Motion PRO Technical Manual Rev 1 - 14

MotionPRO
Technical Manual
Revision 1.14
MotionPRO Technical Manual Revision 1.14 -1-

11429 Grand River Road P.O.Box 748 Brighton, Michigan 48116 (810) 229-9334 FAX (810) 229-8125
Email Address: promess@promessinc.com Web Site: www.promessinc.com
Copyright 2015 Promess Incorporated. All rights reserved.

Contents
Note: In the pdf version of this manual, clicking on an entry in the table of contents or on a reference to
another section of the manual will take you to the corresponding section of the manual. Also, clicking on the
Promess logo at the top of any page or the footer at the bottom of any page will return you to the Table of
Contents.
1.0 Safety ............................................................................................................................ 4

2.0 MotionPRO System ...................................................................................................... 6
2.1 Components ..................................................................................................................................6
2.2 System Overview ..........................................................................................................................6
2.3 System Installation Notes ............................................................................................................7
2.3.1 Servo Amplifier Grounding and Max Speed .....................................................................7
2.3.2 Three-Phase Power in an E-Stop Condition .....................................................................9
2.3.3 Preamplifier .......................................................................................................................9
2.3.4 Cables ...............................................................................................................................9
2.3.5 Discrete I/O Power Supply ................................................................................................9
2.3.6 Computer Location ............................................................................................................9
2.3.7 Servo Amplifier Environment ............................................................................................9
3.0 EMAP Mechanical Layout .......................................................................................... 10
4.0 Input Signals ............................................................................................................... 11
5.0 Output Signals ............................................................................................................ 12
6.0 MotionPRO Controller Connections ......................................................................... 14
6.1 MotionPRO Card ........................................................................................................................ 14
6.2 Servo Amplifier Connections ................................................................................................... 15
6.3 PRO-MC Connections ............................................................................................................... 15
7.0 MotionPRO Input and Output Circuits ...................................................................... 16
8.0 Timing Diagrams ........................................................................................................ 17
8.1 Homing with the Require Sustained Home Signal Box Not Checked .................................. 17
8.2 Homing with the Require Sustained Home Signal Box Checked ......................................... 18
8.3 Cycle Start .................................................................................................................................. 19
8.4 Cycle Stop via a Program Cycle Stop Command ................................................................... 20
8.5 E-Stop and Recovery when EMAP is Idle ............................................................................... 21
8.6 E-Stop and Recovery When Press is Moving Case #1 ....................................................... 22
8.7 E-Stop and Recovery When Press is Moving Case #2 ....................................................... 23
8.8 Calling Up Programs Remotely................................................................................................ 24
8.9 Sending a Serial Number Using the Serial Number Strobe Input ........................................ 25
9.0 GPA Preamplifier ........................................................................................................ 26
9.1 Signal Cable Wiring MotionPRO to Load Cell Preamplifier ............................................... 26
9.2 Load Cell Wiring (GPA Preamplifier) ....................................................................................... 27
9.3 Proximity Switch Cable Wiring-3 Wire (GPA Preamplifier) ................................................... 27
9.4 External Analog Position Transducer Cable Wiring (GPA Preamplifier) ............................. 27
10.0 Dimensions ............................................................................................................... 28
10.1 GPA Strain Gauge Preamplifier ............................................................................................. 28
10.2 MotionPRO Controller Dimensions ....................................................................................... 29

11.0 EMAP Load Cell Calibration .................................................................................... 31

12.0 MotionPRO Specifications ...................................................................................... 33
12.1 Description ............................................................................................................................... 33
12.2 Electrical Connection .............................................................................................................. 33
12.3 Physical Environment Requirements .................................................................................... 33
13.0 Safety Circuit Requirements ................................................................................... 33
13.1 E-stop Stop Time ..................................................................................................................... 33
14.0 Spare / Replacement Parts ...................................................................................... 33
15.0 Lubrication ................................................................................................................ 33
16.0 Servo Amplifier Fault Codes ................................................................................... 34
16.1 Errors ........................................................................................................................................ 34
16.2 Warnings .................................................................................................................................. 35
17.0 Fieldbus Documentation ......................................................................................... 36
17.1 Byte Swapping ......................................................................................................................... 36
17.2 Profibus .................................................................................................................................... 36
17.3 DeviceNet ................................................................................................................................. 36
17.4 Ethernet I/P ............................................................................................................................... 36
17.5 ProfiNet ..................................................................................................................................... 37
17.6 Establishing Fieldbus Communication ................................................................................. 37
17.6.1 Profibus ........................................................................................................................ 37
17.6.2 DeviceNet..................................................................................................................... 38
17.6.3 Ethernet IP ................................................................................................................... 39
17.6.4 ProfiNet ........................................................................................................................ 40
17.6.5 Modbus TCP ................................................................................................................ 41
17.7 Fieldbus Memory Map ............................................................................................................. 42
17.7 Sending the MotionPRO a Serial Number ............................................................................. 54
17.8 Live Sensor Readings/Exchanging Data Between MotionPRO and a PLC ....................... 55
18.0 PRO-MC Installation Instructions ........................................................................... 56
18.1 About the PRO-MC .................................................................................................................. 56
18.2 Installation Instructions .......................................................................................................... 56
18.3 Target Group ............................................................................................................................ 56
17.4 Safety Instructions .................................................................................................................. 57
18.5 Enclosure and Electrical Drawings ....................................................................................... 58
18.6 Approvals ................................................................................................................................. 64
18.6.1 Conformance with UL .................................................................................................. 64
18.6.2 UL Markings ................................................................................................................. 64


WARNING!
FAILURE OR IMPROPER SELECTION OR IMPROPER USE OF THE PRODUCTS
AND/OR SYSTEMS DESCRIBED HEREIN OR RELATED ITEMS CAN CAUSE
DEATH, PERSONAL INJURY AND PROPERTY DAMAGE.
This document and other information from Promess Incorporated, its subsidiaries and
authorized distributors provide product and/or system options for further investigation by
users having technical expertise. It is important that you analyze all aspects of your
application and review the information concerning the product or system in the current
product catalog. Due to the variety of operating conditions and applications for these
products or systems, the user, through its own analysis and testing, is solely responsible for
making the final selection of the products and systems and assuring that all performance,
safety and warning requirements of the application are met. The products described herein,
including without limitation, product features, specifications, designs, availability and
pricing, are subject to change by Promess Incorporated and its subsidiaries at any time
without notice.
Offer of Sale
Promess Incorporated, its subsidiaries or its authorized distributors hereby offer the items
described in this document for sale. The provisions stated in the Offer of Sale govern this
offer and its acceptance.
1.0 Safety
Important Considerations
It is very important for the user to consider the possible adverse effects of power, wiring, component,
sensor, or software failures in designing any type of control or monitoring system. This is especially
important where property loss or human life is involved. It is important that the user employs
redundancy, and comprehensive failure analysis to ensure a safe and satisfactory overall system
design. It is agreed between the Buyer and Promess, that this is the Buyers responsibility.


Safety Precautions
The press unit may only be used to perform the operations it is intended for. The use in other operations or for
other purposes may lead to operator injuries and damages to the unit.
If you have acquired the unit as components without the optional safety circuit and mounting plate, you are
solely responsible for the installation of the Emergency Stop circuit according to EN 418 Cat 1. Damages
resulting from an improper installation are not covered by Promess.
The servo amplifier may only be installed, connected and taken into operation by competent personnel.
It is strictly forbidden to disconnect, bridge, or remove any safety devices or installations!
The belt protection may only be removed when the unit is completely electrically disconnected from the servo
amplifier. Power must be off and locked out to the station or machine before any work can be done.
It should not be possible to start the unit through a technical disturbance or functional problem of the
protective equipment. If it is, the faulty part or equipment must be repaired or exchanged.
It is forbidden to operate the press unit, without the proper function of the safety equipment
e.g. through manipulation of the safety devices!
The press unit may only be operated by personnel having been duly instructed in its proper operation.
If problems occur during normal operation and they cant be resolved through known and recommended
strategies, competent personnel from the responsible department must be informed.
The press unit must be completely disconnected from any electrical power supply before any service, repair
work or problem solving may be started! Proceed as follows:
Put main switch in OFF position.

