Technical Manual

UFM SP V5

Promess Montage- und Prüfsysteme GmbH Nunsdorfer Ring 29 D-12277 Berlin Phone: +49 (0) 30 / 628872-0 Fax: +49 (0) 30 / 628872-59 Email : promess@promessmontage.de www.promessmontage.de

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Copyright

Copyright by Promess Montage- und Prüfsysteme GmbH Nunsdorfer Ring 29 D-12277 Berlin Federal Republic of Germany

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1 Correct usage ......................................................................................................................................... 4

2 Transport ................................................................................................................................................. 5

3 Safety Measures ..................................................................................................................................... 5

3.1 Hazard Analysis ................................................................................................................................. 8

3.2 Safety of Electromechanical Joining Units ...................................................................................... 10

4 Loading the ram by torque and radial forces .................................................................................... 11

5 Lubrication advice ................................................................................................................................ 13

6 Strain Gauge amplifier ......................................................................................................................... 15

6.1 Calibrating the Strain Gauge Amplifier ............................................................................................ 17

6.2 Strain Gauge Amplifier PDM-S (Digital) .......................................................................................... 18

6.3 Connectors PDM-S .......................................................................................................................... 19

6.4 LED Functions PDM-S ..................................................................................................................... 20

7 PROMESS Bus ...................................................................................................................................... 21

7.1 Bus Terminator. ............................................................................................................................... 22

7.2 Cable Shield Connections ............................................................................................................... 23

7.3 Node - Address ................................................................................................................................ 24

8 Software installation ............................................................................................................................ 26

9 Communication PC - Application module ......................................................................................... 26

9.1 Connection Ethernet module ........................................................................................................... 26

9.2 Ethernet Communication ................................................................................................................. 27

9.3 Assignment IP address Ethernet Module ........................................................................................ 29

9.4 Assign IP Adress PC ....................................................................................................................... 31

9.5 Assign IP Adress PC Windows 7 ..................................................................................................... 32

9.6 No Ethernet module found ............................................................................................................... 34

10 Firmware Update .................................................................................................................................. 35

10.1 Version 5.00 to V5.2x ...................................................................................................................... 36

10.2 .............................................................................................................................................................. 39

From Version 5.03 ........................................................................................................................................ 40

11 Installation of CPR V4 Manager .......................................................................................................... 44

11.1 COM Test......................................................................................................................................... 48

12 PLC Interface ........................................................................................................................................ 49

12.1 Reference motion after start-up ....................................................................................................... 49

12.2 Reference motion without a request ................................................................................................ 50

12.3 Cycle start ........................................................................................................................................ 50

12.4 Emergency Stop during a motion .................................................................................................... 51

12.5 Emergency Stop during standstill process ...................................................................................... 51

12.6 Cycle Stop........................................................................................................................................ 52

12.7 Transfer of program number ............................................................................................................ 53

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1 Correct usage

The press unit is designed and built for assembly operation tasks, e. g. for pressing in bearings, absorbers and shafts or to press in and caulk seals.

Operations, other than the above, may not be performed on the machine.

The permissible loads are determined by the performance data of the unit and must not be exceeded by any larger extent.

Avoid the following situations in particular:

Abrupt loads at high positioning velocities - “collisions”,

Forces under normal operations that exceed the nominal load by more than 110%,

Excessive loads through unpredicted operational conditions, exceeding the nominal load by 100%.

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2 Transport

The units are supplied packaged in standard cases. The belt drive protection is not mounted to facilitate the use of lifting equipment when unpacking the unit. Please follow the instructions below to remove the unit:

Use a broad double belt, placed under the motor plate and around the mounting flange, to unload the press unit.

ATTENTION:

Do not put any loads on the proximity and limit switches when attaching the lifting device!

There is also the possibility of using an eyebolt, attached to the thread of the ball screw, to unload the press unit.

After the unit has been unloaded, inspect it for visible transport damages.

The press unit and related servo amplifier may only be installed in appropriate and suitable locations. In particular, please observe all protection regulations. Should you require information concerning requirements about the admissible locations, please contact the manufacturer.

After the installation of the press unit, please make sure you comply with the manufacturer's specific measures before operation:

Mount the belt protection, prior to connecting the power cable.

Only use the power cables supplied.

Assemble the power amplifier with the supplied filters and choking coils according to the power amplifier manual instructions.

Make sure all cables are correctly installed. Avoid laying power and data cables next to each other.

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3 Safety Measures

The joining unit may only be used for its intended purpose. Use of the joining unit for other purposes may cause injuries to operating personnel and damage to the unit.

