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Operation Manual UFM V5.04
Operation Manual UFM V5.04
Operation Manual
UFM V5.04
Copyright
DATE: 13/04/16
Copyright by
Promess Montage- und Prüfsysteme GmbH
Nunsdorfer Ring 29
D-12277 Berlin
Federal Republic of Germany
1 Introduction ............................................................................................................................................. 4
2 Installing the Software ........................................................................................................................... 5
3 Software Start ......................................................................................................................................... 7
4 User and Rights Administration ........................................................................................................... 8
4.1 Login .................................................................................................................................................. 8
4.2 User Administration ........................................................................................................................... 9
4.3 User Rights ...................................................................................................................................... 11
5 Log function ..........................................................................................................................................13
6 Program Window ..................................................................................................................................16
7 Program Creation .................................................................................................................................21
7.1 Movement Steps .............................................................................................................................. 23
7.1.1 Positioning ................................................................................................................................... 23
7.1.1.1 Options ................................................................................................................................. 27
7.1.1.2 Trigger Positioning ............................................................................................................... 29
7.1.2 Press to Signal ............................................................................................................................. 32
7.1.2.1 Options ................................................................................................................................. 35
7.1.2.2 Feed Motion ......................................................................................................................... 36
7.1.2.3 “Press to Signal” Trigger ...................................................................................................... 37
7.1.3 Controller Module ........................................................................................................................ 38
7.1.3.1 Control Profile Module ......................................................................................................... 41
7.1.3.2 Trigger Module ..................................................................................................................... 42
7.1.4 Cycle Stop.................................................................................................................................... 43
7.1.5 Program End ................................................................................................................................ 43
7.2 Functions 1 ...................................................................................................................................... 44
7.2.1 Variables ...................................................................................................................................... 44
7.2.2 Gauging ....................................................................................................................................... 47
7.2.2.1 Gaugings from Independent Data Logging .......................................................................... 47
7.2.2.2 Gaugings from Step-based Data Logging (Curve Data) ..................................................... 57
7.2.3 Delay Time ................................................................................................................................... 62
7.2.4 Wait .............................................................................................................................................. 62
7.2.5 Taring ........................................................................................................................................... 62
7.2.6 Set tare ........................................................................................................................................ 63
7.2.7 Strain ............................................................................................................................................ 64
7.2.7.1 Determining the strain .......................................................................................................... 65
7.3 Functions 2 ...................................................................................................................................... 66
7.3.1 Conditional Jump ......................................................................................................................... 66
7.3.2 Jump ............................................................................................................................................ 67
7.3.3 Set Output .................................................................................................................................... 67
7.3.4 Set Status .................................................................................................................................... 68
7.3.5 Dialog Window ............................................................................................................................. 68
7.3.6 Comment ..................................................................................................................................... 69
8 Manual Operation .................................................................................................................................70
8.1 Jog ................................................................................................................................................... 71
8.2 Hand wheel function ........................................................................................................................ 72
8.3 Graph Recording in Manual Mode ................................................................................................... 72
1
9 Program Change...................................................................................................................................74
9.1 PC as program storage device ........................................................................................................ 74
9.2 PDM as program storage device ..................................................................................................... 76
9.2.1 Synchronisation PDM - PC .......................................................................................................... 77
10 Graph .....................................................................................................................................................80
10.1 Graph Window ................................................................................................................................. 80
10.2 Graph Menu ..................................................................................................................................... 82
10.2.1 Zooming in the Graph .............................................................................................................. 82
10.2.2 Edit Gaugings .......................................................................................................................... 83
10.2.3 Editing Envelopes .................................................................................................................... 84
10.2.4 Name Step ............................................................................................................................... 85
10.3 Edit as Table .................................................................................................................................... 85
10.4 Curve overlay ................................................................................................................................... 87
10.5 Graph Settings ................................................................................................................................. 87
11 Print .......................................................................................................................................................89
11.1 Curve Report ................................................................................................................................... 89
11.2 Program Listing ................................................................................................................................ 90
11.3 Printer Settings ................................................................................................................................ 90
12 Service ...................................................................................................................................................91
12.1 Station Settings ................................................................................................................................ 91
12.1.1 Station ...................................................................................................................................... 91
12.1.2 Inputs ....................................................................................................................................... 93
12.1.2.1 Position ............................................................................................................................ 94
12.1.2.2 Force ................................................................................................................................ 95
12.1.2.3 Virtual Inputs 1 – 4 ......................................................................................................... 101
12.1.2.4 Calibration ...................................................................................................................... 103
12.1.2.5 Slope .............................................................................................................................. 106
12.1.2.6 Live Input ....................................................................................................................... 108
12.1.3 Profibus DP ............................................................................................................................ 109
12.1.4 PROMESS Bus ...................................................................................................................... 110
12.1.5 Homing................................................................................................................................... 111
12.2 General Settings ............................................................................................................................ 113
12.3 Inputs/outputs ................................................................................................................................ 116
12.4 Service Dialog for Bus Systems .................................................................................................... 116
12.5 PROMESS BUS ............................................................................................................................ 117
12.5.1 Beckhoff Expansion Service Dialog ....................................................................................... 120
12.6 Safe data export ............................................................................................................................ 121
12.7 Parameter Access ......................................................................................................................... 122
12.8 Backing Up the Parameters ........................................................................................................... 122
13 Software installation ..........................................................................................................................124
14 Communication PC - Application module .......................................................................................124
14.1 Connection Ethernet module ......................................................................................................... 124
14.2 Ethernet Communication ............................................................................................................... 125
14.3 Assignment IP address Ethernet Module ...................................................................................... 127
14.4 Assign IP Adress PC ..................................................................................................................... 129
2
14.5 Assign IP Adress PC Windows 7 ................................................................................................... 130
14.6 No Ethernet module found ............................................................................................................. 132
15 Firmware Update ................................................................................................................................133
15.1 Version 5.00 to V5.2x .................................................................................................................... 134
15.2 From Version 5.03 ......................................................................................................................... 138
16 Installation of CPR V4 Manager ........................................................................................................142
16.1 COM Test....................................................................................................................................... 146
17 PLC Interface ......................................................................................................................................147
17.1 Reference motion after start-up ..................................................................................................... 147
17.2 Reference motion without a request .............................................................................................. 148
17.3 Cycle start ...................................................................................................................................... 148
17.4 Emergency Stop during a motion .................................................................................................. 149
17.5 Emergency Stop during standstill process .................................................................................... 149
17.6 Cycle Stop...................................................................................................................................... 150
17.7 Selection of Program Number ....................................................................................................... 151
18 Calibrating the Strain Gauge Amplifier (BA 626) ............................................................................152
19 PROMESS Bus ....................................................................................................................................154
19.1 Bus Terminator. ............................................................................................................................. 155
19.2 Cable Shield Connections ............................................................................................................. 156
19.3 Node - Address .............................................................................................................................. 157
3
Introduction
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1 Introduction
The UFM-NC-MODULE system is a powerful tool to rapidly setup, alter, optimize
and adapt press and positioning tasks.
The basic element is the electro-mechanical assembly unit from PROMESS,
consisting of:
Several press units can be connected via a network and programmed from a single
programming device.
The following figure shows a block schematic:
4
Installing the Software
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To install the UFM software and database plugin on a PC, run “Setup.exe” from the
installation CD.
Choose the language to be used for the installation.