When needed, pull the power connector.
IMPORTANT: The power disconnect(s) in the OFF position must be locked out and marked with a
sign when the unit is being serviced:
WARNING!
UNIT IS BEING SERVICED OR REPAIRED
DO NOT SWITCH ON!
In the event the unit must be disassembled you must first loosen all electrical connections.
The Promess Electro Mechanical press unit may harm the

operator when used improperly. Please adhere to the following.
1. DO NOT attempt to undertake any internal system configurations without prior consultation with
PROMESS.
2. DO NOT keep your hand in working area.
3. The Safety Circuit must be functional when operating the press unit.
4. DO NOT operate the unit in areas for which it was not designed.
5. Only authorized personnel may operate the press unit.
6. Unique IP Addresses must be used for each MotionPRO controller on a plant network. The default single
station IP Address (192.168.1.106) must never be used unless the MotionPRO controller is isolated from
any machine or plant network system.
7. If unique addresses are not used, the system Warranty will be voided.


2.0 MotionPRO System

2.1 Components
Ball screw servo-driven press head, or servo-controlled Torque-PRO or REMAP
Integrated force/torque transducer
Servo motor with integrated position feedback
Load Cell/Torque Transducer Preamplifier
Servo amplifier
MotionPRO Promess controller with Windows - based software
Promess Windows - based Motion Control and Monitoring software (XP and Windows 7)
Cables
Motor power cable
Motor resolver/encoder cable
Signal Cable from preamplifier to MotionPRO controller
PC with Windows - based software (optional)
External sensor(s) with signal conditioning electronics (optional)
2.2 System Overview
Cable Lengths:
Motor Power Cable (6m std.)
Resolver / Encoder (Feedback) Cable (6m std. / For cable lengths greater than 25m consult Promess)
Preamplifier (Signal) Cable (20 feet std. / 50 feet max.)
Ethernet Cable (25 feet std. / 50 feet max.)


2.3 System Installation Notes

2.3.1 Servo Amplifier Grounding and Max Speed
The servo amplifier must be properly grounded. Failure to do so could result in intermittent system faults
and/or damage to the servo amplifier. See below for acceptable grounding configurations.
Note: The rated maximum speed for a Promess system is calculated based on a 480VAC, three-phase
supply voltage. Using a lower voltage may reduce the maximum speed of the system. Please contact
Promess to inquire about the effect on a specific system.




2.3.2 Three-Phase Power in an E-Stop Condition

The DrivePRO servo amplifier used with the MotionPRO system is intrinsically safe. In an E-stop condition,
three-phase power will be internally disconnected from the output stage of the motor. Note: Using an extra
contactor to cut three-phase power to the servo amplifier in an E-stop condition can damage the
servo amplifier and will void the Promess warranty. Please see the Promess electrical drawings for the
recommended safety circuit wiring. For a description of the safety circuit operation, see section 13.0.
2.3.3 Preamplifier
For calibration purposes, design consideration should be given to all Promess installations utilizing a
preamplifier. Promess recommends that the preamplifier(s) be located in an easily accessible (from ground
level) location outside of all machine guarding. Also, the preamplifier(s) should be mounted in such a location
that access to the preamplifier(s) does not interrupt machine power (i.e. does not generate an E-stop
condition).
Preamplifier(s) Mounting Detail

If the preamplifier(s) are mounted to a grounded surface, the mounting screw is an acceptable chassis
ground. If the amplifier(s) are mounted to a surface of unknown or questionable ground, run a ground wire
(green 18ga MTW minimum) from the chassis mounting screw to the machine frame or another suitable earth
ground.
Preamplifier
base mounting Prior to installation,
hole remove paint as
indicated if not already
done.
2.3.4 Cables
To help ensure the highest possible signal quality, the motor power cable (high voltage) should be separated
from the encoder/resolver cable and the signal (preamplifier) cable (low voltage). Running these cables
together could introduce electrical noise to the system and result in less reliable readings.
2.3.5 Discrete I/O Power Supply

To avoid a possible ground loop potential between devices, Promess recommends that a common 24VDC
and 0VDC source be used for all discrete I/O wiring connections between the machine logic controller (i.e.
PLC) and the Promess controller I/O connection points.
2.3.6 Computer Location

When a dedicated PC will be located at the station, whenever possible, place the PC in close proximity to the
system. This will make it easier to see the system during manual motion, setup, and calibration. Also, if
possible, place the PC close to the preamplifier. This will make it much easier to perform calibration.
2.3.7 Servo Amplifier Environment

The drive must be installed in clean air according the enclosure classification. Cooling air must be clean, free
from corrosive materials and electrically conductive dust.


3.0 EMAP Mechanical Layout
Belt
Force
Transducer
AC Servo
Ball
Motor
Screw
Encoder
Press Ram


4.0 Input Signals
All of the digital and Fieldbus inputs to the MotionPRO controller can be configured for a specific function on
the Inputs tab in the System Setup screen, under the Setup pulldown menu. If an input is left as
Unassigned, it will not be available for use with any of the programming commands. The following is a list of
functions that can be assigned to an input: User, Cycle Start, Reset, Homing, Binary Input, Program Strobe,
Serial Number Strobe, Jog Input, and Reset Part Counter.
Note: All inputs to the MotionPRO Controller are 24VDC / 20mA.

Input Signal Description
User When an input is configured as a User Input, it can be used within the part program for
controlling the program flow (handshaking) with the PLC. This can be done by using
Conditional Jumps.
Cycle Start The Cycle Start input is used to initiate and execute the Promess program. The Cycle
Start input must be set high and maintained high until the Cycle End output goes high,
indicating the program is completed. The Cycle Start input must also be dropped low if
the Cycle Stop output or the Home Required output goes high. If the Ready output is
not high, the Cycle Start input will be ignored. See the Cycle Start Timing diagram in
section 8.3.
Reset The Pass and Fail outputs are reset with this input. The Reset input must be set high
for at least 50ms to be recognized. If the Ready output is not high, the Reset input will
be ignored.
Home When the Home input is set high, the homing routine is executed. The Home input
must be set high for at least 50ms for the input to be recognized. If the Ready output is
not high, the Home input will be ignored. See the Homing Timing diagrams in section
8.1 and 8.2 for more information.
Binary Inputs / The Part Program Number inputs allow for the remote selection of different part
Part Program Number programs. The relationship between number and program is set in the MotionPRO
software in Part Program Assignment under the Setup pulldown menu. See section 8.8
for a timing diagram for calling programs remotely.
Program Strobe The binary coded part number is read after the Program Strobe input is set high for at
least 50ms. The binary inputs must be set high for at least 50ms before the Program
Strobe is sent. The Ready output will go low while the program is being opened. A
Cycle Start cannot be sent until the Ready output is high. See section 8.8 for a timing
diagram for calling programs remotely.
Serial Number Strobe The Serial Number Strobe input is used in conjunction with an optional Fieldbus
module to send a serial number from the machine controller to the MotionPRO. When
the Serial Number Strobe input is pulsed, the Ready output will go low and the
MotionPRO will set the contents of the String Input section of the Fieldbus memory map
as the serial number. The serial number will be associated with any data collected and
will remain in the serial number field until it is overwritten by another serial number. See
section 8.9 for the timing diagram or section 17.7 for an example of setting a serial
number.
Jog Input The Jog Input allows the machine controller (PLC) to jog the press without running a
part program. The jog speed, direction, and an overload for the input are configured in
the input setup.
Reset Drive Faults The Reset Drive Faults input can be used to reset any drive faults that occur during
operation. Most drive faults will also be reset by running a homing routine. For a list of
fault codes that appear on the drive, see section 16.0.
Reset Part Counter The Reset Part Counter input can be used to reset the system part counter and
number of failed parts counter in the MotionPRO software. If the Ready output is not
high, the Reset Part Counter input will be ignored.


