Cooper Tools Cleco mPro400GC User manual
uick Set-Up Guide
PL12-1004EN
03/31/2010
mPro400GC
Global Controller
For additional product information visit our website at
http://www.cooperpowertools.com
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PL12-1004EN
03/31/2010
Cleco®
mPro400GC Controller
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:
• It provides important instructions for safe and effective operation.
• It describes the function and operation of the mPro400GC controller.
• It points out options.
The following documents provide additional information for the operation and service of the mPro400GC
controller.
P 12-1000EN Parts Manual
P 12-1001EN Programming Manual
Workplace safety symbols:
This warning sign identifies all references to safe work practices in this quick set-up guide, alerting
of hazards to life and health of personnel. 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 this quick set-up guide, all local safety and accident prevention rules must be
observed.
This warning sign identifies all references to potential electrical shock, alerting of hazards to life
and health of personnel. 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 this quick set-up guide, all local safety and accident prevention rules must be observed.
This “Note” symbol identifies the portions of this quick set-up guide requiring special attention to
ensure that guidelines, rules, hints and correct procedures are observed and to prevent damage
to or destruction of the machine and/or parts.
Disclaimer:
Cooper Tools 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 Cooper Tools.
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Cleco®
mPro400GC Controller
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Cleco®
mPro400GC Controller
1 Set-Up Guide:
1.1 Controller description
The mPro400GC product line consists of three controllers; Master, Primary and Secondary.
•Primary – Controls up to ten (10) Cordless ivewire tools and one (1) standard corded
handheld or fixtured tool. This unit includes a servo.
•Master – Controls up to ten (10) Cordless tools and one (1) Intelligent Fixtured Spindle. This
controller ivewire does not include a servo. The servos are on-board the cordless ivewire and
Intelligent Spindle Fixtured tools.
•Secondary – Controls one (1) corded handheld or fixtured tool. Must be used with a Master or
Primary controller.
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.
To avoid the hazard of electrical shock or burn, the following instructions must be adhered to. Failure
to follow these instructions may also cause damage to your unit and void existing warranties.
• 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 an isolation transformer and surge arrestor on the incoming isolated line.
• Use oversized feeder lines to reduce electrical noise and voltage drop.
Figure 1-1: Controller Description
Master / Primary Unit Secondary Unit
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mPro400GC Controller
1.3 Mounting the Controller
1. oosen the two long mounting screws at the bottom of the controller so the mounting plate can be
separated from the controller, see Figure 1-17.
2. Figure 1-16 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 M12 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- B
connector 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, P 12-1001EN, for all other connections.
1.5 Accepting a Corded Tool
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 the Navigator button as shown in
Figure 1-2.
Figure 1-2: Run Screen
Navigator Button
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mPro400GC Controller
2. From the Navigator menu press TOO SETUP.
3. Touch the horizontal bar indicating the Primary tool to highlight it. Touch the Tool Settings button.
Figure 1-3: Navigator Screen
Tool Setup
Figure 1-4: Tool Setup - Tool List
Tool Settings
Primary Tool
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mPro400GC Controller
4. Verify that the tool shown is the tool connected. Check the model and serial number. If the tool is
correct press the ACCEPT button. In the window that appears press the ACCEPT button for that
window. A screen will appear indicating that the settings are being saved. When the save process
is complete press the CANCE button to return to the Tool Setup-Tool list screen. Press the
NAVIGATOR button. Advance to Section 1.9 for programming instructions.
Figure 1-5: Tool Setup - Tool Settings
Accept Button
Model Number
Serial Number
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mPro400GC Controller
1.6 Accepting a Livewire Tool
ivewire 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 controller.
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 Figure 1-17.
2. Apply power to the controller and access point.
Setting Up the Livewire Tool:
Controller IP address:
1. From the NAVIGATOR screen press the COMMUNICATIONS menu and then select the Network
Settings tab.
2. If not using server assigned addresses disable DHCP for Card One. See Figure 1-6
3. Enter the IP address and subnet that will be assigned to the controller. See Figure 1-6
4. Press the Navigator key to accept entries.
5. Click Accept on the message window that appears. The screen will return to the NAVIGATOR
menu then begin storing data.
6. A message will appear to restart the controller.
Figure 1-6: Communications - Network Settings
Navigator Button
Card 1 DHCP
IP Address
Subnet Mask
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mPro400GC Controller
1.7 RF (Radio Frequency) Settings
1. From the NAVIGATOR menu press the TOO SETUP menu then RF Settings. Select IRDA
Serial and the correct port depending on the port connected to at the base of the controller.
See Figure 1-17. (CON 1 and CON 2 are X4 and X5 respectively at the controller.)
2. See Figure 1-8. If serial connectivity has been made the SSID, Encryption, and remaining fields
will become available 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 the “Write RF settings” button.