• C:\Promess\UFM5
Standard – installation directory (can be chosen freely).
• Directory for storing runtime data that is created or modified while using the
program.
– Windows 7 / Vista
C:\ProgramData\Promess\UFM5
C:\ProgramData\Promess\UFMRDatabase
The “ProgramData” folder is not visible by default in Windows 7 and Vista. You
can also open this folder from the path
“Programs\Promess\UFM5\Service\Backup”.
5
Installing the Software
– Windows XP
The “Application Data” folder is not visible by default in Windows XP. You can also
open this folder on the path “Programs\Promess\UFM5\Service\Backup”.
6
Software Start
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3 Software Start
To run the software please click the installed icon. If the network is set up correctly
the following screen opens.
7
User and Rights Administration
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4.1 Login
The login dialog for logging in to the system is available in the menu
bar.
There are two different cases of logins into the UFM software:
Case 1: There is no standard user.
Start of UFM
• Login dialog appears
• The user must log in correctly.
• If “Cancel” is pressed, the software will close.
Logout
• If a user logs out (logout button in login dialog), then the login dialog remains
open (modal) until the login is correctly performed. In this situation, the
software cannot be ended.
Change User
• If a user opens the login dialog to change users, the logout option does not
have to be used. Instead, the user can simply enter their login name and
password and confirm them.
8
User and Rights Administration
Start UFM
• The login dialog does not appear and the software starts directly.
• The standard user is not logged in automatically.
Logout
Case 1: log in as standard user.
• It is not possible to log out.
Case 2: Another user has logged into the system as the standard user.
• The logout button causes the current user to be logged out and the standard
user logged in.
Change User
• If a user opens the login dialog to change users, the logout option does not
have to be used. Instead, the user can simply enter their login name and
password and confirm them.
9
User and Rights Administration
Right codes:
C = Configure system (service)
P = Edit program
S = Edit steps
L = Load/save programs
M = Start movement
A user with administrator rights is entitled to create new users, to delete them and
to assign rights.
By default, a standard “UFM User” has been created with reduced rights. You can
delete this user at any time.
Delete User
To delete a new user, select the user in the user list. Next, click “Delete User”.
Change Password
When logged in as administrator, you can change the password of a user. First
select the user in the list and then enter the new password. Next, click “Apply
User”.
Users who are currently logged in can also change their own passwords. To do this,
click “Change Password” to open the following dialog:
10
User and Rights Administration
Standard User
A standard user can be defined. If this is the case, the login dialog does not appear
when the program is started and the standard user will be logged on automatically.
To activate a user as a standard user, select the user in the user list and click the
“Standard User” button.
To deactivate the standard user, click the button again.
Export Users
This button can be used to export the entire User List including their rights.
Import Users
This button can be used to import a saved User List including their rights.
1 Administrator (permission for all actions and granting rights to other users)
a. Open/edit user administration
b. Edit reference run
2 Program editing
a. Insert/remove steps
b. Edit program preselection
c. Create new programs
d. Automatically receives rights 3 and 4
4 Load programs
a. Load programs to change current program in NC module
b. Send programs
5 Movements
a. Start, step, stop, reference run
b. Manual operation, hand wheel
11
User and Rights Administration
6 Configuration
a. Service
b. Unidrive parameters (parameter backup)
c. Safe data export
No rights
• The following message will appear: “No permission for this function”.
Default settings
The UFM is delivered with the following settings:
12
Log function
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5 Log function
You can access the log function through the user administration
• Log table
The Log Table stores the following results for the stations:
– Logging in
– Logging out
– Saving programs
– Changes to program
– Parameter backup
– Changes to program presets
– Station settings
– User settings (permissions)
13
Log function
• Log file
Log files are stored under the *.log file extension for each station in the “log”
subdirectory under the ID path. This is where details on the changes to the
programs and system configuration are stored.
A separate log file is created for each joining program.
Double-clicking a log file in the log table will open it if a log entry exists in
“Details”.
14
Log function
Choose the file to be deleted using “Open” and confirm your choice with
“Yes”
15
Program Window
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6 Program Window
The program window consists of the following elements that you can show and
hide using the “Display” menu.
Sensor display
Menu bar
Parts ID
Toolbar
Plugin bar
Step List
Variables
Status information
Step information
16
Program Window
Measurement values and variables have docking feature that allows them to be displayed at any of 4
different positions.
Available docking
positions
The bar with the sensor indicators and buttons for starting movements cannot be
hided.
Function List
Step List
17
Program Window
• Step:
Step number
Signal graphs
Status information
Communication errors
18
Program Window
Parts ID
If IDs have been captured for manufactured parts, they can be displayed here.
Variables
Displays values of variables used in program.
Measurement data
Plugin
Toolbar
Optimum view
Open Print Insert
Delete Arrange stations Load program
program step step
Full view from NC module
of graph
Buttons
19
Program Window
Sensor indicators
The force, path and other definite sensor values can be displayed here.
Lock
Locking can be used to “freeze” the screen so that the arrangement can no longer
be modified. Both this and the “unlocking” function require administrator rights.
By pressing the F11 function key, you can switch between full screen and normal
view.
20
Program Creation
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7 Program Creation
To create a new program, choose “File / New” or click the button on the toolbar.
You create a program by inserting functions into the Step List. The Step List is
processed step-by-step when the program is started.
Choose
the required function:
21
Program Creation
All functions required to create the program steps can be accessed by right-clicking
the Step List.
Steps can be copied, inserted or deleted using the mouse or keyboard.
CTRL + Del.: Erase Step
CTRL + Ins.: Insert step
CTRL + C: Copy step
CTRL + V: Paste step
The right mouse button can also be used to copy and paste program steps.
Once saved, programs can be opened or deleted in the file menu under “Open
Program“.
A comment can be added to any function step using the comment field. This
appears in the comment column of the Step List.
22
Program Creation
Parameter
In the following boxes, enter the values you require or choose a variable:
• Position
Depending on which option is selected, positions can be approached
relatively or absolutely.
• Speed
• Acceleration
• Braking rate
The ratio of acceleration to braking rate should not exceed 5:1 or 1:5.
Recommendation 1:1
Overload
23
Program Creation
Data Acquisition
Choose the sensors for X and Y as well as the resolution for the X variable. You
can use the position or the time as the reference variable X of the data acquisition.
This recording can also be monitored.
A second sensor can be chosen for a second data acqisition using the same
reference variable. This recording can not be monitored.
Monitoring
24
Program Creation
• Only load NOK curves: When this option is selected, NOK curves are
transferred to the PC.
The envelope curves are employed relatively to the end Y value of the step.
The differences between curve end value end the points of the envelope
curves are defined by the teaching procedure. If the envelope curve is
edited, the difference is accordingly corrected.
Y
Y
Y
curve 2
X
curve 1
25
X
Program Creation
The envelope curves are employed relatively to the end Y value of the step.
The differences between curve end value end the points of the envelope
curves are defined by the teaching procedure. If the envelope curve is
edited, the difference is accordingly corrected.
• Teach Adjustment
After defining your monitoring strategy, determine the number of points to be used
to teach the envelope and the distance from the envelope to the actual curve.
26
Program Creation
7.1.1.1 Options
• Target window
• Strain compensation
– Standard
The strain compensation is active until the target window is reached.
27
Program Creation
If slip-stick effects occur, it might happen that high peak forces are gauged shortly
before reaching the target position. This might create an over shoot of the axis.