Input Signals Continued

The PSTOP (E-Stop) and the NSTOP (Home-Switch) inputs are located directly on the servo drive. The
status of these inputs can be seen by selecting Service from the Setup pulldown menu, then going to the
DrivePRO tab. Under normal operating conditions, both indicators should be red.
Upon request, Promess will provide electrical drawings showing how these signals must be wired in the
recommended safety circuit.
Input Signal Description

E-Stop (PSTOP) The PSTOP input is the E-Stop input for the MotionPRO Controller. The
Promess system will be in an E-Stop condition when this input is low. See the
Promess safety circuit drawings for wiring. When in an E-Stop condition, the
indicator on the DrivePRO tab of the service screen will be gray.
Home Switch The NSTOP input is where the signal from the proximity switch mounted on
(NSTOP) the press housing is terminated. This proximity switch is used for the homing
routine of the press. To create a failsafe condition, a normally closed proximity
switch is used.
5.0 Output Signals

All of the digital and Fieldbus outputs on the MotionPRO controller can be configured for a specific function on
the Outputs tab of the System Setup screen, under the Setup pulldown menu. If an output is left as
Unassigned, it will not be available for use with any of the programming commands. The following is a list of
functions that can be assigned to an output: User, Limit Switch, Binary Output (Part Program Number
Acknowledge), Ready, Cycle End, Cycle Start Release, All Monitors Active, Pass, Fail, Cycle Stop, Home
Required, Overload, Drive Fault, PC Connected, and Data Committed.
The following outputs are Mandatory and must be used: Ready, Cycle End or Cycle Start Release, Cycle
Stop, and Home Required.
Note: All outputs are 24VDC / 100mA

Output Signal Description
User Output When an output is configured as a User Output, it can be used within the program
for controlling the program flow (handshaking) with the PLC. This is done by using
the Set Event command. A label can be given to the output that will be used to
identify it throughout the rest of the software. The output can also be defined as
Normally Open or not.
Limit Switch The Limit Switch output is a software limit switch used to turn on or off the output
based on some user defined condition. The Limit Switch output can be based on a
timer, position, force, or velocity value.
Binary Output The part program number can be read back by the PLC to verify that the correct
program is loaded. If a program is assigned in the Part Program Assignment menu,
(Part Program Acknowledge)
the corresponding Binary Outputs will be set after the program is loaded. See section
8.8 for the timing diagram for calling programs remotely.
Ready When the Ready output is high, the MotionPRO controller will accept an external
command through the digital or Fieldbus inputs. No command will be acknowledged
unless it is sent when the Ready output is high.


Ready (Contd) The Ready signal is NOT set if:

The E-Stop (PSTOP) input is low The Cycle Start input is high (on)
The Home input is high (on) A program change is occurring
A software limit has been reached A command is being executed
The Edit, Manual Motion, or some other screens are open in the MotionPRO software
A servo drive fault occurs or the servo drive is not ready
Cycle End The Cycle End output is set when the cycle is completed and the motion is at a
complete stop. The Cycle End output can be used as the trigger to turn off the Cycle
(Program Complete)
Start input. See the Cycle Start Timing diagram in section 8.3.
Cycle Start Release The Cycle Start Release output was added to simplify PLC interface by providing a
logic signal with which to latch and release the Cycle Start input. The Cycle Start
Release output will be low during normal operation. It will be set high when an event
occurs that requires the Cycle Start input to be set low (end of program, cycle stop,
E-Stop during operation, etc), then set low again once the Cycle Start input has
been set low. For more information, see the timing diagrams in section 8.0.
All Monitors Active The All Monitors Active output will be on when the active curves are in Monitor
mode (limits on the curve are being monitored as pass/fail criteria). When the curves
are put in Stand By mode, the output will be low. The curves can be changed to
Monitor mode or Stand By mode under the Command pulldown menu.
Pass The Pass output will be set high after the completion of the program or after an
Update Part Status command is executed in the program. The Pass output is
automatically reset on the leading edge of the Cycle Start signal at the beginning of
the next cycle. The Pass output can also be reset by using the Reset Input.
Fail The Fail output will be set high after the completion of the program or after an Update
Part Status command is executed in the program. The Fail output is automatically
reset on the leading edge of the Cycle Start signal at the beginning of the next cycle.
The Fail output can also be reset by the using the Reset input.
Cycle Stop The Cycle Stop output is set high when:
A Cycle Stop command is executed in the program.
The Cycle Start input is dropped low before a cycle is completed, if Allow
program continuation after lost cycle start is enabled on the General tab of the
System Settings screen, under the Setup pulldown menu.
After each step, when the Step button is used to go through the program one
line at a time.
Home Required The Home Required output is an indication that the system must be homed. The
Home Required output will be set high after the MotionPRO is powered up, after the
system has been manually jogged, or when one of the conditions listed below occurs.
No other commands are accepted until the press is homed.
Errors that require homing:
Force Overload
Drive Fault
Lag Error
Overload The Overload output will be set high when a step or system overload has occurred at
any point during a program or manual motion. The output will be reset after the
system has been homed.
Drive Fault The Drive Fault output is set high when there is a servo amplifier fault. When there is
a fault, the display on the face of the servo amplifier will display a fault code. For a list
of fault codes, see section 16.0.
PC Connected The PC Connected output can be used by the PLC to monitor when the MotionPRO
software is connected and storing data to the PC.
Data Committed The Data Committed output is used to indicate that the monitoring and gauging data
were stored to the database. If the MotionPRO Application Software is not running or
the Ethernet cable is not connected to the MotionPRO controller, this output will not
change states. This output is set low on the leading edge of a cycle start and goes
high after the data has been sent at the end of the cycle.


6.0 MotionPRO Controller Connections

The MotionPRO controller comes in several different configurations, depending on the size of the system and
the communication option selected. The servo amplifier will be either a DrivePRO S300 or DrivePRO S700
series. The MotionPRO card itself can either have an Expanded I/O board, or one of several different
Fieldbus options. ProfiNet and ModBus TCP are not pictured, but are also available as options.
6.1 MotionPRO Card

Every MotionPRO card has two analog inputs. By default, they are configured for 4-20mA, however, each
analog input can be configured to accept a number of different signals: 4-20mA, 0-5VDC, 0-10VDC, 5VDC,
or 10VDC.
Note: On Promess electrical drawings, I/O on the MotionPRO Board is labeled MP Digital
Note 2: The orientation shown is for S700 drives. On S300 drives, the MotionPRO card is rotated 180 from
orientation shown.
MotionPRO Card w/ Expanded I/O Board MotionPRO Card w/ Ethernet I/P
RDY RDY
STAT STAT
A1 Analog Input 1 A1 Analog Input 1

AG Analog Ground AG Analog Ground
0V 0VDC for Promess strain gauge preamplifier 0V 0VDC for Promess strain gauge preamplifier
O4 Output 4 O4 Output 4
24V CF Supply Power 24VDC 24V CF Supply Power 24VDC
0V O4 Supply Power 0VDC 0V O4 Supply Power 0VDC
I1 I1 Input 1 I1 I1 Input 1
O3 O3 Output 3 O3 O3 Output 3
E-NET
E-NET
C Input Common 0VDC

