Technical Manual UFM SP V5

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
Copyright
 Copyright by
Promess Montage- und Prüfsysteme GmbH
Nunsdorfer Ring 29
D-12277 Berlin
Federal Republic of Germany
2
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
6.1
6.2
6.3
6.4
Strain Gauge amplifier .........................................................................................................................15
Calibrating the Strain Gauge Amplifier ............................................................................................ 17
Strain Gauge Amplifier PDM-S (Digital) .......................................................................................... 18
Connectors PDM-S .......................................................................................................................... 19
LED Functions PDM-S ..................................................................................................................... 20
7.1
7.2
7.3
PROMESS Bus ......................................................................................................................................21
Bus Terminator. ............................................................................................................................... 22
Cable Shield Connections ............................................................................................................... 23
Node - Address ................................................................................................................................ 24
7
8
Software installation ............................................................................................................................26
9
Communication PC - Application module .........................................................................................26
Connection Ethernet module ........................................................................................................... 26
Ethernet Communication ................................................................................................................. 27
Assignment IP address Ethernet Module ........................................................................................ 29
Assign IP Adress PC ....................................................................................................................... 31
Assign IP Adress PC Windows 7 ..................................................................................................... 32
No Ethernet module found ............................................................................................................... 34
9.1
9.2
9.3
9.4
9.5
9.6
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
Pos : 1 /UFM SP/UFM V5/T echnisc hes H B V5/Besti mmungsgemäße Ver wendung @ 0 \mod_1297249097588_71.doc x @ 2579 @ 1 @ 1
3
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%.
Pos : 2 /Sei tenumbr uch @ 0\mod_1133348983396_71.doc x @ 306 @ @ 1
4
Pos : 3 /UFM SP/UFM V5/T echnisc hes H B V5/Transport @ 0\mod_1297249030870_71.doc x @ 2571 @ 1 @ 1
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.
Pos : 4 /UFM SP/UFM V5/T echnisc hes H B V5/Sic her heit @ 0 \mod_1297248864825_71.doc x @ 2563 @ 12 @ 1
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, standalone 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
5
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 emergencystop 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.
6
•
•
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.
C AUT IO N: M AI NT E N ANC E, R E P AI R S AN D S ER V IC E W O R K
UN DE RW AY , DO NO T SW IT CH O N !
If the unit has to be removed, first disconnect all of the power supplies.
The PROMESS electromechanical joining unit can cause injury to
operating personnel when not operated in the intended manner. Please
observe the following guidelines:
7
1.
2.
3.
4.
5.
3.1
Never hold your hands in the work area
The safety chain must be closed while operating the joining unit.
Never operate the unit in areas where it is not intended to be used.
Only authorized personnel is permitted to operate the unit.
During repairs, support the die of the joining unit or drive the die to
its lower stop.
Hazard Analysis
Risk assessment
Frequency of exposition
rare
frequent
Potential damages
Probability of occurrence
high
1 2 3 1 2 3 Countermeasures
A B C D E F
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
8
low
Hazards from faulty functioning of mechanical elements
Type of malfunction
Possible
injuries
Guide: Wear, blockage after
destruction
None
Axial bearing: Wear, destruction
None
Ball screw: Wear
Destruction
None
Countermeasures
Tearing of toothed belt
After belt tears, brakes will not be
able to stop die
1A 3F Category 1 and 10-fold safety against breakage under
2
normal operating conditions
Release tooth wheel coupling
1A 3F Category 1 and The couplings are self-locking; thus,
2
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
Pos : 5 /Sei tenumbr uch @ 0\mod_1133348983396_71.doc x @ 306 @ @ 1
9
Pos : 6 /UFM SP/UFM V5/T echnisc hes H B V5/Sic her heit el ektr omechanis cher F ügeeinhei ten @ 0\mod_1305792763628_71.doc x @ 2713 @ 2 @ 1
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, standalone 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, B 10
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.
Pos : 7 /Sei tenumbr uch @ 0\mod_1133348983396_71.doc x @ 306 @ @ 1
10
Pos : 8 /UFM SP/UFM V5/T echnisc hes H B V5/Belas tbar kei t UFM @ 0\mod_1297248724102_71.doc x @ 2547 @ 1 @ 1
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.
UFM-Classic
Force
Max. allowable
torque
Max. allowable radial
forces
kN
Nm
N
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
11
Article
Nr.