The safety requirements for joining applications must be defined by the machine manufacturer who determines the manufacturing concept – assembly line, stand-alone stations, automatic mounting, manual operation – together with the plant operator. Based on these requirements, the safety concept can be developed for the plant or parts thereof.

The joining units are to be fitted with safety components – brakes, speed monitoring, versatile safety switches – and their integration into the safety concept is determined on the basis of the required plant functionality.

It is forbidden to operate the units with the safety functionality bypassed. Should operators to occasionally or always be required to enter the hazardous area due to technical reasons, a safety concept must be developed for the plant with these considerations in mind.

For joining units operated without brakes, the die weight must not exceed the limits defined by PROMESS. The permissible weights are given in the specifications. If larger weights are required for processing reasons, brakes must be implemented

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for the unit. Standard brakes can be used in normal cases or specially dimensioned brakes for larger weights.

Typical Installation Conditions

The typical installation conditions are described below (four typical solutions are given, other variants are possible):

Machines with permanent protective equipment:

The units are installed in a protected workroom with permanent safety equipment and doors that are monitored and locked. Access to the hazardous area is only possible through the monitored and locked doors.

PROMESS provides mounting plates with integrated emergency off switches to be integrated in this concept. By using appropriate emergency stop switches together with suitable locking elements for the doors, safety functionality can be achieved with PI = e.

Machines with Light Curtain

The hazardous area is to be protected by a light curtain.

In this operating mode, the safety function “Safety stop after actuating emergency-stop device” must have PI = d.

PROMESS provides the required components to achieve this PI value as well as verification that this PI value has been achieved.

Machines with two-hand actuation:

The joining unit can be started using two-hand actuation.

Systems with two-hand actuation require the same PI ratings as with machines with light curtains.

The required equipment is provided by PROMESS.

Machines without protective equipment:

No special protective equipment is planned.

In this rare case, the speed of the joining unit must be reliably limited to 10 mm/s.

Damages resulting from inappropriate implementation of the required PI values will not be covered by PROMESS.

The power amplifier may only be connected and started up by specially trained technicians.

It is forbidden to switch off, bypass or remove the safety equipment.

In particular, the protective hood of the belt drive may only be removed when the unit is disconnected from the power amplifier and fully de-energized.

If the unit cannot be started due to technical faults or function problems in the protective equipment, the faulty component must be repaired or exchanged. It is strictly forbidden to operate the joining unit after the safety equipment has been manipulated and is no longer functioning properly.

The unit may only be operated by personnel who have been instructed in its operation.

If any faults occur during normal operation that cannot be eliminated using known and given strategies, technicians from the responsible departments must be informed.

Before beginning any maintenance, repairs or troubleshooting work, the unit must be de-energized.

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The PROMESS electromechanical joining unit can cause injury to

operating personnel when not operated in the intended manner. Please

observe the following guidelines:

• Set the main switch to “OFF”

• Remove the voltage plug

Important!

ANY SWITCHES IN THE “0” OR “CLOSED” POSITION MUST BE MARKED BY A WARNING SIGN.

CAUTION: MAINTENANCE, REPAIRS AND SERVICE WORK

UNDERWAY, DO NOT SWITCH ON!

If the unit has to be removed, first disconnect all of the power supplies.

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1. Never hold your hands in the work area

2. The safety chain must be closed while operating the joining unit.

3. Never operate the unit in areas where it is not intended to be used.

4. Only authorized personnel is permitted to operate the unit.

5. During repairs, support the die of the joining unit or drive the die to its lower stop.

3.1 Hazard Analysis

Risk assessment

Frequency of exposition Probability of occurrence

rare frequent high low

Potential damages

1

A

2

B

3

C

1

D

2

E

3

F

Countermeasures

Category 1

Slight injuries,

crushing or pinching of hand and fingers

Category 2

Severe injuries,

dismemberment of fingers,

severe injuries to

hand

Category 3

Death

Severe contusions

to head

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Hazards from faulty functioning of mechanical elements

Type of malfunction Possible

injuries

Countermeasures

Guide: Wear, blockage after destruction

None

Axial bearing: Wear, destruction None

Ball screw: Wear

Destruction

None

Tearing of toothed belt

After belt tears, brakes will not be able to stop die

1A 3F Category 1 and 2

10-fold safety against breakage under normal operating conditions

Release tooth wheel coupling 1A 3F Category 1 and 2

The couplings are self-locking; thus, loosening the screws will not release the coupling unless heavy vibrations or impacts occur at the machine

Slippage of tooth wheel on

Shaft, incorrect positioning, excessive force

None

Force sensor, destroyed from overloading

None

Cable breakage in force sensor None

Cable breakage in limit switch None

Cable breakage in motor resolver None

Cable breakage in power cable None

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3.2 Safety of Electromechanical Joining Units

The European Machinery Directive contains regulations pertaining to the safety of machines and plants that are valid throughout Europe. All of the standards and regulations relevant to this application are listed in Machinery Directive.

