Cleco DGD mPro400GC User manual

For additional product information visit our website at http://www.apextoolgroup.com
mPro400GC
Global Controller
Quick Set-Up Guide
PL12EN-1004
2011-01

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About this Quick Set-Up Guide
This quick set-up guide is the -- original Quick Set-Up Guide -- and is intended for all persons who configure
settings on the mPro400GC controller.
The quick set-up guide does the following:
• describes a quick and facile way to start-up and configure the mPro400GC controller.
• It provides important instructions for safe and effective operation.
The following documents provide additional information for the operation and service of the mPro400GC
controller.
• Programming manual, no. PL12EN-1001
• Recovery Installation
• Parts manual, no. PL12-1000EN
• System description, Fastening technology, no. P1730E
Disclaimer:
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 other-
wise, without the express permission of DGD.
Symbols in the text:
italics Identifies menu items such as Diagnosis
> Identifies the selection of a menu item from the menu such as File > Print
<…> Identifies elements such as buttons, push button or external keyboard input, e.g. <F5>
Courier Identifies elements such as input fields, checkboxes, radio buttons or drop-down menus.
Indicates the name of paths and files, e.g. setup.exe
/ Separates the subdirectories of file paths, e.g. file/print
(OS9 operating system)
• Identifies lists
➔Identifies instructions to be followed

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Workplace safety symbols
Warning notes are identified by a signal word and a pictogram:
• The signal word describes the severity and the probability of the impending danger.
• The pictogram describes the type of danger.
Observe these notes and proceed with special care in the situations described. Pass all safety instructions
on to other operators. In addition to the safety instructions in these programming instructions, all local safety
and accident prevention rules must be observed.
WARNING! Indicates a potentially hazardous situation
which, if not avoided, could result in death or serious injury.
CAUTION! Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury or
property and environmental damage. If this warning is not observed, injuries, property or environmental
damage may occur.
This pictogram identifies all references to potential electrical shock, alerting of hazards to life
and health of personnel.
This sign warns of a possibly damaging situation.
If the note is not adhered to, the product or parts of it may be damaged.
NOTE General notes
include application tips and useful information but no hazard warnings.
ATTENTION!

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Set-Up Guide
1
1 Set-Up Guide
1.1 Controller description
The mPro400GC product line consists of three controllers; Master, Primary and Secondary.
•Primary - Controls up to sixteen (16) tools. This unit includes a servo. One (1) standard corded hand-
held or fixtured tool could directly connect. For further corded tools / fixtured spindles are Secondary
controllers required. Maximum number of cordless LiveWire tools is limit to ten (10).
•Master - Controls up to sixteen (16) tools. This controller does not include a servo. For corded tools / fix-
tured spindles are Secondary controllers required. Maximum number of cordless LiveWire tools is limit
to ten (10).
•Secondary - Controls one (1) corded handheld or fixtured tool. Must be used with a Master or Primary
controller.
Fig. 1-1 Controller Description
Controller Order no. Controls up to
(…) tools Servo included Tool compatibility
Primary mPro400GC-P 16 1 18–48 AirLB1)
Cordless EC tool
DGD-Intelligent-Spindles (BTS Series)2)
1) Limited to 1 tool
2) Additional Hardware necessary. For programming mark Advanced > Controller Settings > Display Mpro Button.
Master mPro400GC-M 16 – Cordless EC tool
DGD-Intelligent-Spindles (BTS Series)3)
Secondary mPro400GC-S 1 1 18–48 AirLB1)
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Set-Up Guide 1
1.2 General Information
It is mandatory that national, state and local safety and wiring standards be followed during installation.
These standards take precedence over any information presented in this section.
• Do not energize the unit until all connections have been properly made.
• Equipment must be properly grounded before applying power. Units energized by cord and plug must be
connected to an approved and properly grounded receptacle.
• All units must be energized by an isolated line.
• The unit must always be closed and secured prior to energizing the unit.
• Ensure the power switch is in the „off“ position prior to connecting the power cord.
Though it is not mandatory, the following instructions are highly recommended for the protected operation of
your unit.
• Use oversized feeder lines to reduce electrical noise and voltage drop.
1.3 Mounting the Controller
1. Loosen the two long mounting screws at the bottom of the controller so the mounting plate can be
separated from the controller. See Fig. 1-16.
2. Fig. 1-17 illustrates the bolt pattern for hanging the mounting plate on a wall. Note the hole size
dimensions so the correct size bolts are chosen. Size ¼“ or M6 bolts (4) should fit the mounting plate
holes and support the controller.
3. Once the mounting plate is installed in its location the controller can be hung on the bracket utilizing
the four studs protruding from the back of the controller. Once in place, the controller can be secured
at the bottom using the two long screws removed in Step 1.
1.4 Making Connections to the Controller
1. Connect the cable to the tool.
2. Connect the other end of the cable to the controller. The connector at the controller is an Air-LB con-
nector and utilizes a push-pull style connector. Before attempting to attach the cable verify that the
collar on the controller connector is pushed towards the controller. If the collar is pulled away from the
controller the cable will not connect to the controller. Insert the cable connector and pull the collar
away from the controller (towards the cable) to lock the cable in place.
3. Insert the power cord into the controller and into a 115 or 230 VAC power source.
4. Using the ON/OFF power switch at the front of the controller power the controller ON.
5. Refer to the Programming Manual, PL12-1001EN, for all other connections.
CAUTION! To avoid the hazard of electrical shock or burn, the following instructions must be adhered to. Failure to fol-
low these instructions may also cause damage to your unit and void existing warranties.