UFM-Precision
Force
Max. allowable
torque
Max. allowable radial
forces
kN
Nm
N
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
364020
1
90
50
378050
50
180
1000
378055
50
180
1000
UFM-Compact
Pos : 9 /Sei tenumbr uch @ 0\mod_1133348983396_71.doc x @ 306 @ @ 1
12
Pos : 10 /UFM SP/UFM V5/Tec hnisc hes HB V5/Schmi erhi nweis e @ 0\mod_1297248656398_71.doc x @ 2539 @ 1 @ 1
5 Lubrication advice
Preliminary Remarks
All electro-mechanical presses from PROMESS must be re-lubricated. Overlubrication 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:
The ball screw:
The thrust bearing:
Lubrication Points A and B,
Lubrication Point C,
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
UFM 03 / 05/ 12 / 20 / 30
M6
Thread extension
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:
13
LUBRICATION POINT E
Please remove the frame cover.
AMOUNT OF LUBRICANT FOR LUBRICATION
For the amount and the necessary interval of lubrication please see the data
sheet of your UFM.
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.
Pos : 11 /Seitenumbruc h @ 0\mod_1133348983396_71.doc x @ 306 @ @ 1
14
Pos : 12 /UFM SP/UFM V5/Tec hnisc hes HB V5/DM S Verstär ker @ 1\mod_1367926991708_71.doc x @ 3820 @ 122222 @ 1
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 C
Storage temp. range:
-40 to +70 C
EN 60529 safety class:
IP 65
•
o
o
Simplified diagram / pin assignments
15
•
Dimensions / connections
Stromversorgung /
supply voltage
2.Stabilisierung/
stabilization
1.Stabilisierung/
stabilization
X 2.5 (UB)
X 2.4 (0V)
Speisespannung/
excitation voltage
(+EX) X1.2
(-EX) X1.5
Verstärkung/
amplification
Ausgang/
output
(+SI) X1.3
X 2.2 (A+)
(-SI) X1.4
Messsignal/
signal input
X 2.3 (A-)
V
Ø
Nullpunkt/
zero
Jumper
X 2.1 Test
R test 200K
Force sensor
Kraftaufnehmer
Gruppe
Angewandte System Technik
BA 626
XKC 041
XKC 032.01
16
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
17
Required
starting
position
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:
6.2
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
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 C
Humidity:
Not condensing
Storage temp. range:
-40 ...+70 C
Housing
Aluminium Druckguss
EN 60529 safety class:
IP 40
Dimensions:
125*80*57 mm (L*W*H)
Height without connectors
o
o
18
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=A3=B+
4 = B5 = Z+
6 = Z7 = 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
19
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
Pos : 13 /Seitenumbruc h @ 0\mod_1133348983396_71.doc x @ 306 @ @ 1
20
Pos : 14 /UFM SP/UFM V5/Tec hnisc hes HB V5/Promess-Bus @ 0\mod_1343377001138_71.doc x @ 3581 @ 1222 @ 1
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.
Bus master
node 12
Bus terminator
Bus slave
node 13
Bus
terminator
Promess digital module
node 23
Promess digital module
node 22
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.
21
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
22
•
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.
Traco
Power
DIP terminator switch
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.
23
Node - Address
•
SM – Applications
These settings are made using the UFM software under:
“Service / Station Settings / PROMESS-BUS”
The following addresses can be assigned:
Function
12
Slave
13
Slave
14
Slave
15
PDM-S
Traco
Power
•
Node Address
Master
OFF
1
2
3
4
5 6
DIP switch
ON
7.3
24
DIP
Function
0ff
On
5 MBit
2.5 MBit
1
Node address binary-coded as bit
1
2
Node address binary-coded as bit
2
3
Baudrate
4
Not used
5
Boot loader
Start
6
Default parameters
Load
DIP 1 (Bit
1)
DIP 2
(Bit 2)
Node Address
PROMESS
Bus
off
off
22
on
off
23
off
on
24
on
on
25
All switch changes do not take effect until first switching the unit off and then
switching it back on.
Pos : 15 /Seitenumbruc h @ 0\mod_1133348983396_71.doc x @ 306 @ @ 1
25
Pos : 16 /UFM SP/UFM V5/Tec hnisc hes HB V5/Ins tallation Software / Kommuni kati on UFM PC @ 0 \mod_1305802993105_71.doc x @ 2761 @ 11222222 @ 1
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
SM Applikation Module
X1
Power Suppl.
