Cleco Tools BTSE series Bedienungsanleitung

For additional product information visit our Web site at http://www.apextoolgroup.com

mPro400GC-DGD-intelligent-spindle

BTSE series

System Handbook

P2077SB/EN

2011-09

2 P2077SB/EN 2011-09 77a_Deckblatt.fm, 06.09.2011

Notes on 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

Symbols in text

Abbreviations

Apex Tool Group 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 Apex Tool Group.

DGD is a trademark of Apex Tool Group Division.

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

➔Identifies instructions to be followed.

• Identifies lists.

italics Indicates menu items such as Diagnostics in software descriptions

<…> Identifies elements that have to be selected or deselected, such as buttons or control boxes, i.e. <F5>

Courier Indicates the name of paths and files, e.g. setup.exe

\ A backslash between two names indicates the selection of an item from the menu, e.g. file \ print

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

P2077SB-EN_2011-09_m-Pro-400S-DGD-IS_BTSEIVZ.fm, 06.09.2011 P2077SB/EN 2011-09 3

Contents

1 Safety 7

1.1 Warnings and notes ....................................................................... 7

1.2 Basic requirements for safe working practices..................................... 7

1.3 Operator training................................................................................... 8

1.4 Personal protective equipment............................................................. 8

1.5 Designated use..................................................................................... 8

1.6 Ambient conditions ............................................................................... 9

1.7 EMC (Electromagnetic compatibility).................................................... 9

1.8 Noise................................................................................................... 10

2 Transport / Storage 10

3 System description 11

3.1 Components ....................................................................................... 11

4 First Operation 13

5 DGD intelligent spindles 15

5.1 General technical data........................................................................ 15

5.2 Catalogue data ................................................................................... 16

5.3 Component overview.......................................................................... 20

6 Tightening module TSE/TUSE 23

6.1 Description.......................................................................................... 24

6.2 General technical data........................................................................ 24

6.3 "Ready" LED....................................................................................... 25