This is caused by the fact, that the axis cannot reach the target position with the
set brake ramp when the signal peak is reduced.
– Advanced
In the advanced mode it is possible to stop the compensation within 100 and 0
percent of the brake ramp. The axis will move to the target position that is updated
when the strain compensation is stopped.
Since the compensation for the position read out is continued to avoid a position
gap between the steps, there is a difference between the position value in the read
out and the target position. Because the target position is no longer adjusted when
the compensation is stopped. Therefore it might be necessary to adjust the target
position of the step.
28
Program Creation
The trigger function allows you to control the movement in various ways using up
to 7 sequential conditions. Using the signal inputs and digital user inputs, you can
modify the following parameters:
• User outputs
• Variables
• Tare
• Speed and target position (parameters)
• Resolution of recorded data (other)
When the specified condition becomes true, you can control the ensuing action in
the following manner.
29
Program Creation
Target
30
Program Creation
When the switch is set, the status will be set to NOK, if the trigger chain is not fully
executed.
31
Program Creation
Parameter
• Signal source: Choose the sensor input to be used to stop the movement.
In the following boxes, enter the values you require or choose a variable:
• Sensor limit: Enter the required condition to trigger the stop.
• Preliminary position: The entered speed is used while approaching this
position (depending on the option, the positions can be entered as relative or
absolute values).
• Speed to Prel. Pos.: Enter the speed to be used while approaching the
preliminary position.
• Acceleration: Acceleration during movement
• Max. force-fitting position: The joining unit is driven up to this position as a
maximum.
• Force-fitting speed: Speed up to the start of the block range. The speed
change from the speed up to the preliminary position for force-fitting is
performed using a maximum braking ramp. For an increasing signal, the
speed is reduced to minimum 1% or maximum 100% (no controlling) of the
32
Program Creation
entered force-fitting speed. (For settings, see Options). The minimum speed
for controlling can be adapted to your problem in the program parameters.
Overload
Data Acquisition
Choose the sensors for X and Y as well as the resolution for the X variable. You
can use the absolute encoder (internal or external) or the time as the reference
variable X of the recording.
A second sensor (Y2) can be chosen for a second data recording using the same
reference variable.
Monitoring
33
Program Creation
• Only load NOK curves: When this option is selected, NOK curves are
transferred to the PC.
The envelope curves are employed relatively to the end Y value of the step.
The differences between curve end value end the points of the envelope
curves are defined by the teaching procedure. If the envelope curve is
edited, the difference is accordingly corrected.
Y
Y
Y
curve 2
X
curve 1
34
Program Creation
The envelope curves are employed relatively to the end Y value of the step.
The differences between curve end value end the points of the envelope
curves are defined by the teaching procedure. If the envelope curve is
edited, the difference is accordingly corrected.
• Teach Adjustment
After defining your monitoring strategy, determine the number of points to be used
to teach the envelope and the distance from the envelope to the actual curve.
7.1.2.1 Options
As the shutdown value is approached, the speed is slowed down. You can set the
minimum force-fitting speed to between and 1 and 100 percent. 100 percent
means no speed controlling; thus, the module will travel constantly at the force-
fitting speed.
The controller profile allows you to control how strongly the speed depends on the
approach to the target.
35
Program Creation
When the switch is set, the status will be set to NOK, if the trigger chain is not fully
executed.
36
Program Creation
The trigger function allows you to control the movement in various ways using up
to 7 sequential conditions. Using the signal inputs and digital user inputs, you can
modify the following parameters:
• User outputs
• Variables
• Tare
• Speed and target position (parameters)
• Resolution of recorded data (other)
When the specified condition becomes true, you can control the ensuing action in
the following manner.
When the switch is set, the status will be set to NOK, if the trigger chain is not fully
executed.
37
Program Creation
Setpoint
Start
controller
profile
Controller profile
38
Program Creation
Parameter
• Setpoint
• Start controller profile
This entry is relative to the setpoint.
• Signal direction
Enter whether or not the signal to be controlled becomes larger with
increasing position.
• Min. controller position
Enter the minimum permissible position (absolute or relative to start position
of function).
• Max. controller position
Enter the maximum permissible position (absolute or relative to start position
of function).
If the permissible positioning range is overrun, the step is stopped, the part
status will be set to NOK and the error message “Signal limit not reached”
will appear.
• Start Speed
This is the speed at which the controlling process begins and it is reduced
within the controller profile.
• Acceleration
This value applies to how setpoints are approached and the value can be
reduced for the controller profile under “Profile”.
• Duration
Enter the required controller duration. This time starts counting down when
the control value is reached for the first time. The time You can also set the
duration by using a variable.
Notice
You can also stop the control process by the rising edge of an arbitrary input.
Overload
Data Acquisition
39
Program Creation
During the control process, all activated sensor inputs can be recorded as a
function of Time.
This recording can also be monitored.
An additional sensor can be used for a second recording. This recording cannot be
monitored.
Monitoring
40
Program Creation
• Transfer only NOK curve: When this option is selected, only NOK curves
are transferred to the PC.
The envelope curves are employed relatively to the end Y value of the step.
The differences between curve end value end the points of the envelope
curves are defined by the teaching procedure. If the envelope curve is
edited, the difference is accordingly corrected.
The envelope curves are employed relatively to the end Y value of the step.
The differences between curve end value end the points of the envelope
curves are defined by the teaching procedure. If the envelope curve is
edited, the difference is accordingly corrected.
• Teach Adjustment
41
Program Creation
• Min. acceleration
Here you can enter the maximum reduction for the acceleration in the control
profile. The reference value is the acceleration entered under Parameters.
You can enter a minimum acceleration for the profile range as a value
between 1 and 100 percent.
The trigger function allows you to control the control process in various ways using
up to 7 sequential conditions. Using the signal inputs and digital user inputs, you
can modify the following parameters:
• User outputs
• Variables
• Tare
• Speed and target position (parameters)
• Resolution of recorded data (other)
When the specified condition becomes true, you can control the ensuing action in
the following manner.
42
Program Creation
Jumps back to the previous trigger condition. This is always the last trigger in
a trigger chain.
When the switch is set, the status will be set to NOK, if the trigger chain is not fully
executed.
43
Program Creation
7.2 Functions 1
7.2.1 Variables
There are 64 variables available for the process. This function can be used to
assign a variable to, for instance, the current position, a numerical value, the value
of a recorded variable or external sensor through the analogue input.
Furthermore, you can also perform calculations using these variables.
The values 1 to 58 of the variables are only saved temporarily in RAM.
When changing the program, variables 1 to 58 are set to zero.
Variables 59 to 64 will still be saved after changing the program and shutting
down.
• Current station
A value is assigned to a variable of the current station.
• Other station
To use this option it is necessary to connect another station using the PROMESS-
Bus.
44
Program Creation
Choose a variable to which you want to assign the value of a variable of another
station.
Choose the node address of this station.
In this example the value of variable 9 of the station with the node address 13 is
assigned to variable 1.
Alais name
45
Program Creation
46
Program Creation
7.2.2 Gauging
It is possible to record values during step recording and for independent data
logging.
This function can be used to determine the actual values, maximum values,
minimum values and average values for all active signals independently from the
step recordings. The measurements are captured at a frequency of 500 Hz.
47
Program Creation
Alias Names
Gauing definition
• Gauging
Choose the measurement to be defined.