6 Input 6
NS
5 Input 5
Input
4 Input 4
3 Input 3
Input 2
EtherNet/IP
2
1 Input 1
X23
Expanded I/O
C Output Common - 24VDC
LINK
6 Output 6
5 Output 5
Output
4 Output 4
3 Output 3
MS
2 Output 2
1 Output 1
MotionPRO Card w/ Profibus MotionPRO Card w/ DeviceNet

RDY RDY
STAT STAT

AG Analog Ground AG Analog Ground
O4 Output 4 O4 Output 4
24V CF Supply Power 24VDC 24V CF Supply Power 24VDC

0V O4 Supply Power 0VDC 0V O4 Supply Power 0VDC
I1 I1 Input 1 I1 I1 Input 1
E-NET
E-NET
NS
OP
1
PROFIBUS DP-V1
2
DeviceNet
X23
X23
3
4
5
MS
ST


6.2 Servo Amplifier Connections

Note: On Promess electrical drawings, I/O on the DrivePRO face is labeled DP Digital
Note 2: For S700 servo amplifiers, the part number on the side of the drive will indicate if it is a Single STO-
Enable or Dual STO-Enable. Ex: S72401 is a Single STO-Enable; S72402 is a Dual STO-Enable.
S300 Servo Amplifier S700 Servo Amplifier (Single STO-Enable) S700 Servo Amplifier (Dual STO-Enable)
Note: MotionPRO Card is on top of Note: MotionPRO Card is on face of drive Note: MotionPRO Card is on face of drive
drive
PROMESS E24 DrivePRO

E24 DrivePRO
X3 BTB/RTO 1
BTB/RTO 2
ANALOG-IN 1 + 3
ANALOG-IN 1- 4
ANALOG-IN 2+ 5
ANALOG-IN 2- 6
AGND 7
DIGITAL-IN 1 8
DIGITAL-IN 2 9
PSTOP 10
NSTOP 11
ENABLE 12 X3A X3B X3A X3B
DIGITAL-OUT 1 13
DIGITAL-OUT 2 14 ENABLE 1 9 ANALOG-IN 1- ENABLE 1 9 ANALOG-IN 1-
DIGITAL-IN 1 2 10 ANALOG-IN 1 + DIGITAL-IN 1 2 10 ANALOG-IN 1 +
X4 +24V 1
DIGITAL-IN 2 3 11 ANALOG-IN 2- DIGITAL-IN 2 3 11 ANALOG-IN 2-
+24V 2
PSTOP 4 12 ANALOG-IN 2+ PSTOP 4 12 ANALOG-IN 2+
DGND 3
4 NSTOP 5 13 AGND NSTOP 5 13 AGND
AS-ENABLE 5 DIGITAL-OUT 1 6 14 BTB/RTO DIGITAL-OUT 1 6 14 BTB/RTO
DIGITAL-OUT 2 7 15 BTB/RTO DIGITAL-OUT 2 7 15 BTB/RTO
E03 +24V
+24V
XGND
1
2
8
1
2
4
5
16
4
5
DGND
+24V
XGND
+24V
+24V
XGND
1
2
8
1
2
4
5
16
4
5
DGND
+24V
XGND
XGND 3 3 6 6 STO-ENABLE STO2-ENABLE 3 3 6 6 STO1-ENABLE
X4A X4B X4A X4B
PROMESS PROMESS
DrivePRO
6.3 PRO-MC Connections

Note: The PRO-MC is a package that includes a servo amplifier, MotionPRO controller, safety circuit, and
24VDC power supply all in one enclosure, prewired and tested before shipping from Promess. See section
18.0 for more information about the PRO-MC.
X3.1 X12 X11.2

X3.1 - Analog X12 Preamplifier X11.2 Expanded I/O
AN_1+ 0V 0V = 0VDC out (supply for secondary
AN_1+ = DrivePRO Ana Input 1 Sig+ I_1 = Input #1
ANALOG
AN_1- 24V AN_1- = DrivePRO Ana Input 1 Sig- Preamplifier)

I_1 I_2 = Input #2
AN_2+ AN_2+ = DrivePRO Ana Input 2 Sig+ 24V = 24VDC out (supply for I_3 = Input #3
I_2
AN_2- AN_2- = DrivePRO Ana Input 2 Sig- secondary Preamplifier) I_4 = Input #4
INPUTS
Ain_1 I_3 AGND = DrivePRO Ana Input GND I_5 = Input #5

AGND AGND I_4 Ain_1 = MotionPRO Ana Input 1 I_6 = Input #6
PRE-AMP
DO_1 Ain_2 I_5 X3.2 Digital I/O AGND = MotonPRO Ana Input GND I_C = Input Com (0V)
0V DO_1 = MotionPRO Board Dig. Out. 1 Ain_2 = MotionPRO Ana Input 2
DO_2 I_6
DO_2 = MotionPRO Board Dig. Out. 2 0V = 0VDC to Preamplifier O_1 = Output #1
DO_3 24V I_C 24V = 24VDC to Preamplifier
DO_3 = MotionPRO Board Dig. Out. 3 O_2 = Output #2
DIG I/O
DPO_1 DO_4 O_1 DPO_1 = DrivePRO Dig. Out. 1 DO_4 = MotionPRO Board Dig. Out. 4 O_3 = Output #3
DPO_2 Prox_Sw O_2 DPO_2 = DrivePRO Dig. Out. 2 Prox_Sw = Home Switch O_4 = Output #4
OUTPUTS
DI_1 DI_1 = MotionPRO Board Dig. In. 1 O_5 = Output #5

O_3
DPIn_1 = DrivePRO Dig. In. 1 X13 E-Stop O_6 = Output #6
DPIn_1 ES_1 O_4 ES_1 = Contact 1
DPIn_2 = DrivePRO Dig. In. 2 O_C = Output Com (24V)
E-STOP
DPIn_2 ES_2 O_5 0V = Reference GND for Dig. Inputs ES_2 = Contact 1
0V ES_3 O_6 24V =Internal 24VDC. Only used for ES_3 = Contact 2
testing when internal jumper is set. ES_4 = Contact 2
24V ES_4 O_C
X3.2 X13


7.0 MotionPRO Input and Output Circuits
7.1 Inputs
Internal to the MotionPRO controller
24 VDC / 20mA
7.2 Outputs
Internal to the MotionPRO controller
24 VDC / 100mA


8.0 Timing Diagrams

8.1 Homing with the Require Sustained Home Signal Box Not Checked
Signal
Signal Direction
1
Home Input 0
1
Ready Output 0
1
Cycle End Output 0
Cycle Start 1
Output 0
Release
1
Home Required Output 0
The Require Sustained Home Signal box is on the Homing tab of the System Settings screen, under the
Setup pulldown menu.
1. The Home input must be set high for at least 50 ms.

2. The Ready and Cycle End signals are set low with the recognition of the Home command.
3. When the motion is completely stopped, the Cycle End and the Ready signal are set high again. The Cycle
Start Release will be set and immediately reset (or never set).
4. The Ready signal is set high when the Homing routine is complete (Cycle End output is high) and the
Home input is set low.
Note: The Homing sequence depends on how the Homing routine is configured on the Homing tab of
the Axis Settings screen, under the Setup pulldown menu.
Typical Homing Motion Sequence
The following motion occurs when the press is homed:

1. If the ram is on the Home proximity switch (Home Axis input signal is low) it is first extended until it is off the
Home proximity switch (Home Axis input signal is high).
2. With the ram extended so it is not triggering the Home proximity switch, the ram is retracted. When the
ram makes the Home proximity switch, the motion is reversed.
3. The ram is then extended until the Home proximity switch is not made and will continue until the next index
marker on the encoder is recognized.
o
Note: Between the Home proximity switch signal and the index mark must be a minimum of 5 rotation.