6.4 Service panel...................................................................................... 25

6.5 Internal assemblies............................................................................. 27

7 Attachment 29

7.1 Centric Attachment............................................................................. 29

7.2 Offset attachment ............................................................................... 29

7.3 Angle head attachment....................................................................... 30

7.4 Spring collet – Optional....................................................................... 31

8 Transducer 33

8.1 Electrical Data..................................................................................... 34

8.2 Pin configuration of transducer........................................................... 34

4 P2077SB/EN 2011-09 P2077SB-EN_2011-09_m-Pro-400S-DGD-IS_BTSEIVZ.fm, 06.09.2011

9 Gearing 35

10 Motor 35

10.1 Technical data .................................................................................... 35

10.2 Electrical Data..................................................................................... 36

10.3 Thermal data....................................................................................... 36

10.4 Pin configuration motor connector ..................................................... 37

11 Power distribution box PDB-CPS… 39

11.1 Brief function description .................................................................... 39

11.2 General technical data........................................................................ 40

11.3 Electrical Data..................................................................................... 40

11.4 Installation........................................................................................... 41

11.5 Supply module CPS3.......................................................................... 42

11.6 Transformer........................................................................................ 47

11.7 General technical data........................................................................ 47

12 Instructions on laying cables 49

12.1 General............................................................................................... 49

12.2 Strain relief clamp............................................................................... 50

12.3 Shielding............................................................................................. 50

12.4 Laying "High-Flex Quality" cables in cable ducts................................ 51

12.5 Wiring of robot area »SuperhighFlex Quality«.................................... 52

13 Cable 53

13.1 HighFlex Quality, suitable for cable ducts........................................... 53

13.2 Super Highflex, suitable for robots...................................................... 58

14 Function description 61

14.1 Torque measurement ......................................................................... 61

15 Troubleshooting 63

15.1 Acknowledgment of Errors.................................................................. 63

15.2 DGD-IS............................................................................................... 64

15.3 Tightening module CPS3 in power distribution box PDB-CPS… ....... 65

15.4 Tightening module TSE/TUSE............................................................ 70

15.5 Nutsetter control unit mPro400GC-M ................................................. 70

16 Maintenance / Service 77

P2077SB-EN_2011-09_m-Pro-400S-DGD-IS_BTSEIVZ.fm, 06.09.2011 P2077SB/EN 2011-09 5

17 Disposal 77

6 P2077SB/EN 2011-09 P2077SB-EN_2011-09_m-Pro-400S-DGD-IS_BTSEIVZ.fm, 06.09.2011

77b_Sicherheit_bedingt-en.fm, 06.09.2011 P2077SB/EN 2011-09 7

Safety 1

1 Safety

1.1 Warnings and notes

1.2 Basic requirements 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.

WARNING! A symbol combined with the word WARNING warns of a potentially dangerous situation for the health

of personnel, If this warning is not observed, death or serious injury may occur.

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.

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.

NOTE This symbol indicates a general instruction.

General instructions include application tips and special useful information, but no warnings against

dangers.

DANGER! High leakage current –

Fatal electric shock could occur!

➔Establish a protective earth (PE) ground connection to the PDB-CPS… before taking into operation!

➔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 & Service Center

(see backside).

WARNING! High temperature –

the motor on the DGD-IS may heat up and cause burns during removal. (max. engine temperature 80 °C).

➔Wear gloves.

CAUTION! Risk of flying parts.

Components of the spindle may rotate, come loose and cause injury.

➔Avoid speed increases of over 3 m/s² on all axes.

8 P2077SB/EN 2011-09 77b_Sicherheit_bedingt-en.fm, 06.09.2011

Safety

➔We do not claim that these safety notes are complete. Read and observe all applicable, general and

local safety and accident prevention rules.

➔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.

1.3 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.

1.4 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-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.

CAUTION! Work area

➔Close all safety devices.

➔Ensure that there is enough space in the work area.

➔Keep the work area clean.

Electrical safety

➔Only operate the tightening system indoors.

➔Observe the safety notes on the DGD-IS.

Safe working with and around fastening tools

➔Inspect screw bits and retaining ring for visible damage and cracks.

Replace damaged parts immediately.

➔Always disconnect the power supply to the DGD-IS before changing screw bits.

➔Only use screw bits for machine-controlled fastening tools.

➔Make sure that the screw bits are retained securely.

77b_Sicherheit_bedingt-en.fm, 06.09.2011 P2077SB/EN 2011-09 9

Safety 1

• 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.

1.6 Ambient conditions

Do not operate the fastening system in an explosive atmosphere.

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.

NOTE

➔Always remove the complete DGD-IS from a unit.

➔A repair is only permitted by DGD authorized personnel. If repair is required, send the complete

DGD-IS to Sales & 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 & 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 & Service Center.

➔Read the following documents when replacing the DGD-IS

• This System Handbook (see 16 Maintenance / Service, page 77)

• Service Manual DGD-IS

• Assembly instructions DGD-IS

• Spare part sheets

System components Ambient temperature Relative humidity Working height

DGD-IS

32 to 113 °F

(0 to 45 °C) 0 to 90 %

no condensation up to 3000 m above

sea level

mPro400GC-M

PDB-CPS…

CP3-…-JH

TSE/TUSE

Motor

CPS3 32 to 158 °F

(0 to 70 °C)

10 P2077SB/EN 2011-09 77b_Sicherheit_bedingt-en.fm, 06.09.2011

Transport / Storage

1.8 Noise

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.

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.

DGD-IS dB(A)

1B(U)TSE-1B012A-… 72

1B(U)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

System components Storage temperature Relative humidity

DGD-IS

-20 to 70 °C 0 to 90 %

no condensation

PDB-CPS…

TSE/TUSE

Motor

CPS3 -25 to 70 °C

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