– Signal
Choose the signal input to be recorded.
• Type
Choose the type of measurement to be performed:
– Actual value
A value (Y) is recorded that exists when the step is performed. A
second signal can be recorded as the X value but not monitored.
– Single value
A single value is recorded when the trigger condition is true.
– Average
The average value is determined across a range when the trigger
condition is true.
– Max. Value
The maximum value is determined across a range when the trigger
condition is true.
– Min. Value
The minimum value is determined across a range when the trigger
condition is true.
– Variable
The measured value is assigned to a variable. This makes it easy to
monitor a variable.
You can assign a freely definable alias to the measured values that will then be
displayed in the functions. These names will be saved in the program files.
48
Program Creation
49
Program Creation
Reference point
• Absolute
The reference point is the absolute sensor value
The reference point of the measurement is the origin of the coordinate
system (0/0) for the X and Y axes.
• Relative
The following can be a reference point:
Start: The start of the next step in the movement.
End: The end of the next step in the movement.
– If: The reference point results from a freely programmable condition.
50
Program Creation
51
Program Creation
rel. 0
Ref. point
Value 3 mm in front of “Block”
X [mm]
-3
rel.0
52
Program Creation
53
Program Creation
Trigger
• Trigger average
• Trigger maximum value
• Trigger minimum value
Choose the sensor input to trip the trigger and enter the
limits to be used when determining the average, maximum or minimum
values.
• Trigger variable
No trigger entry necessary.
Monitoring
The monitored Enter the upper and lower limits for measurement. If these limits are violated, the
signal is status of the measured value and the global status will be set to NOK.
displayed.
Options
54
Program Creation
Choose this option to allow the limits to follow the reference point.
– Limit monitoring absolute, “Rel. to reference point” option has not been
selected.
The movement is “Press to Signal” with a limit value of 50 N. The maximum value
is determined from 0,3 to 0,6 mm in front of the block.
55
Program Creation
Now the limits must be set relative to the block value of 50 N. To set the limits for
an identical curve to the absolute values OG 40 N and UG 30N, the upper limit
must be -10N (40 - 50 = - 10) and the lower limit -20 N (30 – 50 = - 20).
If the option is selected without adapting the relative limits, the following will occur:
The upper limit lie at 90 N and the lower limit at 80 N, since 30 N or 40 N is added
to the reference value of 50 N.
56
Program Creation
! If “Rel. to reference point” is chosen for limit monitoring, the limits must be
entered relative to the reference point.
• Display abs. values
If this option is selected, the X value of the absolute sensor value will be
displayed, even though the trigger causes the measurement to be recorded
relative to the reference point.
To ensure that the data will be recorded, triggering of the reference variable X must
be activated.
57
Program Creation
To create the step-based gaugings, click the “Curve Data” button under
“Monitoring” in the “Position”, “Join on Signal” or “Controller Module” functions.
Both curve and step-independent data share the maximum of 16 data points
and are displayed together in the measurement panel.
All types of measurement data can be defined for step-independent data logging.
See chapter Fehler! Verweisquelle konnte nicht gefunden werden.
58
Program Creation
This type allows the data recorded during the step to be monitored within a window
.
To create a window, enter the min. and max. values for the X and Y axes. This
defines the coordinates of the 4 window edges.
• Not allowed
The actual curve must not cross this edge.
• Neutral
59
Program Creation
The actual curve of this edge may cross this edge from any direction for any
number of times.
If the arrows are used, the curve must enter and exit the window across
these edges. If a neutral edge of the window is crossed instead of the
required edge, a NOK status will be generated.
If several arrows with the same orientation are used, these are linked to
each other by a logical “OR” condition.
• Window value
– Average
– Maximum value
– Minimum value
– Final recorded value
Enter the required settings in order to determine a value within a given window.
Reference point
Measurements can be recorded as absolute or relative values. These are defined
using reference points.
• Absolute
The reference point is the absolute sensor value
The reference point of the measurement is the origin of the coordinate
system (0/0) for the X and Y axes.
• Relative
The following can be a reference point:
Start: The start of the next step in the movement.
End: The end of the next step in the movement.
60
Program Creation
Options
Choose this option to allow the limits to follow the reference point.
If this option is selected, the X value of the absolute sensor value will be
displayed, even though the trigger causes the measurement to be recorded
relative to the reference point.
Step-based gaugings are shown in the step list as a row attached without a
step number.
61
Program Creation
You can program waiting times to be used while running the program cycle. The
delay time is entered in seconds (min = 0.001 seconds / max. 99999999 seconds =
approx. 2777 hours), or transferred as the value of a variable.
7.2.4 Wait
The program continues, when the condition is true. You can set a time out. Within
the set time the condition has to become true, otherwise the cycle is continued with
the set step.
7.2.5 Taring
This function can be used to tare a signal input. This means that the sensor is set
to zero during execution.
62
Program Creation
If the “Tare” command is executed, the software tests whether the nominal load
can still be displayed, because taring the utilizable range of the AD converter may
not be sufficient.
If this is the case, the following warning will be issued: Sensor offset has moved
This function will set the signal input to any given value. If tare is set to zero, it will
be removed from the system. Next, the unaltered values resulting from the
calibration data will be displayed.
63
Program Creation
7.2.7 Strain
This function allows you to compensate for bending in the press frame resulting
from the forces applied during the positioning movement. In accordance with the
Strain factor, the shaft is positioned further down. The compensation is linear.
• Sensor
Choose the sensor to be compensated.
• Signal input
Choose the signal to be used for calculating the Strain compensation.
• Value
Enter the strain to be created by a specific force (per).
Strain can only be compensated for positioning steps. For all other steps
where this is active, only the positioning display is compensated. The
movement is not affected.
The strain factor is reset at each program start regardless whether or not it
has been programmed. This prevents strain factors from other programs from
being re-used in other programs.
64
Program Creation
Determine the difference between the position and the signal value.
Finally, enter these values.
65
Program Creation
7.3 Functions 2
• Condition
• Variables
• Boolean variables (true / false)
• Branch target
Enter the target of the branch.
The branching step is displayed bright blue in the Step List when you select the
condition in the Step List.
66
Program Creation
7.3.2 Jump
With this function you can jump to any step within the cycle.
(For this, hardware expansion modules such as Profibus or CTNet I/O are
necessary)
67
Program Creation
• Message
Enter the text here to appear in the dialog step.
• Input confirmation
Select this option to display only a confirmation message on the screen. The
message may consist of maximum 30 characters.
• Parts ID
Dialog for entering part IDs into the database. A maximum of 20
alphanumerical characters can be used for ID1 and ID2. For ID3 you can
use a maximum of 80 characters.
• DB Integer 1
68
Program Creation
If you choose this option, the unit must be restarted after quitting this dialog with
“OK”.
Once the cycle has been completed, the following input window appears.
Confirm each entry with “OK”. If this confirmation is not given, the unit can not be
started again (cycle stop) or the cycle will remain interrupted until confirmation is
given.
7.3.6 Comment
This command only serves to insert comments into the Step List for purposes of
structure.
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Manual Operation
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8 Manual Operation
To operate manually, open the “Command” menu and select “Manual Operation” or
press the F5 function key.
• Position change
Relative path to travel when extending/retracting.
• Speed
Speed that is traveled during continuous extension/retraction.
• High speed
High speed that is traveled during continuous extension/retraction.