8.2 Homing with the Require Sustained Home Signal Box Checked
Signal
Signal Direction
1
Home Input 0
or
1
Ready Output 0
1
Cycle End Output 0
Cycle Start 1
Output 0
Release
1
The Require Sustained Home Signal box is on the Homing tab of the System Settings screen, under the
1. The Home input must be set high until the Cycle End output is set high.
2. The Ready signal is set low with the recognition of the Home command.
3. When the motion is completely stopped, the Cycle End, Cycle Start Release, and the Ready signal are set
high again.
4. The Ready signal is set high and the Cycle Start Release is set low when the Homing cycle is complete
(Cycle End output is high) and the Home input is set low.


8.3 Cycle Start

Signal
Signal Direction
1
Cycle Start Input 0
or
1
Ready Output 0
1
Cycle End Output 0
100ms
Cycle Start 1 delay
Release Output 0
1. The Cycle Start input must be set for the duration of the complete cycle*. The PLC can latch the Cycle
Start input high with the low Cycle Start Release output.
2. The Ready and Cycle End outputs are both set low with the recognition of the Cycle Start input. There will
be a slight delay (100ms) from the time the Cycle Start is set high until the event is recognized and the
Cycle End and Ready outputs are set low.
3. When the programmed cycle is finished, the Cycle End and Cycle Start Release outputs are set high.
Those signals indicate the cycle is complete and the Cycle Start input can be set low.
4. The Ready output is set high and the Cycle Start Release output is set low after the Cycle Start input is
set low and the software has completed any required data management function.
*Before a new cycle can be started, the Cycle Start input must be set low. If the Cycle Start input is dropped
low during the program, a Cycle Stop will be generated. The Cycle End and Cycle Start Release outputs will
go high at the end of a cycle to indicate the cycle is completed.
The Cycle Start input must be held high until a Cycle End, Cycle Start Release, Cycle Stop, or a Home
Required output occurs.
Cycle Start Release Exceptions:

1. Operation from HMI: Cycle Start Release will not be set/reset when the system is operated from the
MotionPRO HMI.
2. Homing: Homing should work just like a part program, unless the Require Sustained Home Signal
box is not checked on the Homing tab of the System Settings screen and the Homing signal is turned
off before the homing routine is complete. In that case, the Cycle Start Release will be set and
immediately reset (or never set) since the Homing command is already low.
3. E-Stop While Running a Part Program:
a. If Allow Program Continuation After E-Stop is not checked on the General tab of the
System Settings screen, Cycle Stop, Cycle Start Release, and Home Required will all be set
upon recognition of the E-Stop, and homing the system will be required to continue. The
Cycle Start Release will be reset once the Cycle Start signal is reset.
b. If Allow Program Continuation After E-Stop is checked on the General tab of the System
Settings screen, Cycle Stop and Cycle Start Release will be set upon recognition of the E-
Stop. The Cycle Start Release will be reset once the Cycle Start is reset. The cycle will
continue when the Cycle Start signal is set again.


8.4 Cycle Stop via a Program Cycle Stop Command
Signal This is a Cycle Stop command in the program

Signal Direction
Program Internal to the 1
Cycle Stop Program 0
1
Cycle Stop Output 0
1
Ready Output 0
Cycle Start 1
Output 0
Release
1
Cycle End Output 0
1
Cycle Start Input 0
1. The program reaches a "Cycle Stop" program line.

2. The Cycle Stop and Cycle Start Release outputs are set high.
3. The Ready and Cycle End outputs stay low.
4. When the Cycle Start input is set low, the Ready output is set high and the Cycle Start Release output is set low.
Note: The Cycle Stop output or Cycle Start Release output may be used as a trigger for the machine controller to turn
off the Cycle Start.


8.5 E-Stop and Recovery when EMAP is Idle
Signal
Signal Direction
1
E-Stop Input 0
1
Ready Output
0
Output 1
Cycle End
0
Output 1
Cycle Stop
0
1
Home Required Output
0
1. The Ready and Cycle End outputs are high.

2. E-Stop occurs; the E-Stop (PStop) input drops low.
3. The Ready output is set low.
4. The Cycle End and Cycle Stop outputs do not change state.
5. When the E-Stop is cleared, E-Stop (PStop) input is high; the Ready output is set high.


8.6 E-Stop and Recovery When Press is Moving Case #1

(Allow Program Continuation After E-Stop is Enabled in System Setup)
Signal
Signal Direction
1
E-Stop Input 0
1
Cycle Stop Output 0
Cycle Start 1
Output 0
Release
1
Ready Output 0
1
Cycle Start Input 0

0
1. A Cycle is started.
2. The Ready and Cycle End outputs are set low.
3. An E-Stop occurs during a Positioning move (program step).
4. The MotionPRO controller brings the press motion to a controlled stop.
(200-500 ms after the E-Stop occurred, the Enable and AS-Enable inputs drop low).
5. The Servo Amplifier is disabled.
6. The Cycle Stop output and Cycle Start Release output are set high.
7. The Cycle Start Release output is set low when the Cycle Start input is set low. The Ready output is set
high when the Cycle Start input is set low and the E-Stop is cleared. The Cycle Start input must be set low
and no other commands (e.g. Homing, Cycle Start, etc) must be set high.
8. The E-Stop is cleared. The Servo Amplifier will not be enabled by the MotionPRO controller until the
initiation of a Cycle Start or a Home command.
9. After the Ready output is set high, a Cycle Start or a Home signal can be applied. If the Cycle Start input is
set high again, the program will continue where it left off.


8.7 E-Stop and Recovery When Press is Moving Case #2

(Allow Program Continuation After E-Stop is Disabled in System Setup)
Signal
Signal Direction
1
E-Stop Input 0
1
Cycle Stop Output 0
Cycle Start 1
Output 0
Release
1
Ready Output 0
1
Cycle Start Input 0

0
1
Home Input 0
Cycle End Output 1

0
1. A Cycle is started.
2. The Ready and Cycle End outputs are set low.
3. An E-Stop occurs during a Positioning move (program step).
4. The MotionPRO controller brings the press motion to a controlled stop.
(200-500 ms after the E-Stop occurred, the Enable and AS-Enable inputs drop low).
5. The Servo Amplifier is disabled.
6. The Cycle Stop output is set high.
7. The Cycle Start Release output is set low when the Cycle Start input is set low. The Ready output is set
high when the Cycle Start input is set low and the E-Stop is cleared. The Cycle Start input must be set low
and no other commands (e.g. Homing, Cycle Start, etc) must be set high.
8. The E-Stop is cleared. The Servo Amplifier will not be enabled by the MotionPRO controller until the
initiation of a Home command.
9. After the Ready output is set high, a Home signal can be applied. The Ready output will be set low on
recognition of the Home input, and will be set high again when the Cycle End output is turned on at the
completion of the homing routine.


8.8 Calling Up Programs Remotely
Signal
Signal Direction
Program Number 1
Input
Binary 1 0
Program Number 1
Binary 2 Input
0
1
Program Strobe Input
0
1
Ready Output 0
1
Cycle Start Input
0
Binary 1 1
Acknowledge Output
0
Binary 2 1
Output
Acknowledge 0
1
E-Stop Input
0
ta
tb
ta > 50ms, tb > 50ms
Note: The program number will not be read if the machine is in an E-Stop condition.
1. The Binary inputs for the Program Number to be called up are set high.
2. The Program Strobe input is pulsed for a minimum of 50ms. The Program Strobe can not be sent until the
Binary inputs have been high for at least 50ms.
3. The Ready output goes low on the leading edge of the Program Strobe.
4. The MotionPRO controller loads the selected program into memory.
5. Once the program is loaded, the Binary inputs and Program Strobe input MUST be set low.
6. After the program is loaded and the MotionPRO is ready, the Ready output goes high.
7. The Cycle Start input can then be set high to start the cycle.
Note: If there are outputs assigned to the binary numbers, the corresponding outputs will come on after the
program is loaded into memory. These outputs are used for handshaking to the machine controller to verify
that the correct program was loaded.