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Set-Up Guide
1
1.5 Accepting a Corded Tool
Fig. 1-2 Run Screen
1. When the controller has finished booting up it should advance to the Run screen. The screen is a
touch screen. At the lower right corner of the screen press <Navigator>.
Fig. 1-3 Navigator Screen
2. Press Navigator Menu > Tool Setup.
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Set-Up Guide 1
Fig. 1-4 Tool Setup – Tool List
3. Touch the horizontal bar indicating the Primary tool to highlight it. Touch <Tool Settings>.
Fig. 1-5 Tool Setup Tool Settings
4. Verify that the tool shown is the tool connected. Check the Model number and Serial Number. If
the tool is correct press <Accept>. In the screen that appears press <Accept> for that screen. A
screen will appear indicating that the settings are being saved. When the save process is complete,
the Tool Setup - Tool List screen is displayed. Press <Navigator>. Advance to 1.9 Manual Program-
ming, page 12 for programming instructions.
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Set-Up Guide
1
1.6 Accepting a LiveWire Tool
Live wire communication requires three items; Tool, Controller, and Access point. Each item will require an
IP address. All the IP addresses will be similar in structure such as 192.168.0.100, 192.168.0.110,
192.168.0.120, etc. The access point will also have a SSID name, which will need to be entered in the con-
troller.
Hardware Connections
1. Connect the access point to the controller using the cable provided with the access point. The cable
should be a crossover cable. Plug the cable into the X1 Ethernet port. See Fig. 1-16.
2. Apply power to the controller and access point.
1.6.1 Network Settings
Controller IP address:
Fig. 1-6 Communications – Network Settings
1. Select Navigator > Communications > Network Settings.
2. If not using server assigned addresses disable DHCP for Card One.
3. Enter the IP address and Subnet Mask that will be assigned to the controller.
4. Press <Navigator> key to accept entries.
5. Click <Accept> on the message screen that appears. The screen will return to the Navigator Menu
then begin storing data.
6. A message will appear to restart the controller.
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Set-Up Guide 1
1.6.2 RF (Radio Frequency) Settings
Setting Up the LiveWire Tool
Fig. 1-7 Tool Setup – RF Settings
1. Select Navigator Menu > Tool Setup > RF Settings > IRDA Serial. Correct port depending on the port
connected to at the base of the controller. (CON 1 and CON 2 are X4 and X5 respectively at the con-
troller.)
2. If serial connectivity has been made the SSID, Encryption, and remaining fields will become avail-
able for programming. Enter a value for SSID. If Encryption is selected enter a Network Key and
confirm it by re-entering it below the initial Network key entry. If DHCP is not being used select Use
the following IP address and enter the IP address and Subnet mask. Press <Write RF settings>.
1.6.3 Tool Install
Fig. 1-8 Tool Setup – Tool List
1. Select Navigator Menu > Tool Setup. Press the screen at the tool number location you wish to install
the tool. The row should highlight in orange. Position 1 is reserved for the Primary or corded tool.
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Set-Up Guide
1
Fig. 1-9 Tool Setup – Install
2. Press <+ Install> and select the LiveWire w/WLAN choice from the popup screen that appears.
Enter the Live Wire IP Address for the tool. Without DHCP this should be the same address as
entered in Step 2, 1.6.2 RF (Radio Frequency) Settings, page 9. Using DHCP should same IP
address as displayed on Tool display entered. Press <OK> and save the settings.
Fig. 1-10 Tool Setup – Accepting the Tool
3. Select Navigator Menu > Tool Setup > Tool Settings button. Verify the Model Number and Serial
Number. If the information is correct press <Accept> at the bottom of the screen. Continue with saving
settings.
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Set-Up Guide 1
1.7 Programming a Basic Fastening Strategy
Fig. 1-11 Tool Application Fastening Strategy
Select Navigator Menu > Basic and the Basic Application Builder screen with appear. Verify that the Tool
and Application are correct. Select a Fastening strategy, Torque Control/Angle Monitor or Angle
Control/Torque Monitor. The parameters can be programmed manually or by pressing <Auto Program>.
1.8 Auto Programming (Torque Control / Angle Monitor Only)
Fig. 1-12 Controller Settings
1. Before using the Auto Program feature select Navigator Menu > Advanced > Controller Settings and
choose the desired Engineering units. Press <Navigator> to save settings.
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Set-Up Guide
1
Fig. 1-13 Torque Control/Angle Monitor
2. Select Navigator Menu > Basic > Auto Progr…. Enter the desired final stage torque value using the
virtual keypad. Press <Enter> to close the keyboard. Press <OK> from the Auto Program screen. Lim-
its of ±15% will be provided. Parameters can be adjusted if needed. Press <Navigator> button to
return to the Navigator Menu and save parameters.
1.9 Manual Programming
Fig. 1-14 Controller Settings
1. Before programming the application select Navigator Menu > Advanced > Controller Settings and
choose the desired Engineering units. Press <Navigator> to save settings.
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Set-Up Guide 1
Fig. 1-15 Manual Programming
2. Touch the Torque High Limit field and a keyboard will appear. Enter the desired High Torque value.
Whole numbers do not require decimal points. They will be added automatically. Use the Tab key on
the keyboard to move the keyboard to the next field. When finished, press <Enter> on the keyboard.
Select <Navigator> and the screen will return to the Navigator Menu and begin saving parameters.
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Fig. 1-16 Connector Locations
d01223_1.png
Position Description Position Description
1 System Bus Connector 8 Serial Connector #2
2 Tool Connector 9 Anybus Fieldbus
3 Power Connection 10 Serial Connector #1
4 Mounting Bracket Screw 11 USB ports (2)
5 Mounting Bracket Screw 12 Ethernet Connector #2
6 I/O Connectors 13 Ethernet Connector #1
7 Anybus Fieldbus
1
2
3
13
12
11
10
9
8
7
6
54