• Acceleration
Acceleration value to be used for movements.
70
Manual Operation
• Analog
Here, you can select a sensor input and determine the value at which the
unit is to be stopped, similar to the “Join on Signal” function.
Test direction
Determines which direction of movement is to be used to activate
the shutdown by signal.
• Overload
Choose the overload source and the shutdown value for each direction to
protect the system.
8.1 Jog
Starts a reference
run if necessary.
Shaft drives around the
programmed path. If the
button is released before the
movement has ended, the
press will stop. To travel the
programmed path again, When this button is pressed,
press this button again. shaft drives at the
programmed fast speed until
the button is released again.
71
Manual Operation
Switches between
positioning and analog
mode
• Transmission ratio
This option allows you to set the ratio between the input and output pulses. A ratio
from 1:1 to 1:100 can be adjusted.
Deletes
displayed
curve
To do this, select the reference variable X and the dependent variables Y, Y2.
72
Manual Operation
• Optimum View
This option allows you to find the best scaling for the curve in the graph
window.
When this option is not selected, the graph will be scaled according to the
values currently displayed.
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Program Change
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9 Program Change
The NC module programs can be changed manually using the PC or through the
PLC. Using the PC, open the program that you wish to send to the NC module and
confirm this in the next window with “Yes”.
To change the program using the PLC, you first have to enter the programs into an
allocation table because the program can only be opened from the PLC using
binary-coded numbers.
If you use a PDM as storage, you can use the UFM without a PC, in case data
storage is not required.
Program pre-selection
You can access the allocation table through the file menu.
Choose the “Program Pre-selection” option or click the corresponding button on the
toolbar.
74
Program Change
• Program assignment
To delete a program assignment click do right click at the program and choose
“delete”
75
Program Change
To use a PDM as a program storage device, you have to activate this function
in the menu „Service/Station settings/Station“.
Program pre-selection
You can access the allocation table through the file menu.
Choose the “Program Preselection” option or click the corresponding button on the
toolbar.
• Program assignment
When the programm was send successfully to the PDM you see the following
dialog:S
76
Program Change
The synchronisation displays whether the stored programs at the PC and the PDM
are identical.
Green = synchronous
77
Program Change
Programs that are at in asynchronous state are displayed red in the chart.
To re-establish the synchronous state you must overwrite the program either at the
PC or the PDM.
• Program Pre-selection
Using this button you can load a stored program pre-selection chart.
If you close the program pre-selection dialog, the chart is always stored at the PC
in: C:\ProgramData\Promess\UFM5\UFM\“NC-Module Path”\”Program_PDM
serial number.txt“
This is for example helpful, if you like to use the same pre-selection chart at
multiple stations. You do not have to create the chart over and over, because you
can load the chart file from the station you created it once.
Attention
You should make a backup of this file, when you have finished the assignment, so
you can load it, in case the PDM fails.
78
Program Change
To delete part programs in the PDM storage click the button “delete”.
Choose the part programs to be deleted and confirm with “OK”
• Sort
To call the “sort by …” function, do a right mouse click at the program pre-selection
chart.
• # (program number)
• Program name
• Date PC
• Date PDM
• Status (synchronous / asynchronous)
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Graph
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10 Graph
This is only possible for gaugings whose scaling corresponds to the axis
scaling.
80
Graph
81
Graph
• Section
While pressing down the left-mouse button, draw a box containing the view
you wish to display.
While pressing down the right-mouse button in the graph, you can move the
displayed section of the curve in all directions.
82
Graph
To select a gauging or window, left-click the gauging or its limits when the mouse
cursor is displayed as a hand symbol. The limits are shown in magenta.
• Moving the gauging limits without changing the distance to the limit points
Left-click a limit (mouse cursor is displayed as a hand symbol). Hold down the
mouse button and move the limits.
• Moving the gauging limits while changing the distance to the limit points
Left-click a corner point (mouse cursor is displayed as a hand symbol). Press down
the mouse cursor and move the point.
83
Graph
84
Graph
This function can be used to assign names to the tabs of the steps being
monitored.
The following table will open. Click the cell to be edited and enter the new value.
You can copy the table to Clipboard, edit it, and paste it back in from Clipboard.
85
Graph
86
Graph
Here you can set the colours of the graph elements such as curves, gaugings,
backgrounds and the axis scaling, for instance.
Right-click the graphic or open the “Graph” menu and then choose “Settings”.
• General
Settings for axis scaling, background colour, axis labelling and the border
colours of the part status
87
Graph
• Curves
• Gauging
Settings for gauging colour, as well as line width and colours to indicate the
part status
You can also adjust the transparency of the OK and NOK colour for the window
gaugings.
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88
Print
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11 Print
The “Print” function is available in the “File” menu or by clicking the button in the
toolbar.
• Curve report: Printout of graph with status messages for displayed step
• Program listing: CNC program
11.1 Curve Report
89
Print
This dialog can be opened from the File menu and allows you to configure your
printer.
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90
Service
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12 Service
The Service menu allows you to make the following settings:
91
Service
You can store the program in the NC module in various different ways:
1. Non-volatile memory (permanent memory): The programs will be saved
even after switching off the power. (Max. program size: 300 longs)
2. Volatile memory: The programs will be lost when the main power is
switched off and must be reloaded after switching back on again. (max.
program size: 2000 longs)
The program size is displayed beneath the Step List.
Communication parameters
• Baud rate
Sets the baud rate between the Ethernet module and the controller.
• Ack-Bit behavior
92
Service
I/O configuration
Variables
Here, you determine how many decimal places to display with the variables.
• Name: Here, you define the station names as they are to be displayed in the
header of the UFM software for the active station.
12.1.2 Inputs
This is where you define the sensor inputs for your system.
There are two predefined settings: The position of the UFM encoder and the force
input.
Three other inputs offer predefined functionality but are freely programmable:
Slope, Slope 2 and live input.
• Activated
Here you can configure whether to use the sensor in the system.
• Visible
Determines whether the input will be visible in the online sensor display.
93
Service
12.1.2.1 Position
You cannot edit these values because they are predefined by Promess.
• Decimal points
Choose how many decimal places are to be displayed for the position.
94
Service
12.1.2.2 Force
Configuration
Choose the input where the force transducer is connected to. There are the
following possibilities:
PDM-S
95
Service
When selecting PDM-S you can choose the defined link in the PROMESS-Bus.
Select the one that transfers the value you want to use.
To define further links open the link list box or define the link using the PROMESS-
Bus dialogue
.
This input boxes display the maximum values that can be achieved using the
current calibration, since the chosen AD input only reaches its maximum
digital value for these values.
• Unit
Choose the units to be displayed for the sensor.
• Smoothing
This adjusts the force sampling rate in the PDM-S from 0.1 to 2.7ms.
• Decimal points
Choose how many decimal places are to be displayed.
• Alias
You can assign a freely definable alias, that will then be
displayed in the functions
PDM-S offers the option of grid calibration. This allows the force sensor to
be linearized using up to 10 straight lines to compensate for non-linearity in
the sensor characteristic.
96
Service
deviation
deviation
grid calibration
If you have set up a new PDM-S in the PROMESS-BUS, open the standard
settings dialog by clicking the “Standard Settings” button.
97
Service
Enter the sensitivity of the strain-gauge sensor in mV/V together with the nominal
load.
Confirm with “OK”.