• What is a machine?

The Machinery Directive defines a machine as follows:

“… an assembly of linked parts or components, at least one of which moves with the appropriate actuators, control and power circuits, etc. joined together for a specific application, in particular for the processing, treatment, moving or packaging of a material.”

Thus, components and subassemblies are not machines:

“An assembly of linked parts” is exempted from this application area

when it is a component or a nearly finished machine (“quasi-machine”).

(Source: Explanations 98-37-EU, chapter 58).

Thus, the joining units from PROMESS are not machines but the stand-alone stations are.

Responsibilities

The safety requirements for the machine are to be defined by the machine manufacturer who determines the manufacturing concept – assembly line, stand-alone stations, automatic mounting, manual operation – together with the plant operator. Based on these requirements, the safety concept can be developed for the plant or parts thereof.

The plant manufacturer is to stipulate the safety requirements of the various components to their respective suppliers and the suppliers are to describe which equipment is required to comply with these requirements.

The component manufacturer is responsible for providing the safety equipment for the components as stipulated in the safety concept, providing verification of the PI values and providing the data required to calculate the PI values (MTTF,d, B10 values, DC values etc.).

To assist the machine manufacturer, PROMESS has defined the requisite safety equipment for typical machinery and safety concepts.

Verification

PROMESS is to provide proof of compliance with the regulations stipulated by the Machinery Directive in the DECLARATION OF INCORPORATION FOR PARTIALLY COMPLETED MACHINERY.

PROMESS will provide a DECLARATION OF CONFORMITY for stand-alone stations.

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4 Loading the ram by torque and radial forces

The ram can be loaded by torque and radial forces. The following spreadsheet shows in order of the press types the maximum allowable loads.

The data for the radial forces are applies to a 50 % extended ram. When the ram is fully extended, the data has to be reduced by 50 %.

In normal cases there are no excessive radial forces during press operations. However in cases of considerable misalignment or when these forces are generated by the process, radial forces might occur. (Example: testing of helical springs)

Article Nr.

Force Max. allowable

torque Max. allowable radial

forces

kN Nm N

UFM-Classic 374003 3 3 100

374005 5 10 200

374010 5 10 200

374012 12 22 200

374048 12 22 200

374125 20 37 500

374022 20 37 500

374023 20 37 500

374131 30 50 500

374130 30 50 500

374040 40 130 700

374043 40 130 700

374297 40 130 700

374060 60 200 700

374065 60 200 700

374181 80 270 700

374091 80 270 700

374111 100 350 700

374103 100 350 700

374120 100 350 700

374151 150 500 1000

374243 240 450 1500

374291 300 450 2000

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Article

Nr. Force

Max. allowable torque

Max. allowable radial forces

kN Nm N

UFM-Precision 365803 0,1 0,2 20

365802 0,2 0,2 20

364030 1 0,75 50

366030 3 3 100

366830 3 3 100

UFM-Compact

364020 1 90 50

378050 50 180 1000

378055 50 180 1000

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5 Lubrication advice

Preliminary Remarks

All electro-mechanical presses from PROMESS must be re-lubricated. Over-lubrication should be avoided, however, damage to the bearings due to overheating caused by over-lubrication is not to be expected. Over-lubrication as no negative consequences.

Lubrication Points

The following components are lubricated ex works:

The gliding guides: Lubrication Points A and B,

The ball screw: Lubrication Point C,

The thrust bearing: Lubrication Point D.

LUBRICATION POINTS A AND B:

The lubrication points A and B consist of two opposite lubrication fittings in the centre of the press casing.

LUBRICATION POINT C:

Lubrication point C is located behind the seal cap M20*1,5. To re-lubricate the ball screw nut, complete the following steps:

Remove the cover flap,

manually move the spindle slowly downwards, until you see the lubrication

opening on the now open drill hole.