Figure 1-7: Tool Setup - RF Settings
IRDA Serial
Port Selection
Figure 1-8: Tool Setup - RF Settings
SSID
Confirm Network
Key
Network Key
Encryption
IP Address
Write RF Settings
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mPro400GC Controller
1.8 Tool Install
1. Go to the Navigator menu and press TOO 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.
2. Press the “Install” button and select the “ ivewire w/W AN” choice from the pop-up window that
appears. Enter the IP address for the tool. This should be the same address as entered in Step
2, Section 1.7. Press the OK button and save the settings.
Figure 1-9: Tool Setup - Tool List
Select Tool
Figure 1-10: Tool Setup - Install
IP Address
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mPro400GC Controller
3. From the Navigator screen choose the TOO SETUP menu. Press the Tool Settings button.
Verify the tool model and serial number. If the information is correct press the Accept button at
the bottom of the screen. Continue with saving settings.
1.9 Programming a Basic Fastening Strategy
From the Navigator menu press the BASIC button and the BASIC programming 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 using
the Auto Program feature.
Figure 1-11: Tool Setup - Accepting the Tool
Accept Button
Model Number
Serial Number
Figure 1-12: Basic Fastening Strategy
Tool Application Fastening Strategy
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mPro400GC Controller
1.10 Auto Programming (Torque Control / Angle Monitor Only)
1. Before using the Auto Program feature go to ADVANCED menu from the Navigator screen,
Controller Settings tab and choose the desired Engineering units. Press the Navigator button to
save settings.
2. Go to the Navigator screen and press BASIC. From the BASIC screen press the Auto Program
button. Enter the desired final stage torque value using the virtual keypad. Press the Enter key.
Press the OK button from the Auto Program window. imits of +/- 15% will be provided.
Parameters can be adjusted if needed. Press the Navigator button to return to the Navigator
screen and save parameters.
Figure 1-13: Controller Settings
Figure 1-14: Torque Control/Angle Monitor
Engineering Units
Final Stage
Torque Value
Auto Program
K
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mPro400GC Controller
1.11 Manual Programming
1. Touch the Torque High imit 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
down arrow on the keyboard to move the keyboard down so the next field can be entered.
Continue entering parameters and moving the keyboard. If the keyboard won’t move any further
in a particular direction touch a place on the keyboard that doesn’t have a function and drag it to
a new location so parameters can continue to be entered. When finished, touch the Navigator key
and the screen will return to the NAVIGATOR menu and begin saving parameters.
Figure 1-15: Manual Programming
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mPro400GC Controller
Figure 1-16: Mounting Information
1.825”
(46.4mm)
0.075”
(1.9mm)
14.88”
(378mm)
4x 1.315”
(33.4mm)
4x 7.750”
(197mm)
10.38”
(263mm)
2x 1.250” (31.8mm)
2x 12.500”
(318mm)
10x .313”
(1.95mm)
10x .503” (12.8mm)
10x .270” (6.86mm)
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mPro400GC Controller
Figure 1-17: Connector Locations
X1
X2
X3
X6
X4
X8
X5
X7
X10
Mounting Bracket
Screw
X11
X9
Mounting Bracket
Screw
X1 = Ethernet Connector #1
X2 = Ethernet Connector #2
X3 = USB ports (2)
X4 = Serial Connector #1
X5 = Serial Connector #2
X6 = I/ Connectors
X7 = Anybus Fieldbus
X8 = Anybus Fieldbus
X9 = Tool Connector
X10 = System Bus Connector
X11 = Power Connection
Legend
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mPro400GC Controller
1.12 Inputs and Outputs - Primary Controller
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.
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 P C. The following examples utilize Tool Start as an
Input and Cycle OK as an Output.
Pin # I/O Signal Description Pin # I/O Signal 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 +24V2 13 Out +24V2
Pin 1 Pin 13
Figure 1-18: Primary/Master Pin Configuration
Pin 12 Pin 24
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mPro400GC Controller
1.12.1 Inputs and Outputs - Secondary Controller
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.
Note: Some Inputs and Outputs are fixed, not programmable.
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 P C. The following examples utilize Tool Start as an
Input and Cycle OK as an Output.
Pin # I/O Signal Description Pin # I/O Signal Description
12 Out Common GND 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 +24Vdc 13 Out +24Vdc
Pin 1 Pin 13
Figure 1-18: Primary/Master Pin Configuration
Pin 12 Pin 24
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mPro400GC Controller
1.12.2 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
Pins 2 and 14 must be connected to Pins 1 and 13 respectively.
1.12.3 Connections Utilizing the External 24-volt Supply (Primary and Master only)
INPUTS: Pins 11 and 23 (Common GND) are the Input “returns”.
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.
External 24-volt Supply
Pins 2 and 14 must be connected to the external 24-volt supply.
Pin # Function Description Pin # Function Signal 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 (Cycle OK) 19 Output O 04
6 Input I 03 (tool start) 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 +24V2 13 Out +24V2
Connector 1
Connector 2
Pin # Function Description Pin # Function Signal Description
12 Out GND2 24 Out GND2
11 In Common GND External Ground 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 (Cycle OK) To External Ground 19 Output O 04
6 Input I 03 (tool start) From External 24V 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 From External 24V 14 In Output Common O4-O7
1 Out +24V2 13 Out +24V2
Connector 1
Connector 2
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