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Fig. 1-17 Mounting Information
10.38"
(263 mm)
4× 7.750"
(197 mm)
4× 1.315"
(33.4 mm)
2× 1.250"
(31.8 mm)
2× 12.500"
(318 mm)
14.88"
(378 mm)
1.825"
(46.4 mm)
0.075"
(1.9 mm)
10×.270“ (6.86 mm)
10×.503“ (12.8 mm) 10×.313“
(1.95 mm)
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1.9.1 Primary/Master Configuration
Note: Pins are numbered exactly as they are on the controller, Pins 1 and 13 at the bottom, Pins 12 and 24
at the top.
Fig. 1-18 Primary / Master Pin Configuration
The two I/O connectors are populated with both Inputs and Outputs to help reduce cabling when utilizing
four or less Inputs and Outputs. The I/O can be used with the internal 24-volt supply in the controller or an
external 24-volt supply such as a PLC. The following examples 1.9.3 / 1.9.4 utilize Tool Start as an Input
and Cycle OK as an Output.
1.9.2 Secondary Configuration
Note: Pins are numbered exactly as they are on the controller, Pins 1 and 13 at the bottom, Pins 12 and 24
at the top. Some Inputs and Outputs are fixed, not programmable.
Pin # I/O Description Pin # I/O Description
12 Out GND2 24 Out GND2
11 In Common GND 23 In Common GND
10 Output O 03 22 Output O 07
9 Output O 02 21 Output O 06
8 Output O 01 20 Output O 05
7 Output O 00 19 Output O 04
6 Input I 03 18 Input I 07
5 Input I 02 17 Input I 06
4 Input I 01 16 Input I 05
3 Input I 00 15 Input I 04
2 In Output Common O0-O3 14 In Output Common O4-O7
1 Out +24 V2 13 Out +24 V2
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Pin 1 Pin 13
Pin 24
Pin 12