Please screw in the lubrication fitting

Thread for lubrication fitting

Type Preference series Thread Thread extension

UFM 03 / 05/ 12 / 20 / 30 M6

UFM 40 / 60 / 80 / 175 /150 M8 * 1

UFM 40 / 60 / 80 / 330 /240 M8 * 1 M6

UFM 100 / 330 /200 M8 * 1 M6

UFM 150 / 400 / 145 M8 * 1

UFM 240 / 350 /120 M8 * 1

Now you can be re-lubricate with a lubrication press.

LUBRICATION POINT D:

The thrust bearing – especially on the units starting at 20kN nominal load – must be lubricated very carefully. As from the lubrication fitting to the rolling body running path also hollow spaces have to be filled, the following lubricant amounts are necessary:

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LUBRICATION POINT E

Please remove the frame cover.

AMOUNT OF LUBRICANT FOR LUBRICATION

Lubricant

A high-quality roll bearing lubricant must be used.

PROMESS recommends the following lubricant brands:

Klüber - ISOFLEX NBU 15, Klüber - ISOFLEX NCA 15, FAG ARCANOL and comparable types.

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For the amount and the necessary interval of lubrication please see the data

sheet of your UFM.

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6 Strain Gauge amplifier

The force sensor is operated using an analog strain gauge preamp.

Technical data:

Precision class: 0.2%

Nominal sensitivity 0.28 to 3.6 mV/V

Fine setting range of nominal sensitivity:

±20%

Feed voltage of strain gauge bridge: 10 VDC

Signal output: ± 10 VDC

Temperature coefficient

- Of zero point at 2 mV/V: < 0.05%

- Of gain at 2 mV/V: < 0.07%

Power supply:

- Voltage range: 19 to 28 VDC

- Current consumption: Approx. 35 mA

Operating temp. range: -25 to +60 oC

Storage temp. range: -40 to +70 oC

EN 60529 safety class: IP 65

• Simplified diagram / pin assignments

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• Dimensions / connections

Stromversorgung /supply voltage

Speisespannung/excitation voltage

2.Stabilisierung/ stabilization

1.Stabilisierung/ stabilization

Messsignal/signal input

Ausgang/output

Verstärkung/amplification

Nullpunkt/zero

Jumper

X 2.5 (UB)

(+EX) X1.2

(+SI) X1.3

(-SI) X1.4

(-EX) X1.5

X 2.4 (0V)

X 2.2 (A+)

X 2.3 (A-)

X 2.1 Test

R 200K test

Ø

V

Angewandte System Technik

Gruppe

BA 626

Kraftaufnehmer

XKC 041 XKC 032.01

Force sensor

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6.1 Calibrating the Strain Gauge Amplifier

If it is necessary to recalibrate the strain gauge preamplifier, proceed as follows:

• Offset

To eliminate an offset from the force sensor, adjust potentiometer R1. (See amplifier drawing.) Adjust the potentiometer until the digital value displayed in the sensor calibration dialog is approximately zero in the absence of a load.

• Gain

Click “Manual Method”.

Before applying a load, set the speed to a very small value (e.g., 0.5 mm/s).

Drive in small steps to approx. 80% of the rated capacity. Watch the force indicated by the reference sensor.

Apply a load and adjust the amplifier using potentiometer R2 (gain) until the value shown on the joining unit agrees with the value shown on the reference sensor.

With higher loads, avoid remaining in this position for a longer period of time. Relieve the unit from any loads during the calibration process.

• Position of calibration potentiometer

Zero point of potentiometer

Slope potentiometer

Required starting position

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Repeat this step until you are certain that the system is properly calibrated.

To calibrate the unit on a regular basis, PROMESS recommends creating a calibration program.

This program may appear as follows:

Program step Function Description

1 Positioning Positioned just in front of reference sensor

2 Join on Signal Application of definite force

3 Holding time 2 s Reading of applied force

4 Positioning Unit is driven back

6.2 Strain Gauge Amplifier PDM-S (Digital)

The PMD-S is connected to the UFM Control by the PROMESS-Bus

Precision class: 0.1%

Nominal sensitivity 0.1 … 5 mV/V

Speisespannung für DMS Brücke: 10 VDC

Analogue bandwidth 10 kHz typ. (-3dB)

Resolution A/D converter 24 bit

Programmable filter 0.37 … 12.5 kHz

Temperature drift +/- 0,6uV/°C typ, (static temperatures, in thermal equilibrium)

Power supply:

- Voltage range: 19 ... 36 VDC

- Current consumption: ca. 3 W

Operating temp. range: +5 ...+55 oC

Humidity: Not condensing

Storage temp. range: -40 ...+70 oC

Housing Aluminium Druckguss

EN 60529 safety class: IP 40

Dimensions: 125*80*57 mm (L*W*H)