8.9 Sending a Serial Number Using the Serial Number Strobe Input
Signal
Signal Direction
Serial Number 1
Input 0
Strobe
1
Ready Output 0
1
Cycle Start Input 0
processing
serial
number
Note: To send the MotionPRO controller a serial number, an optional Fieldbus module must be used. The
Serial Number Strobe input must be configured on the Inputs tab of the System Settings screen, under the
1. The serial number is put into the String Input section of the Fieldbus memory map.
2. With the Ready output high, the Serial Number Strobe input is set high.
3. When the Serial Number Strobe input is recognized, the Ready Output drops low. The Serial Number
Strobe input can then be set low.
4. The Ready output will remain low while the MotionPRO sets the serial number equal to the contents
of the String Input section of the Fieldbus memory map.
5. When the MotionPRO is done processing the serial number, the Ready output is set high.
6. The MotionPRO is ready to accept a Cycle Start.


9.0 GPA Preamplifier
Analog 1 Gain
Gain
1 10V
2 5V Promess Incorporated
250 40mV GPA Strain Gauge Preamplifier
PN: 1904100450
500 20mV
1000 10mV
Zero
Calibrate
LED Power
LED
Analog 1
Manual
Analog 1 Input Output Offset Analog 1 Output
Cal Enable
4-20mA 0V / 4-20mA Voltage Pos 1,2
Calibration Single 2.5V 3 2 1 4-20mA - Pos 2,3
Resistor Ended 5V
X4 - Analog 1 X3 ANA2 IN X2 PROX X1 Signal
1 2 3 4 5 1 2 3 1
24 VDC 2 3 1 2 3 4 5 6 7 8 9 10
24 VDC
+5 VDC
-5 VDC
5 VDC
ANA1
ANA2
SHD
GND
PROX
ANA
COM
COM
OUT
OUT
CAL
SIG+
SIG-
SHD
SIG
SIG
0V
0V
BRN BLK BLU WHT BRN GRN YEL PNK RED BLU
9.1 Signal Cable Wiring MotionPRO to Load Cell Preamplifier
MotionPRO Signal Preamplifier Preamplifier

Color
Terminals Description Terminal Label
24V 24V white X1.1 24V
0V 0V brown X1.2 0V
A1 Force Signal green X1.4 ANA1 OUT
External
A2 yellow X1.6 ANA2 OUT
Signal 1
No Connection gray No Connection
No Connection blue X1.9 RES/CAL
AG Analog GND pink X1.7 ANA GND
Shield shield connected to preamplifier housing
NStop Home Signal red X1.8 PROX


9.2 Load Cell Wiring (GPA Preamplifier)
X4-ANALOG1 Signal Description Wire Color

+5VDC + Excitation brown
-5VDC - Excitation yellow
SIG + + Signal green
SIG - - Signal white
COM (GND) Shield Shield
9.3 Proximity Switch Cable Wiring-3 Wire (GPA Preamplifier)
X2-PROX Signal Description Wire Color

24V 24V brown
0V 0V blue
SIG Normally Closed black
9.4 External Analog Position Transducer Cable Wiring (GPA Preamplifier)

Note: The Analog 2 input in the GPA preamplifier is for a voltage signal only. A 4-20mA or other current
signals will not work.
X3-ANA2 IN Signal Description Wire Color Position Transducer

5VDC 5VDC White 3
COM 0VDC Brown 1
SIG Position Signal Yellow 2
COM Shield Shield N.C.


10.0 Dimensions
10.1 GPA Strain Gauge Preamplifier
Note: The Preamplifier should be mounted in a serviceable location on the machine (i.e. outside any machine
guarding or light screens) to allow access with power to the system. This is necessary for performing system
calibration. See section 2.3.3 for more information.


10.2 MotionPRO Controller Dimensions

MotionPRO Promess Press Controller
MotionPRO S300 Series


MotionPRO S700 Series
Note: The MotionPRO S748 servo amplifier (not pictured) has dimensions of 385mm high x 190mm wide x
285mm deep.

11.0 EMAP Load Cell Calibration
EMAP Force Sensor Type: Strain Gauge

There are different methods to calibrate the EMAP load cell. The load cell can be calibrated using a
calibrated meter and load cell or using a spring with a known spring constant. If you have any questions or
need assistance, call Promess at 810-229-9334.
Warning: The calibration description in this manual is very general and should only be used as a guide.
Depending on tool fixtures and part fixtures, the described procedure may cause harm to the press, parts, or
fixtures.
Promess will not be responsible for any damage caused by calibration.
Calibration Procedure:
1. Put the press into an E-Stop condition and make sure power is turned off to the servo motor.
2. Install the reference load cell into the fixture. Make sure the load cell is stable and can support the load
that is required to calibrate to EMAP load cell.
3. Reset the E-Stop.
4. Home the press.
5. Check the zero point of the analog signal. Go into the Service Screen under the Setup pulldown menu
and click on the Analog tab. The Promess default analog input for the EMAP load cell is Analog Input 1.
With no load on the ram, this value should be 0.20V. If not, adjust the zero pot in the preamplifier, then
home the press.
6. If you are not sure of the force range for the press or load cell, that information can be found in the System
Setup menu. Go to the Setup pulldown menu, select System Settings and then the Sensor Inputs tab.
The force range is the value in the Overload Limit field of the Analog 1 Properties. If both analog inputs on
the MotionPRO Controller are being used, make sure the correct sensor is checked.
7. Go to the Manual Motion screen by pressing the Jog button in the toolbar or by selecting Manual Motion
from the Command pulldown menu. Also verify that the Manual Motion Overload is high enough to allow
the press to reach full force.
8. Pre-position the press ram so it is close to the reference load cell but not putting any load on it.
9. To apply load to the load cell, set the motion to a very low speed (e.g. = 0.5mm/s).
10. Manually advance the ram in small steps until the reference load cell shows the desired force level.
During this move monitor the force readout from the press in the upper right section of the Manual Motion
window. It is recommended to check the force calibration in at least three points to make sure it is linear
(i.e. 25%, 50%, and 75% of the full range of the press).
Note: If the overload limit is reached the press goes into an emergency stop and the press will have to be
homed.
11. If the press reading is outside the acceptable tolerance, move to 50% of the full range of the press and
adjust the gain potentiometer inside the preamplifier until the force displayed on the EMAP matches the
reference load cell. Retract the ram to relieve the load, then home the press.
12. Repeat steps 8-11 at least one time to ensure the system is correctly calibrated. If no adjustments to the
gain pot are made, the calibration is finished
13. Home the press
14. Press the E-Stop to remove power from the Servo Motor.
15. Remove the reference load cell.