The following message appears:
If you really want to configure a new PDM-S, confirm again by clicking “OK”.
Otherwise click “Cancel” to prevent deleting the existing calibration.
Click OK to calculate a two-point calibration curve for the PDM-S using the values.
This does not replace the calibration curve of the force sensor.
You have the possibility to adjust the ADC input voltage to use a wider range of the
AD converter, if the sensor sensitivity differs to the 2 mV/V standard. Further you
have the ability to use sliding wage scaling to filter.
The supply voltage of the strain gauge sensor is 10 VDC. The sensor signal can be
amplified by factor 21 or 231.
The input range of the AD converter you can choose3 levels:
– +/- 0.625 V
– +/- 1.25 V
– +/- 2.5 V
Next, perform the calibration as described below or use the PROMESS calibration
plugin:
Calibration PDM-S
98
Service
Next, open the “Manual Procedure” dialog and apply a force load to the sensor for
a point to be defined.
Attention
While moving along the axis, be sure to read the force value from the
reference sensor to prevent overloading the test specimen.
While entering the calibration points, you can move the sensor with no restrictions.
You can also freely choose both the quantity (2 to 11) and position of the various
points.
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Service
Configuration
• Factor / Offset
These values are only for purposes of display and are calculated from the
results of the calibration (see Calibration section 12.1.2.4).
• As with Unit, the Min. and Max values are given by the UFM type.
(only for display purposes)
Max. possible value
sensor
( max. value A/D
converter
• Smoothing
This applies a smoothing function to the force value from 1 to 8 ms.
• Decimal points
Choose how many decimal places are to be displayed.
• Alias
Here you can enter a freely definable name for the force sensor. This sensor
is then displayed in the functions under this name.
If the max. possible sensor value is lower than the nominal value of the
sensor in use, the analogue preamp has to be recalibrated. See Technical
Manual (“Strain Gauge Amplifier” section).
If you choose a distance unit, you have set whether the signal chance is
100
Service
Configuration
• Input
Choose the hardware source here that is connected to the sensor.
Sources can include:
o PDM-S
Force (Strain gauge)
Encoder
o Drive
Analog input 1 (force)
Analog input 2
Analog input 3
Encoder input: drive
Encoder input: module
Motor current
Current speed
Speed setpoint
101
Service
Acceleration setpoint
Current position
Position setpoint
Target Position
o Variables
64 variables
o Drive Com
– Requires release of sensor from other stations (see section
Fehler! Verweisquelle konnte nicht gefunden werden.)
o Beckhoff
4 analog inputs (1 – 4)
o User Inputs
16 inputs
Optional; field bus or CTNet I/O expansion module required
• Factor / Offset
These values are only for purposes of display and are calculated from the
results of the calibration (see Calibration section).
This input boxes display the maximum values that can be achieved using the
current calibration, since the chosen AD input only reaches its maximum
digital value for these values.
• Unit
Choose the units to be displayed for the sensor.
Changing the units, e.g., from N to kN, has no effect on the calibration factor.
This has to be manually changed.
• Smoothing
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Service
• Decimal points
Choose how many decimal places are to be displayed.
• Alias
Here you can enter a freely definable name for the input. This sensor is then
displayed in the functions under this name.
12.1.2.4 Calibration
You can directly enter the factor and offset of the straight-line approximation
if your sensor is equipped with a standardized ±10 Vdc.output signal, for
instance.
In general, you can record the first point as a reference point because no force is
applied there.
To create the first point, click the button in front of the Digital Value box of Point 1.
103
Service
Install the reference sensor inside the holder. Ensure that the nominal load of the
reference corresponds to the load of the joining unit.
• Position change
Relative path to travel when extending/retracting.
• Speed
Speed that is traveled during continuous extension/retraction.
• Speed (fast)
Speed that is traveled during fast extension/retraction.
• Acceleration
Acceleration value to be used for movements.
104
Service
• Analog
Here, you can select a sensor input and determine the value at which the
unit is to be stopped, similar to the “Join on Signal” function.
Test direction
Determines which direction of movement is to be used to activate
the shutdown by signal.
This function is only effective if you start using the Analog
Retract/Extend function or when Analog mode is selected while using
the hand wheel mode.
• Overload source
Choose the overload source and the shutdown value to protect the system.
Drive in small steps to approx. 80% of the rated capacity. Watch the force indicator
of the reference sensor so that the unit is not overloaded.
To create the second point, click the button in front of the Digital Value box of Point
2.
When recalibrating, you can also use the “Analog Extend” method.
As the source of the signal limit, choose the sensor to be calibrated and enter
approx. 80% of the nominal capacity as the signal limit. While extending, the unit
will be automatically held at the limit value.
105
Service
12.1.2.5 Slope
• Delta X:
Here, you define the spacing to be used when calculating the slope = ∆Y /
∆X. The higher the noise levels in your signal, the larger the value of delta X
to be used.
• Oversampling
The oversampling function is used to calculate the slope at up to 6
intermediate points when, due to disturbances, a relatively large value of
delta X is used to calculate the slope. This calculation is performed using the
selected delta X. This helps to increase the reaction speed, which is
relatively slow due to the large value of delta X being used.
• Smoothing
Applies a smoothing function to the sensor value. A maximum of 3 values
can be used for smoothing. (zero = single values)
• Decimal places
Choose how many decimal places are to be displayed.
• Alias
Here you can enter a freely definable name for the input. This sensor is then
displayed in the functions under this name.
106
Service
107
Service
• Inputs
Choose the inputs to be combined.
• Operator
The following operations are possible:
+ Addition
- Subtraction
* Multiplication
/ Division
• Factor
This can be multiplied with the result of the operation.
• Decimal points
Choose how many decimal places are to be displayed.
• Alias
Here you can enter a freely definable name for the input. This sensor is then
displayed in the functions under this name.
• Unit
Choose the units to be displayed for the result.
108
Service
12.1.3 Profibus DP
• Profibus settings
Enter the node address for the Profibus DB to be assigned to the station.
109
Service
Do not assign the same node address to different stations. If you do, there will be
no communication on the PROMESS Bus.
Beckhoff extension
110
Service
– program changes and JOG function (7 free digital I/10 free digital O)
– program changes (10 free digital I/10 free digital O)
– free (16 digital I/O)
Using program change, you can use the “Auto-Strobe” function, if you use a
program selector switch. If “Auto-Strobe” is activated, the strobe is set
automatically, when you change the program number.
12.1.5 Homing
Enter the settings here that determine how the system responds to requests for
reference runs.
Overload
Choose the source whose sensor is to be monitored for overloading during the
reference run. Next, enter appropriate limit values. (Source and value have been
preconfigured at factory by PROMESS).
Settings
111
Service
• Home offset
Enter the offset by which to displace the system from the zero point
determined during the reference run.
112
Service
Connect stations
Choose whether all of the network stations are to log on the PC automatically when
the program starts or whether only the preselected stations are to be connected.
To preselect the stations that are to be connected, click the “TCP/IP” button.
Click the “Find” button to display all of the stations available in your network (LED
is lit bright green). Clear the selection for stations that you do not want to connect
to manually.
113
Service
To add further TCP/IP addresses, type them directly into the “TCP/IP Address”
field.
Error message
Here you can configure whether to display the error messages in a window .