Height without connectors

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6.3 Connectors PDM-S

Connector Description Type Num. of poles

Pin-assignement

Power supply 24 VDC M12 * 1

Binder Serie 713

4 1 = 24 VDC

2 = NU

3 = 0 VDC

4 = NU

Force F M16 * 0.75

Binder Serie 680

6 1 = Supply. -

2 = Supply. +

3 = NU

4 = Signal +

5 = Signal -

6 = NU

Encoder ENC M12 * 1

Binder Serie 713

8 1 = A +

2 = A -

3 = B +

4 = B-

5 = Z+

6 = Z-

7 = 5 VDC

8 = GND

PROMESS BUS

BUS M12 * 1

Binder Serie 713

5 1 = NU

2 = Bus A

3 = NU

4 = Bus B

5 = Shield

NU = Not used

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6.4 LED Functions PDM-S

LED State

24 V Green = 24 VDC

OK / NOK Indicates the status of the Cycle of the assigned station.

COM Permanent green = Communication OK

Green flashing = Communication NOK

1 time red flashing, pause = hardware initialisation fault

2 times red flashing, pause = Doppelte Node Adresse im Bus.

3 times red flashing, pause = not connectet to the bus

4 times red flashing, pause = no bus token

Possible causes:

- The PDM is reconfigurating

- Topology not porper

- No other Node in the Bus

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7 PROMESS Bus

The PROMESS bus is based on the CTNet BUS from Control Techniques.

This bus allows digital PROMESS PDM modules to be interconnected and also enables communications between UFM controllers.

In this example, the Promess Digital Modules transmit signals to the master power component (node 12) as well as to the slave power component (node 13).

The power components can also transmit signals and variables to each other.

Bus terminator

Bus master

node 12

Bus slave

node 13

Promess digital module

node 22

Promess digital module

node 23

Bus terminator

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7.1 Bus Terminator.

Make sure to correctly terminate the bus using terminating resistors. The bus data lines must be terminated using 82 Ω (0.25 W) at the SM Applications of the master and behind the last node in the bus.

• Master

Terminate the SM Applications of the master using terminals 6 and 8.

Pin 8 Pin 6

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• Terminator for PDM-S

The bus on the Promess PDM-S digital module can be terminated using the DIP switch provided there. The location of the switch is shown in the figure below.

7.2 Cable Shield Connections

The cable shields should be connected to each other at the location where they emerge from the cable. Use them to create a short wire strand that connects the CTNet shield to the corresponding terminal. For reasons of safety, the CTNet shield must be grounded at one point. In case of a catastrophic failure, this ground connection prevents the cable shield from transmitting electrical current to another device in the CTNet network or within the cable itself. For EMC reasons, the ground line should only be connected at a single point.

DIP terminator switch

Tra

co

Po

wer

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7.3 Node - Address

• SM – Applications

These settings are made using the UFM software under:

“Service / Station Settings / PROMESS-BUS”

The following addresses can be assigned:

• PDM-S

DIP switch

Function Node Address

Master 12

Slave 13

Slave 14

Slave 15

Tra

co

Po

wer

ON

OF

F

1 2

3

4

5

6

25

DIP Function 0ff On

1 Node address binary-coded as bit 1

2 Node address binary-coded as bit 2

3 Baudrate 5 MBit 2.5 MBit

4 Not used

5 Boot loader Start

6 Default parameters Load

All switch changes do not take effect until first switching the unit off and then switching it back on.

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DIP 1 (Bit 1)

DIP 2

(Bit 2)

Node Address PROMESS

Bus

off off 22

on off 23

off on 24

on on 25

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8 Software installation

Place the disk or CD-ROM in the appropriate drive. Go to the Windows start button (bottom far left), select 'Execute' and then type “Setup”. Follow the on-screen instructions to install the program.

9 Communication PC - Application module

The communication can be done using the delivered Ethernet module.

9.1 Connection Ethernet module

Cable No. 11592001 Pin

Ethernet X2 21 22 23 24 18

App. Mod 5 3 2 4 1

X3 Ethernet

10/100 Mbit

PC

X2 (RS 422) (Pin) 21 22 23 24 RX+ TX+ TX- RX- 25 26 27 28 NC NC NC GND

SM Applikation Module

X1 Power Suppl. (extern.) 11 12 13 14 24V 0V GND NC Stromaufnahme: max. 90 mA

X4 RS485 (RJ45) 1 2 3 4 NC RX/TX 0V +24VDC 5 6 7 8 0V NC RX/TX NC

X5 RS485 (RJ45) 1 2 3 4 NC RX/TX 0V +24VDC 5 6 7 8 0V NC RX/TX NC

Unidrive SP

Ethernet Module

Cable:

Cat 5 Crossover PC

Cat 5 Switch

Cable Cat 5

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9.2 Ethernet Communication

To communicate by Ethernet, you have to assign a common IP address to the PROMESS Ethernet Module and your PC!