Calibration Continued:
Load Cell Preamplifier Layout:
Analog 1 Gain
Gain
1 10V
2 5V Promess Incorporated
250 40mV GPA Strain Gauge Preamplifier
PN: 1904100450
500 20mV
1000 10mV
Zero
Calibrate
LED Power
LED
Analog 1
Manual
Analog 1 Input Output Offset Analog 1 Output
Cal Enable
4-20mA 0V / 4-20mA Voltage Pos 1,2
Calibration Single 2.5V 3 2 1 4-20mA - Pos 2,3
Resistor Ended 5V
X4 - Analog 1 X3 ANA2 IN X2 PROX X1 Signal
1 2 3 4 5 1 2 3 1 2 3 1 2 3 4 5 6 7 8 9 10
24 VDC
24 VDC
+5 VDC
-5 VDC
5 VDC
ANA1
ANA2
SHD
GND
PROX
ANA
COM
COM
OUT
OUT
CAL
SIG+
SIG-
SHD
SIG
SIG
0V
0V
BRN BLK BLU WHT BRN GRN YEL PNK RED BLU
Load Cell Verification

For verifying the force calibration of the EMAP on a regular basis, a calibration program can be created which
could look like the example below.
Example Program
Warning: Do not run a program like this if the load cell preamplifier or the load cell has been changed. You
must use Manual Motion to apply the load to calibrate the load cell before running this verification program.
Step Function Description

1 Positioning Moves the ram close to the reference load cell without touching it.
2 Set Sensor Value Zeros the force transducer.
Press to desired force level; 25% of press load range.
3 Move to Signal Speed: 0.1mm/sec
2
Acceleration: 400mm/sec
Stops the program so the loads can be compared. Click Cycle Start to
4 Cycle Stop
continue.
2
6 Cycle Stop
continue.
2
8 Cycle Stop
continue.
9 Positioning Return to start position.


12.0 MotionPRO Specifications

12.1 Description
The Promess MotionPRO controller is a single axis motion controller and monitoring system. The MotionPRO
can control one axis of motion and has two analog inputs with signature analysis capabilities.
12.2 Electrical Connection

Refer to Promess electrical schematics.
12.3 Physical Environment Requirements

Operating Temperature Range: +10 to 50C
Relative Humidity (non-condensing): 5 to 95 %
Note: The MotionPRO should be mounted in an appropriate electrical enclosure for the environment
the equipment will be used in.
13.0 Safety Circuit Requirements

To obtain drawings showing the recommended safety circuit, please call Promess.
How the Safety Circuit Should Work

The DrivePRO servo amplifier boots up using 24VDC. Supplying the servo amplifier with high power (three
phase 480VAC or 230VAC) before it is booted up and ready could potentially damage it, which would not be
covered under the Promess warranty. There are two BTB/RTO contacts on the servo amplifier that should
control a contactor (Drive Healthy), which in turn allows the high power in to the servo amplifier. When the
servo amplifier is booted up and ready, the BTB/RTO contacts close internally, which closes the Drive Healthy
contact and supplies high power to the servo amplifier.
NOTE: ANY DAMAGE CAUSED BY NOT USING A DRIVE HEALTHY CONTACT WILL NOT BE
COVERED UNDER THE PROMESS WARRANTY.
Upon an E-Stop condition the power to the PStop input on the MotionPRO controller must be dropped
immediately. When an E-stop is activated there must be a 500-millisecond delay before the Enable and STO-
Enable (AS-Enable) inputs to the servo amplifier are interrupted. This prevents any coasting of the system
under high speeds and allows the press to come to a controlled stop. The safety circuitry must be designed
with redundancy, i.e. more than one E-Stop relay contact, so the safety circuit remains functional, should a
relay contact failure occur.
13.1 E-stop Stop Time

When planning machine layouts, sometimes it is necessary to know the time needed to bring a press to a
complete stop. This time can be affected by settings in the MotionPRO software that can be changed by the
user, but the example below uses the default Promess settings and typical maximum speed for a Promess
press. The calculation should be verified/redone for each system based on that systems settings.
The maximum speed for most Promess presses is 200mm/s and the E-stop deceleration is set by Promess to
be 2000mm/s, so once the MotionPRO gives the command to stop, the press will take 100 milliseconds
(200mm/s / 2000mm/s) to come to a complete stop. There will be 10ms or less of response time for the
electronics, meaning that the longest time from E-stop to complete stop of motion will be 110ms.
14.0 Spare / Replacement Parts

Please consult your job documentation or call Promess for part descriptions and part numbers for your
Promess system.
15.0 Lubrication
Please contact Promess for the latest greasing procedure for your system.

16.0 Servo Amplifier Fault Codes

When in normal operating mode, the LED display on the face of the servo amplifier will show one of two
messages: Pxx or Exx, where xx is the amperage rating of the drive. The P indicates that the drive has three
phase power; the E indicates that the drive is enabled. For example, a drive that displays E24 is a 24 amp
drive, and is enabled. There are two different types of faults that can show up on the servo amplifier. For
assistance troubleshooting, please contact Promess. Note: When a servo amplifier only shows the amperage
rating of the drive (03 or 24, for example), but not the P or E, it means that the three phase power is not
getting through to it. This is usually an indication of a wiring problem with the Drive Healthy contact.
16.1 Errors
A servo amplifier error will result in the output stage of the motor being turned off. The system will not run with
an error and will need to be homed before any other commands will be accepted.
Servo Amplifier Error Codes

Number Designation Explanation
Servo amplifier has high power and is enabled. This is the normal
Exx Status Message
operating state.
Servo amplifier has high power but is not enabled. This is the normal
Pxx Status Message state when the system has not been given a motion command since it
was powered up or since an E-stop has been cleared.
... Status Message Amplifier is updating the startup configuration
- Status Message Status message, no error, programming mode (contact Promess)
The safety circuit is not clear. This message should be displayed when
-S- AS-Enable
an E-stop button is pressed or a light screen is broken.
F01 Heat Sink Temperature Heat sink temperature too high (default: 80C)
Overvoltage in DC bus link. Limit depends on the electrical supply
F02 Overvoltage
voltage
F03 Following Error Message from the position controller
Cable break short-circuit, short to ground. Could be an indication of a
F04 Feedback
problem with the encoder cable.
F05 Under voltage Under voltage in DC bus link (default: 100V)
Motor temperature too high or temp. sensor defect. Could be an
F06 Motor Temperature
indication of a problem with the encoder cable.
F07 Internal Voltages Internal supply voltages not ok
F08 Overspeed Motor runs away, speed is too high
F09 EEPROM Checksum error
Signal failure X5 (cable break or similar). Could be an indication of a
F10 Signal Failure X5 problem with the X5 connector or cable (only used for external digital
probes).
F11 Brake Cable break short-circuit, short to ground
Motor phase missing (cable break or similar). Could be an indication of
F12 Motor Phase a problem with the motor power cable or incoming three phase power.
May require a system reboot when the issue is corrected.
F13 Ambient Temperature Ambient temperature too high
F14 Output Stage Fault in the power output stage
F15 It max. It maximum value exceeded
F16 Mains BTB/RTO 2 or 3 phases missing in the mains supply feed
Error in the analog-digital conversion, normally caused by extreme
F17 A/D Converter
electromagnetic interference
F18 Regen Regen circuit faulty or incorrect setting
F19 DC Bus Link DC bus link breakdown
Slot error, depends on the type of expansion card (see ASCII command
F20 Slot Error
reference)
F21 Handling Error Handling error on the expansion card
F22 Reserved Reserved
F23 CAN-Bus Off Severe CAN bus communication error


Servo Amplifier Error Codes

F24 Warning Warning is displayed as fault
F25 Commutation Error Commutation error
F26 Limit Switch Hardware limit switch error on homing move
Usually an indication of a safety relay timing issue. The STO-Enable
(AS-Enable) and Enable signals should be run through a delayed
F27 AS-Enable/STO-Enable
contact on the safety relay that drops low at least 500ms after the PStop
input drops low.
F28 Fieldbus Error Fieldbus error (see ASCII command reference)
This is usually generated because the delay for the delayed contacts on
F29 Safety Relay Fault the safety relay is not set long enough. The delay should be at least
500ms.
F30 Emergency Timeout Timeout emergency stop
F31 Reserve Reserve
F32 System Error System software not responding correctly
16.2 Warnings
A servo amplifier warning will not result in the output stage of the motor being turned off.
Servo Amplifier Warning Codes