11 12 13
24V 0V GND
X2
(RS 422) (Pin)
(extern.)
21 22 23
24
RX+ TX+ TX- RX-
14
NC
25 26
NC NC
Stromaufnahme: max. 90 mA
27
NC
28
GND
Cable:
Cat 5 Crossover
Ethernet Module
X4
RS485 (RJ45)
X5
RS485 (RJ45)
1
4
1
+24VDC
NC RX/TX
0V
5
0V
7
8
RX/TX NC
2
3
NC RX/TX
0V
5
0V
7
8
RX/TX NC
2
3
4
+24VDC
Cat 5
Switch
X3
Ethernet
10/100 Mbit
6
NC
6
NC
PC
Cable Cat 5
Unidrive
SP
26
PC
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
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:
Which address should you assign
to your PC?
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.
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.
27
Ethernet
Point to point connection with only one press unit.
Ethernet
Switch
28
Ethernet
Ethernet
Ethernet
Ethernet
Sub Net mit mehreren Fügeeinheiten und Switch
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.
Please click the “binocular”
button to search for
connected Ethernet
Modules in the network.
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“.
29
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.
30
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“
31
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
32
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.
33
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
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.
Pos : 17 /Seitenumbruc h @ 0\mod_1133348983396_71.doc x @ 306 @ @ 1
34
Pos : 18 /UFM SP/UFM V5/Tec hnisc hes HB V5/UFM Firmware U pdate @ 0\mod_1328520238078_71.doc x @ 3193 @ 122 @ 1
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.
New
Old
35
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.
36
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.
37
=> “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.
38
End the update process by clicking “Finish”.
After a successful update please reset the drive by switching off and on
10.2
39
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”
40
“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”.
Enter the IP address of
the station you like to
update..
Choose slot 2
(Slot des Applikationsmoduls)
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.
41
Adjust if necessary the „Advanced…“ settings.
Enter 3001 as TCP
Server Port
=> “Next”
=> “Next”
42
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
Pos : 19 /Seitenumbruc h @ 0\mod_1133348983396_71.doc x @ 306 @ @ 1
43
Pos : 20 /UFM SP/UFM V5/Tec hnisc hes HB V5/Ins tallation C PR M anager @ 0\mod_1305797695176_71.doc x @ 2730 @ 12 @ 1
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.
2.
3.
4.
x86 (32 bit): Windows XP, 2003 Server, Vista, 7, and 2008 Server
x64 (64 bit): Windows Vista, 7, and 2008 Server
Microsoft .NET Framework v4.0
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:
44
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”.
45
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.
46
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.
47
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.
Pos : 21 /Seitenumbruc h @ 0\mod_1133348983396_71.doc x @ 306 @ @ 1
48
Pos : 22 /UFM SP/UFM V5/Tec hnisc hes HB V5/SPS Schnittstelle @ 0\mod_1305797708296_71.doc x @ 2739 @ 1222222 @ 1
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
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
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.
49
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
Home request
ts
Life Bit
Start
Ack
4
1
2
5
OK
3
NOK
Description
tprg
ta
tb
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.
50
12.4 Emergency Stop during a motion
Emergency-Stop
Ack
Start
Ref-request
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.
51
12.6 Cycle Stop
Ref. request.
ts
L Bit
4
1
Start
5
2
Quit
3
OK
NOK
6
tb
Cycle stop
tsch
ta
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.
52
12.7 Transfer of program number
I Start
I Reference start
I Prog. Bit 1
I Prog. Bit 2
1
I StrobeI Prog.
Prog.Bit
non
2
4
O Prog. Bit 1
O Prog. Bit 2
3
O Strobe Prog.
O Prog. Bit n
tb
tload
ta
5
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 T extmar ke Inhalt ===
53
Index
A
L
Acknowledgement 49
Assign IP Adress PC 31
Lubrication advice 13
B
No Ethernet module found 34
bus terminator 22
P
C
PLC interface 49
COM Test 48
Connection Ethernet module 26
Correct usage 4
Cycle Stop 52
R
N
Radial forces, max. load 11
Reference motion without a request 50
S
E
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
Emergency Stop during a motion 51
Emergency Stop during standstill process 51
Ethernet Communication 27
F
Firmware Update 35
H
T
Hazard analysis 8
Torque, max. load 11
Transfer of program number 53
Transport 5
I
IP address Ethernet Module 29
IP Adresse PC Windows 7 32
54