Which address is assigned to the Ethernet Module?

Change the IP address of the Ethernet module: => 9.3

Which address should you assign to your PC?

Change IP Address PC: => 9.4 Windows XP / 9.5 Windows 7

Promess recommends the installation of a Sub net, in case of using more then one press.

The address is assigned by PROMESS and you can find it in

the delivery protocol of the unit.

In the state of delivery the IP address is in the range:

192.168.x.x

range:

192.168.x.x

To connect to an Ethernet Moduls, that is in delivery state,

assign a IP adrerss in the 192.168.x.x range and 255.255.0.0 as

subnet mask.

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Eth

ern

et

Eth

ern

et

Sub Net mit mehreren Fügeeinheiten und Switch

Switch

Eth

ern

et

Eth

ern

et

Eth

ern

et

Point to point connection with only one press unit.

Eth

ern

et

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9.3 Assignment IP address Ethernet Module

To assign a IP address to the Ethernet Module you need to have a functional TCP/IP network connection on your PC.

If you have not assigned a fixed IP address please do this as described in chapter 9.4 (windows XP), chapter 9.5 (Windows 7)

To assign a new IP address to the Ethernet Module, please run the program “Detector” in the PROMESS / Ethernet installation folder.

The Lantronix Detector opens.

This following window displays the IP adresses off all PROMESS Ethernet Modules, that are running in your network.

Wählen sie anhand der IP Adresse oder der Hardware - Adresse (MAC Adresse) das Modul, dessen IP Adresse sie ändern möchten und klicken sie anschließend auf die Schaltfläche „IP“.

Please click the “binocular” button to search for connected Ethernet Modules in the network.

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Choose by IP or Mac address the module you like to change. Then click the button “IP”

The MAC address you can find at the name plate of the Ethernet module.

Enter the IP address you would like to use in the future and if necessary the subnet mask.

When done, please reset the Ethernet module, by interrupting the power supply.

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9.4 Assign IP Adress PC

Open the „Network and Dial-up Connections“ in your “Windows Control Panel“. and open the properties of the LAN connection you like to use.

Click on Internet Protocol (TCP/IP) and then on „Properties“

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Enter the IP adress and the Subnet mask

9.5 Assign IP Adress PC Windows 7

Open the „Network and Dial-up Connections“ in your “Windows Control Panel“. and open the properties of the LAN connection you like to use

33

The property window of the connection opens.:

Klick on Internet Protocol version 4 (TCP/IPv4) and then „properties“. The following window opens:

Enter the IP adress and the Subnet mask

.

If necessary ask your Network administrator for the right settings.

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In case your PC has more then one network device, please choose “Advanced” and enter “1” for Inteface Metric.

9.6 No Ethernet module found

If you can not find any Ethernet Module using „Find“ in the program „UdpChangeIP“, this might be caused by the fact, that the address of your PC and your Ethernet Module are not in the same network.

The IP Adress of your Ethernet Module, whenit was shipped, is documented in the protocol you have got with the shipment.

Make sure, that you set the address of your PCcorresponding to this address.

If the Ethernet Module is not anymore in the state of delivery and you do not know the address, go ahead as follows:

If possible, connect the PC and the module directly.

Open the properties of your PC Ethernet network connection.

Enter a abritary IP addres out of the 4 permitted ranges. The IP addres has to start with 192.168.x.x, 169.254.x.x, 172.16.x.x or 10.x.x.x.

As Subnet mask use 255.255.0.0. or 255.0.0.0 for 10.x.x.x networks

Open the program „UdpChangeIP“and click on „Find“.

If there is no Ethernet Module found, change the IP addres to the next range and open „UdpChangeIP“again.

If there is no Ethernet module in all ranges, it must be damaged.

Please contact Promess for the exchange.

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Permissible address range Frequently used network masks

10.0.0.0–10.255.255.255 255.0.0.0

172.16.0.0–172.31.255.255 255.255.0.0

192.168.0.0–192.168.255.255 255.255.255.0

169.254.0.0–169.254.255.255 immer 255.255.0.0

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10 Firmware Update

Before you update the UFM firmware please make sure which Promess Ethernet Module you are using.