Overload Bit 0
Homing error Bit 1
Emergency stop Bit 2
Start signal lost Bit 3
Program error, no program loaded Bit 4
Strain compensation Bit 5
Contouring error too large Bit 6
Max. position reached Bit 7
Reset module Bit 8
Converter has tripped Bit 9
ADC overload Bit 10
Parking brake Bit 11
CTNet Beckhoff IO coupler error (commun./version) Bit 12
Motor overload Bit 13
Sensor Konfiguration Bit 14
Signal limit too early Bit 16
Signal limit not reached Bit 17
Measured value not captured Bit 18
Upper limit violated Bit 19
Lower limit violated Bit 20
Left limit violated Bit 21
Right limit violated Bit 22
Top envelope Bit 23
Bottom envelope Bit 24
Curve memory full Bit 25
Trigger Bit 26
Math error Bit 27
Man. OK Bit 28
114
Service
The slider can be used to set the size of the following elements:
Sensor displays
Size of step tabs used to page between different graphs
Size of start button
– Wide
Language
115
Service
12.3 Inputs/outputs
Here, you can check the digital 24 Vdc I/Os as well as the analogue inputs on the
Unidrive and application module.
• CPU Load
Unidrive SP
Selected control parameters
of the power component are
Application module displayed here. Definitions of
these can be found in the
Unidrive SP manual.
SP.
Profibus
In this window, you can check which of the input or output bits are to be transmitted
through the bus.
116
Service
117
Service
Sources include PDM modules as well as UFM controllers. Only UFM controllers
can be targets.
• PDM
Several signals can be transmitted from a PDM. Typically all available signals are
to be transmitted. In certain exceptions when many links have been configured, it
might be necessary to switch off the excessive signals.
To do this, click the button.
.
The following window appears:
In this window you can activate or deactivate signal transmission from a PDM. The
configured node address, firmware version, serial number and baud rate are all
displayed in addition to the type.
– The OK/NOK source allows you to determine which UFM controller controls
the OK/NOK LED of the PDM_S.
118
Service
Choose the source and target controller and then the signal whose value is to be
transmitted from a source to a drive com input of the target. A maximum of four
drive com inputs can be defined to control the targets.
119
Service
To open this dialog, choose “I/O monitor” in the “Service” menu. Choose the
“Beckhoff I/O” tab.
This option can be used to expand the system to include a maximum of four analog
inputs (12-bit resolution) and 16 user-defined I/Os. When choosing the Program
Transfer option, you also have ten inputs or ten outputs freely available.
Inputs I11 to I15 plus strobe (I16) are used for binary-coded transmission of
program numbers. Outputs O11 to O15 with strobe (O16) are used to mirror the
program number after loading the transferred program.
When Program Transfer and Jog are selected, inputs I8 to I10 have the following
function:
I10 = Jog enable (must be set to use the jog function)
I9 = Jog out (press stamp extends)
I8 = Jog in (press stamp retracts)
The statuses of the inputs and outputs and the digital values of the analog inputs
can be viewed.
120
Service
Safe data export means that the DB healthy bit of the higher level controller (PLC)
is not set until all plugins have written their cycle data and communicated this to
the UFM controller.
If a registered plugin has been quit for instance, this will be shown in red. The DB
healthy bit of the higher level controller is not set until the checkmark is cleared
from the “safe writing” box.
If the plugin was stopped unintentionally, please restart it and do not clear the
checkmark from the box.
121
Service
Parameters from the main component can be viewed and modified here.
Only highly experienced users are permitted to modify the parameters. If you
have any questions about these parameters, be sure to contact the PROMESS
service department.
– Converter parameters
– Parameters of currently connected SM application module
122
Service
• Extensions
The name uses a combination of the UFM type and serial number with the
px5 file extension. The type and serial number are separated by underscore
characters.
Example: 364022_47111802.px5
• Writing Parameters
Click the “Open” button to choose the file that you wish to overwrite. If
preferred, de-select some of the parameters in the file. Only those
parameters that are contained in the file are available here.
Station tag
The article number, serial number of the Electromechanical Press and teh
identification number ot the station are stored here.
When the Mechanical Unit or the Applications module is exchanged, you have to
adapt the data. The maintenance of these data makes sure, that you do not restore
a wrong parameter set.
To change this data you have to have admin rights.
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Software installation
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13 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.
SM Applikation Module
X1 X2
Power Suppl. (extern.) (RS 422) (Pin)
21 22 23 24
11 12 13 14
RX+ TX+ TX- RX-
24V 0V GND NC
25 26 27 28
Stromaufnahme: max. 90 mA
NC NC NC GND Cable:
Cat 5 Crossover PC
Ethernet Module Cat 5 Switch
X4 X5
RS485 (RJ45) RS485 (RJ45)
X3
1 2 3 4 1 2 3 4
NC RX/TX 0V +24VDC NC RX/TX 0V +24VDC Ethernet
10/100 Mbit
5 6 7 8 5 6 7 8
0V NC RX/TX NC 0V NC RX/TX NC
PC
Cable Cat 5
Unidrive
SP
124
Communication PC - Application module
125
Communication PC - Application module
Ethernet
Sub Net mit mehreren Fügeeinheiten und Switch
Ethernet
Ethernet
Ethernet
Ethernet
Switch
Ethernet
126
Communication PC - Application module
If you have not assigned a fixed IP address please do this as described in chapter
14.4 (windows XP), chapter 14.5 (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“.
127
Communication PC - Application module
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.
128
Communication PC - Application module
129
Communication PC - Application module
130
Communication PC - Application module
131
Communication PC - Application module
132
Firmware Update
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15 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.
• PC software UFM
Behind the IP address of the station there is a little star.
(baud rate 115200 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
133
Firmware Update
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.
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.
134
Firmware Update
Click “Next”.
Choose “CT-RTU (Unidrive SP)” as the connection protocol and “Slot 2” under
“Settings”.
135
Firmware Update
=> “Next”
=> “Next”
While an update is running, you can click “Cancel” if necessary to abort the
process.
136
Firmware Update
After a successful update please reset the drive by switching off and on
137
Firmware Update
Before continuing with the “Update”, press the Emergency Stop button on
your system and close all running programs on your PC.
Choose the following in the next window: “Download a compiled program” =>
“Next”
138
Firmware Update
“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 slot 2
(Slot des Applikationsmoduls)
139
Firmware Update
=> “Next”
140
Firmware Update
While an update is running, you can click “Cancel” if necessary to abort the
process.
After a successful update please reset the drive by switching off and on
141
Installation of CPR V4 Manager
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In order to update the firmware in the NC module, the CPR Manager must be
installed on your PC.
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:
142
Installation of CPR V4 Manager
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.
143
Installation of CPR V4 Manager
Next, search for any connected Ethernet modules by choosing the “Search” option
in the “Device” menu.
144
Installation of CPR V4 Manager
Next, choose the IP address that you would like to connect to.
Double-click the selection.
To save the settings, choose “Save Settings” in the “Com Port” menu or click the
Save icon.
145
Installation of CPR V4 Manager
146
PLC Interface
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17 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
Reference request
ACK
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.
147
PLC Interface
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.
17.3 Cycle start
Home request
ts 4
Life Bit
1
Start
2 5
Ack
OK
3
NOK
Description ta tprg 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.
148
PLC Interface
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,
Emergency-Stop
Ack
Description
149
PLC Interface
Ref. request.
ts
L Bit
4
1
Start
5
2
Quit
3
OK
NOK
6
Cycle stop tb
tsch
ta
ta >= 10ms, tb >= 20ms, tsch = Duration of program step to cycle stop
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.