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Fig. 1-19 Secondary Pin Configuration
• After address change is a reboot required.
1.9.3 Connections Utilizing the Internal 24-volt Supply
(Primary, Secondary, Master)
INPUTS: Pins 11 and 23 (Common GND) are the Input “returns”.
• Controller Internal 24-volt Supply
Pins 11 and 23 must be jumpered to Pins 12 and 24 respectively.
OUTPUTS: Pins 2 and 14 (Output Common) are the voltage source for the Outputs.
• Controller Internal 24-volt Supply
Pin # I/O Description Pin # I/O Description
12 Out Common GND2 24 Out Common GND
11 In Common GND 23 In Common GND
10 Output O 03 22 Output O 07
9 Output O 02 (Yellow LED) 21 Output O 06
8 Output O 01 (Green LED – OK) 20 Output O 05
7 Output O 00 (Red LED – NOK) 19 Output O 04
6 Input I 03 18 Input I 07
5 Input I 02 17 Input I 06
4 Input I 01 (Reverse) 16 Input I 05
3 Input I 00 (Start) 15 Input I 04
2 N. C. 14 N. C.
1 Out +24 VDC 13 Out +24 VDC
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Pin 1 Pin 13
Pin 24
Pin 12

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Pins 2 and 14 must be connected to Pins 1 and 13 respectively.
1.9.4 Connections Utilizing the External 24-volt Supply
(Primary and Master only)
INPUTS: Pins 11 and 23 (Common GND) are the Input “returns”.
• Controller External 24-volt Supply
Pins 11 and 23 will have to return to the GND of the external 24-volt supply.
OUTPUTS: Pins 2 and 14 (Output Common) are the voltage source for the Outputs.
• Controller Internal 24-volt Supply
Pins 2 and 14 must be connected to the external 24-volt supply..
Connector 1 Connector 2
Pin # I/O Description Pin # I/O Description
12 Out GND2 24 Out GND2
11 In Common GND 23 In Common GND
10 Output O 03 22 Output O 07
9 Output O 02 21 Output O 06
8 Output O 01 20 Output O 05
7 Output O 00 (Linking OK) e. g. 19 Output O 04
6 Input I 03 (Tool Start) e. g. 18 Input I 07
5 Input I 02 17 Input I 06
4 Input I 01 16 Input I 05
3 Input I 00 15 Input I 04
2 In Output Common O0-O3 14 In Output Common O4-O7
1 Out +24 V2 13 Out +24 V2
Connector 1 Connector 2
Pin # I/O Description Pin # I/O Description
12 Out GND2 24 Out GND2
11 In Common GND 23 In Common GND
10 Output O 03 22 Output O 07
9 Output O 02 21 Output O 06
8 Output O 01 20 Output O 05
7 Output O 00 (Linking OK) e. g. 19 Output O 04
6 Input I 03 (Tool Start) e. g. 18 Input I 07
5 Input I 02 17 Input I 06
4 Input I 01 16 Input I 05
3 Input I 00 15 Input I 04
2 In Output Common O0-O3 14 In Output Common O4-O7
1 Out +24 V2 13 Out +24 V2
External Ground
External Ground
From External
24 V
From External
24 V

Sales & Service Centers
Note: All locations may not service all products. Please contact the nearest Sales & Service Center for
the appropriate facility to handle your service requirements.
Dallas, TX Detroit, MI Houston, TX Lexington, SC
Apex Tool Group Apex Tool Group Apex Tool Group Apex Tool Group
Sales & Service Center Sales & Service Center Sales & Service Center 670 Industrial Drive
1470 Post & Paddock 2630 Superior Court 6550 West Sam Houston Lexington, SC 29072
Grand Prairie, TX 75050 Auburn Hills, MI 48326 Parkway North, Suite 200 Tel: [phone]
Tel: [phone] Tel: [phone] Houston, TX 77041 Tel: [phone]
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Tel: [phone] Tel: [phone] Tel: [phone] Canada
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Cooper Power Tools Cooper Power Tools Cooper Power Tools SAS Cooper (China) Co., Ltd.
GmbH & Co. OHG a company of a company of a company of
a company of Apex Tool Group, LLC Apex Tool Group, LLC Apex Tool Group, LLC
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Postfach 30 Seven Stars Industrial Estate BP 28 Heqing Pudong, Shanghai
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Tel: [phone] England France Fax: [phone]
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Parque Industrial Querétaro 18087-170 Sorocaba, SP Brazil
Querétaro, QRO 76220 Tel: [phone]
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