From version V5.03 the Ethernet Module is delivered with a different internal software version. This version enables a faster communication to the PC (baud rate 115200 bit/S) as well as updating the UFM firmware without the need of using the CPR manager.

Who to recognize the new version?

• PC software UFM

Behind the IP address of the station there is a little star.

(baud rate 115200 bit/S),

or a star in brackets (baud rate 38400 bit/S)

• In the cabinet

At the front view of the Ethernet module underneath the Promess logo you can see a green sticker.

Old

New

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10.1 Version 5.00 to V5.2x

Before starting a firmware update, make sure that the CPR Manager is installed and correctly configured on your PC. (See CPR Manager section)

Before continuing with the “Update”, press the Emergency Stop button on your system and close all running programs on your PC.

Start the “Winflash.exe” program in the installation directory “UFM_NC.EXE”. The start window appears.

Click “Next”.

Choose the following in the next window: “Download a compiled program” => “Next”

“Search” for the file “CTNet0_Node_12.bin” that you used to perform the update.

You can find the file in the installation directory of the UFM software.

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Click “Next”.

Choose “CT-RTU (Unidrive SP)” as the connection protocol and “Slot 2” under “Settings”.

Under “Change Communications Settings”, adapt the COM interface (hardware) to the interface defined in the Redirector. Use 38.4 Kbit/s as the baud rate.

38

=> “Next”

=> “Next”

To start the “Download”, click the red button.

It is absolute necessary to close the UFM software.

While an update is running, you can click “Cancel” if necessary to abort the process.

39

End the update process by clicking “Finish”.

After a successful update please reset the drive by switching off and on

10.2

40

From Version 5.03

Before continuing with the “Update”, press the Emergency Stop button on your system and close all running programs on your PC.

Start the “Winflash.exe” program in the installation directory “UFM_NC.EXE”. The start window appears.

Click “Next”.

Choose the following in the next window: “Download a compiled program” => “Next”

41

“Search” for the file “CTNet0_Node_12.bin” that you used to perform the update.

You can find the file in the installation directory of the UFM software.

Click “Next”.

Choose „CT-TCP/IP“ as the connection protocol and “Slot 2” under “Settings”.

Under “Change Communications Settings”, adapt the COM interface (hardware) to the interface defined in the Redirector. Use 38.4 Kbit/s as the baud rate.

Enter the IP address of the station you like to

update..

Choose slot 2

(Slot des Applikationsmoduls)

42

Adjust if necessary the „Advanced…“ settings.

=> “Next”

=> “Next”

Enter 3001 as TCP Server Port

43

To start the “Download”, click the red button.

It is absolute necessary to close the UFM software.

While an update is running, you can click “Cancel” if necessary to abort the process.

End the update process by clicking “Finish”.

After a successful update please reset the drive by switching off and on

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11 Installation of CPR V4 Manager

In order to update the firmware in the NC module, the CPR Manager must be installed on your PC. Changes on the PC to operate CPR Manager: 1. x86 (32 bit): Windows XP, 2003 Server, Vista, 7, and 2008 Server 2. x64 (64 bit): Windows Vista, 7, and 2008 Server 3. Microsoft .NET Framework v4.0 4. 30 MB free space on hard drive Proceed as follows:

• Please install “CPR Manager”

• Follow the installation instructions.

Access the configuration of the CPR Manager under Programs:

The following window appears:

45

To define the COM port that you want to use, choose “Add and Remove”.

In the next window, choose a COM port not used on your computer such as COM10.

Exit the window with “OK”.

46

Choose the COM you have created:

Clear the “Buffer Writes” option.

Next, search for any connected Ethernet modules by choosing the “Search” option in the “Device” menu.

47

Next, choose the IP address that you would like to connect to. Double-click the selection.

Next, change the TCP port value to 3001.

To save the settings, choose “Save Settings” in the “Com Port” menu or click the Save icon.

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11.1 COM Test

Click the “COM … Tests” tab to open it.

Click “Open” to test the connection.

If your settings are correct, you will see that you are connected to the chosen address. Stop the test with “Close”.

If your PC is connected to several stations, enter the addresses of the additional stations.

Next, save the new settings.

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12 PLC Interface

1 Remarks

The interface is designed to ensure a complete handshake, so that times do not have to be programmed or considered for the signal transmission.

2 Acknowledgement

The output signal "Ack." is used to confirm "System ready" and to acknowledge the detection of a PLC signal.