150
PLC Interface
E Prog. Bit 1
E Prog. Bit 2
E Prog. Bit n
E Strobe
A Prog. Bit 1
A Prog. Bit 2
A Prog. Bit n
A Strobe Prog.
Description
1. Creates a binary coded program number
2. Strobe is set for the transfer.
3. Program number is mirrored (0 if no program is valid)
4. Strobe is acknowledged after loading program.
5. Strobe is reset by PLC and NC module.
6. Acknowledgement of program number remains valid until a new Program is
loaded by the other side.
151
Calibrating the Strain Gauge Amplifier (BA 626)
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• 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.
Zero point of
potentiometer
Slope
potentiometer
Repeat this step until you are certain that the system is properly calibrated.
152
Calibrating the Strain Gauge Amplifier (BA 626)
153
PROMESS Bus
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19 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
Bus node 13
terminator
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.
154
PROMESS Bus
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
Pin 6 Pin 8
155
PROMESS Bus
The bus on the Promess PDM digital module can be terminated using the DIP
switch provided there. The location of the switch is shown in the figure below.
terminator
Power
Traco
DIP switch
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.
156
PROMESS Bus
Master 12
Slave 13
Slave 14
Slave 15
• PDM-S
Power
Traco
DIP switch
5 6
4
3
2
1
OFF
ON
157
PROMESS Bus
ON
OFF
1
2
3
4
5
6
158
PROMESS Bus
Node Address
DIP 1 (Bit DIP 2 PROMESS
1) (Bit 2) 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.
159
Index
display abs. values ............................................. 61
A
Display abs. values ............................................ 57
Ack-Bit behavior ..................................................92
Do not test sensor offset .................................... 63
Acknowledgement ............................................147
E
administrator password.......................................12
Alais name variable ............................................45 Edit as Table ...................................................... 85
Alias Names for Data ..........................................48 Edit menu ........................................................... 18
Assign IP Adress PC ........................................129 editing envelopes ............................................... 84
Editing the Step List ........................................... 18
B
Emergency Stop during a motion ................... 149
Beckhoff expansion service dialog ...................120
Emergency Stop during standstill process....... 149
bending compensation........................................64
Envelope monitoring .............................. 24, 34, 40
Bundle at step end ........................................24, 40
envelopes, editing .............................................. 84
bus terminator ...................................................155
Error message ................................................. 114
C Ethernet Communication ................................. 125
Calibrating .........................................................152 Export Users ...................................................... 11
calibration .........................................................103 F
Change Password ..............................................10
Fast motion to zero point ................................. 112
COM Test .........................................................146
feed motion ........................................................ 36
Communication errors ........................................18
Firmware Update ............................................. 133
communication parameters ................................92
Full screen ......................................................... 20
Complete measurement at end of step ..............57
G
Conditional jump .................................................66
Connect stations ...............................................113 Gauging ............................................................. 47
Connection Ethernet module ............................124 graph .................................................................. 80
controller module ................................................38 graph display, functions of left-mouse button .... 80
controller profile, Join on Signal .........................35 Graph menu ....................................................... 82
CPU Load .........................................................116 graph settings .................................................... 87
Creating a new user ............................................10 graph zoom ........................................................ 82
current station .....................................................44 Graphs in manual mode..................................... 72
curve data ...........................................................57 H
custom settings ...................................................98 Hand wheel ........................................................ 70
Cycle Stop ........................................................150 Home offset...................................................... 112
Cycle Stop dialog window ...................................69 Homing ............................................................. 111
D I
DAQ from start control ........................................40 Import Users ...................................................... 11
DB integer ...........................................................68 input confirmation............................................... 68
DB string .............................................................69 input position ...................................................... 94
deactivate trigger ..........................................29, 42 inputs.................................................................. 93
default settings ....................................................12 Inputs of Unidrive LT 24 VDC .......................... 116
Delay time ...........................................................62 Introduction .......................................................... 4
Delete User .........................................................10 IP address Ethernet Module ............................ 127
Determining the strain .........................................65 IP Adresse PC Windows 7 ............................... 130
Dialog window .....................................................68
Display ................................................................16
160
J Profibus DP ...................................................... 109
Join at last step ...................................................34 Program assignment
Jump ...................................................................67 delete ............................................................. 75
Program change ................................................ 74
L
program creation ................................................ 21
language ...........................................................115
program end ....................................................... 43
Learn curve limit .....................................24, 34, 40
Program pre-selection.................................. 74, 76
leave trigger activated ...................................29, 42
Program start ....................................................... 7
limits rel. to reference point.................................61
Program window ................................................ 16
Limits rel. to reference point ...............................55
PROMESS BUS ............................................... 117
Live input ..........................................................108
R
Log file ................................................................14
Log function ........................................................13 Real-time envelope test ............................... 24, 34
Log table .............................................................13 Reference motion without a request ................ 148
Login ..................................................................... 8 reference point ............................................. 50, 60
relative to reference point .................................. 61
M
relative to reference point .................................. 55
Manual mode ......................................................70
rights .................................................................. 11
Manual operation ................................................70
S
monitoring ...........................................................54
monitoring window ..............................................59 Selection of program number .......................... 151
sensor display .................................................. 115
N
Service ............................................................... 91
Name Step ..........................................................85
service dialog for bus systems ......................... 116
next trigger ....................................................29, 42
set output ........................................................... 67
No Ethernet module found ................................132
Set Status .......................................................... 68
No rights..............................................................12
Set tare .............................................................. 63
O Setting node address ....................................... 119
Online Monitoring ..........................................24, 40 Signal description PLC interface...................... 147
Only load NOK curves ........................................25 Signal flow cycle start ...................................... 148
open program .....................................................22 Signal flow reference motion after start-up ...... 147
Options, Press to Signal .....................................35 Single execution ................................................. 69
Outputs of Unidrive 24 VDC .............................116 Size of variable display .................................... 115
P slope................................................................. 106
Software installation ......................................... 124
parameter backup .............................................122
Standard User .................................................... 11
parts ID ...............................................................68
station settings ................................................... 91
PDM as program storage device ........................76
Station tag ........................................................ 123
PDM-S ................................................................95
Step tab ............................................................ 115
PDM-S grid calibration ........................................96
step-based gaugings.......................................... 57
PDM-S Standard Settings...................................97
storage type for programs .................................. 92
PLC interface ....................................................147
Strain .................................................................. 64
Positioning ..........................................................23
Press to Signal ....................................................32 T
previous trigger .......................................29, 37, 42 Taring ................................................................. 62
Print.....................................................................89 TCP/IP ............................................................. 113
Printer Settings ...................................................90 Toolbar ............................................................... 19
Printer setup .......................................................90 trigger always true........................................ 29, 42
Profibus DB node address ................................109 trigger chain ..................................... 31, 36, 37, 43
161
trigger measurement...........................................54 virtual inputs ..................................................... 101
trigger positioning ...............................................29 volatile memory .................................................. 92
Trigger, Press to Signal ......................................37 W
U Wait .................................................................... 62
User administration ............................................... 9 window ............................................................... 58
User Rights .........................................................11 window value ..................................................... 60
V Z
variables .............................................................44 zoom .................................................................. 82
162
163
PROMESS. For more efficiency.