C.P. 54870
Phone: +52-55-5899-9510
Fax: +52-55-5870-5012
Cooper Tools Industrial Ltda.
Av. Liberdade, 4055
Zona Industrial - Iporanga
18087-170 Sorocaba, SP
Brazil
Tel: +55-15-3238-3929
Fax: +55-15-228-3260
Cooper Industries, Ltd.
600 Travis, Ste. 5800
Houston, TX 77002-1001
P: 713-209-8400
www.cooperindustries.com
PL12EN-1660 101008
Specifications subject to change without notice. © 2008 COOPER INDUSTRIES, INC.
Los Angeles, CA
Cooper Tools
Sales & Service Center
15503 Blackburn Ave
Norwalk, CA 90650
Tel: (562) 926-0810
Fax: (562) 802-1718
York, PA
Cooper Tools
Sales & Service Center
3990 East Market Street
York, PA 17402
Tel: (717) 755-2933
Fax: (717) 757-5063
Seattle, WA
Cooper Tools
Sales & Service Center
2865 152nd Ave N.E.
Redmond, WA 98052
Tel: (425) 497-0476
Fax: (425) 497-0496
Canada
Cooper Tools
Sales & Service Center
5925 McLaughlin Road
Mississauga, Ont. L5R 1B8
Canada
Tel: (905) 501-4785
Fax: (905) 501-4786
Cooper Power Tools SAS
Zone industrielle – B.P. 28
77831 Ozoir-la-Ferrière Cedex
France
Téléphone: +33-1-6443-2200
Téléfax: +33-1-6440-1717
Cooper Tools Hungária Kft.
Berkenyefa sor 7
H-9027 Györ
Hungary
Tel: +36-96-505 300
Fax: +36-96-505 301
Cooper Power Tools
Cooper (China) Co., Ltd.
GmbH & Co. OHG
955 Sheng Li Road,
Postfach 30
Heqing Pudong, Shanghai
D-73461 Westhausen
China 201201
Germany
Tel: +86-21-28994176
Phone: +49 (0) 73 63/ 81-0
+86-21-28994177
Fax: +49 (0) 73 63/ 81-222
Fax: + 86-21-51118446
E-Mail:
htwe.sales@cooperindustries.com
www.coopertools.com