Signal description

12.1 Reference motion after start-up

Reference request

ACK

Reference motion start

Description

After a start-up of the NC module, the reference request and Ack are set The PLC sets the signal reference motion, The NC module acknowledges the signal by resetting the Ack signal, The PLC resets the signal start reference motion, when the signal reference request has been reset by the

NC module, The NC module confirms that the signal start reference motion has been reset, by setting the Ack signal.

If the signal start reference motion is cancelled during execution of the command, the PC stops the reference motion and the signal reference request remains set.

Signal Function Meaning

Reference motion Input Start of reference motion

Cycle start Input Cycle start

OK Output Part OK and cycle end

NOK Output Part NOK and cycle end

Ack Output Acknowledgement signal

Reference request Output Reference request from the NC module

OK/NOK Outputs Program interruption / cycle stop

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12.2 Reference motion without a request

Reference request

Ack

Reference motion

Description

The PLC sets the signal reference motion, The NC module confirms the signal by resetting the Ack signal and setting the signal reference request, The PLC resets the signal start reference motion, when the signal reference request has been reset, The NC module confirms that the signal start reference motion has been reset by setting the Ack signal.

If the signal start reference motion is cancelled during execution of the command, the PC stops the reference motion and the signal reference request remains set.

12.3 Cycle start

Description

The PLC sets the start signal The NC module confirms the signal by resetting the Ack signal and resetting OK or NOK The PLC detects the cycle end through the signal OK or NOK The NC module confirms the start-signal reset, by setting the Ack signal

If the signal start is cancelled during the program cycle, the NC module stops the motion and the signals Ack, OK and NOK are set.

ts

tb ta

Home request

tprg

5

4

3

2

1

Life Bit

Start

Ack

OK

NOK

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12.4 Emergency Stop during a motion

Description

In the case of an Emergency Stop, the Emergency Stop chain is opened, The press unit reacts by stopping the motion, The PLC resets the start signal, when an Emergency Stop situation is detected, After clearing the Emergency Stop situation, the PC confirms the flank change of the Emergency Stop signal

after the start-signal has been reset,

12.5 Emergency Stop during standstill process

Emergency-Stop

Ack

Description

In the case of an Emergency Stop, the Emergency Stop chain is opened, The NC module confirms by resetting the Ack, Closing of the Emergency Stop chain is responded to by setting the Ack.

Emergency-Stop

Ack

Start

Ref-request

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12.6 Cycle Stop

ta >= 10ms, tb >= 20ms, tsch = Duration of program step to cycle stop

ts = Save data in database

Description

The PLC sets the start signal when live bits are present and no reference request is present.

The NC module acknowledges the signal by resetting the acknowledgement.

The PLC recognizes the cycle stop from the OK or NOK signal plus Quit or from the signal cycle stop.

(This signal is only available via the bus system or the expansion module)

The PLC resets the start signal.

Setting the start signal again continues the cycle.

The outputs OK or NOK plus Quit are reset.

tb

3

5

4

ts

ta

Ref. request.

6

2

1

L Bit

Start

Quit

OK

NOK

Cycle stop

tsch

53

12.7 Transfer of program number

ta >= 10ms, tb >= 20ms, tload = Program load time

Description:

Assignment of binary coded program number

Set strobe for transfer

Reflection of program number

Strobe acknowledgement after program loaded

Reset strobe of PLC and NC module

=== Ende der Liste für Textmar ke Inhalt ===

tb

5

4 2

I Prog. Bit 1

I Prog. Bit 2

I Prog. Bit n I Strobe Prog. no

O Prog. Bit 1

O Prog. Bit 2

O Prog. Bit n

O Strobe Prog.

I Reference start

I Start

1

3

tload ta

54

Index

A

Acknowledgement 49

Assign IP Adress PC 31

B

bus terminator 22

C

COM Test 48

Connection Ethernet module 26

Correct usage 4

Cycle Stop 52

E

Emergency Stop during a motion 51

Emergency Stop during standstill process 51

Ethernet Communication 27

F

Firmware Update 35

H

Hazard analysis 8

I

IP address Ethernet Module 29

IP Adresse PC Windows 7 32

L

Lubrication advice 13

N

No Ethernet module found 34

P

PLC interface 49

R

Radial forces, max. load 11

Reference motion without a request 50

S

Safety measures 5

Signal description PLC interface 49

Signal flow cycle start 50

Signal flow reference motion after start-up 49

Software installation 26

Strain gauge amplifier 15

Strain Gauge Amplifier PDM-S (Digital) 18

T

Torque, max. load 11

Transfer of program number 53

Transport 5