Number Designation Explanation
Servo amplifier has high power and is enabled. This is the normal
Exx Status Message
operating state.
Servo amplifier has high power but is not enabled. This is the normal state
Pxx Status Message when the system has not been given a motion command since it was
powered up or since an E-stop has been cleared.
... Status Message Amplifier is updating the startup configuration
Normal E-stop message,
-S- AS/STO-Enable input is 0V (with disabled drive only)
AS-Enable
- Status Message Status Message, no error, programming mode (contact Promess)
n01 It It threshold exceeded
n02 regen power reached preset regen power limit
Exceeded preset following error limit (the systems actual position is too
far away from the commanded position). If the system has a brake, it
n03 Lag Error Fault
could be an indication that the brake is not releasing. Verify that the brake
has 24VDC when the system is enabled (given a motion command).
n05 supply phase mains supply phase missing
n06 SW limit switch 1 Negative software limit switch activated
n07 SW limit switch 2 Positive software limit switch activated
n08 motion task error a faulty motion task was started
n10 PSTOP PSTOP limit-switch activated
The NSTOP input does not have 24VDC. Make sure the preamplifier has
power and that the press is not retracted far enough to make the home
n11 NSTOP (home switch)
switch. For a Torque-PRO system that does not use a home switch, the
NSTOP input can be jumpered to 24VDC.
There is a communication issue between the MotionPRO card and the
Communication between MotionPRO DrivePRO servo amplifier. Sometimes accompanied by an F29 fault. Make
n17
and Drive sure you are supplying both the MotionPRO card and the DrivePRO with a
steady 24VDC.
n19 motion task ramps are limited range overflow on motion task data
n20 invalid motion task invalid motion task
the user can shut down the process before the temperature error will
n22 max. motor temperature reached
interrupt the process immediately
n25-n31 Reserve Reserve
n32 firmware beta version The drive firmware is a beta version. This will not affect operation.


17.0 Fieldbus Documentation

The MotionPRO controller can be ordered with an optional Fieldbus module for added I/O and data
exchanging capabilities. The standard choices for the type of Fieldbus are Profibus, DeviceNet, Ethernet I/P,
ProfiNet, and ModbusTCP. If you need to use a Fieldbus option that is not listed, please contact Promess to
check availability. The memory map is the same for each of the options (see section 17.7). When defining the
size of the input and output blocks on the PLC side, they should be set to match the number of bytes that will
be used from the memory map. The number of bytes is configured on the Fieldbus tab of the System Settings
screen, under the Setup pulldown menu. For example, if only Digital outputs (4 bytes) and Real outputs (64
bytes) will be used, the Output Size should be set to 68 bytes.
17.1 Byte Swapping

If data being sent to or from the PLC shows up different after it is sent, there could be a byte swapping issue.
This is a compatibility issue between the PLC and MotionPRO and has to do with the order in which each one
sends and interprets bytes of data. The Number Format option in the MotionPRO software is used to correct
this problem by selecting the type of chip being used in the PLC Intel or Motorola. This selection is made on
the Fieldbus tab of the System Settings screen, under the Setup pulldown menu. Select the correct chip for
your PLC and the data should be interpreted correctly.
17.2 Profibus
Configuration information for the PLC connection to the MotionPRO Profibus module can be found in the gsd
file supplied by Promess (PROM0935.gsd for the Version 1 memory map or HMSB1811.gsd for Version 2).
NOTE: When using the Version 2 memory map with Profibus, the total number of bytes (inputs +
outputs) is limited to 152.
17.3 DeviceNet
Configuration information for the PLC connection to the MotionPRO DeviceNet module can be found in the
eds file supplied by Promess (324-8172-EDS_ABCC_DEV_V_2_3.EDS for both memory map versions).
17.4 Ethernet I/P

Configuration information for the PLC connection to the MotionPRO Ethernet I/P module can be found in the
eds file supplied by Promess (368-9523-EDS_ABCC_EIP_V_2_2.eds for both memory map versions.). Below
is an example screen shot of the configuration for the PLC setup to communicate with the Ethernet I/P
module. The example was created using an Allen-Bradley PLC. The IP Address should match that of the
MotionPRO Ethernet I/P module which is configured on the Fieldbus tab of the System Settings screen,
under the Setup pulldown menu. The Assembly Instance for the Input, Output, and Configuration fields
should be 100, 150, and 1 respectively, as shown. The Size for the Inputs and Outputs should match the
number of bytes being used from the Fieldbus memory map. The number of bytes being used can be found
by adding the number of bytes for each option that is selected. For example, if all options are selected (Digital
= 4 bytes, Integer = 64 bytes, Real = 64 bytes, String = 52 bytes), the size should be set to 184 (4 + 64 + 64 +
52). The Size for the Configuration should be set to 0.


17.5 ProfiNet
Promess offers ProfiNet in two different styles: single port and dual port. Configuration information for the PLC
connection to the MotionPRO single-port ProfiNet module can be found in the xml file supplied by Promess
(GSDML-V2.2-PromessInc-MotionPRO-20110608.xml for both memory map versions). Configuration
information for the PLC connection to the MotionPRO dual-port ProfiNet module can be found in the xml file
supplied by Promess (GSDML-V2.25-PromessInc-PRT2P-20120514.xml for both memory map versions).
17.6 Establishing Fieldbus Communication

Each different type of Promess fieldbus module includes indicator lights to show the status of the connection
between the module and the PLC. During normal operation when the fieldbus module is communicating with
the PLC, both lights will be solid green. Below is a description of the lights and their meaning in different
situations. If there is a communication problem, make sure that the correct gsd/eds/xml file was used, that the
memory map is setup the same on the PLC side and on the MotionPRO side, and that there are no conflicts
with the IP address/node ID on the fieldbus network.
17.6.1 Profibus


17.6.2 DeviceNet


17.6.3 Ethernet IP


17.6.4 ProfiNet


17.6.5 Modbus TCP


17.7 Fieldbus Memory Map

The MotionPRO Fieldbus Memory Map can be configured in a number of different ways. There are four
different types of inputs and outputs that can be used with the MotionPRO system: Digital, Integer, Real, and
Character, with an additional section of Error bit outputs (only available when Version 2 is selected). In total,
there are up to 184 bytes of inputs and 184 bytes of outputs (192 bytes of outputs in Version 2) that can be
used. That includes 4 bytes each of the Digital Inputs and Outputs (32 individual inputs and outputs), 64 bytes
each of Integer Inputs and Outputs (16 individual integer inputs and outputs), 64 bytes each of Real number
Inputs and Outputs (16 individual real number inputs and outputs), and 52 bytes each of Character Inputs and
Outputs (52 ASCII input and output characters).
The first selection that must be made is the configuration version (Version 1 or 2). Version 1 will allow each
type of input or output to be turned on or off. For example, if Version 1 is selected, for the Digital Inputs, you
will be able to select 32 bits (on) or 0 bits (off).
Version 2 was added to allow additional customization of the Fieldbus memory map. When Version 2 is
selected, the memory map can be configured down to the number of bits (8, 16, 24, or 32 inputs/outputs) for
the Digital Inputs/Outputs and for the Character Inputs/Outputs (12, 24, 36, or 52 characters), and down to the
individual element level (e.g. the user can select the exact number of inputs/outputs of each different type) of
the Integer and Real Inputs/Outputs, which allows the user to define the size of the memory map. In addition,
with Version 2 there is also the option to use additional Error bits that are dedicated to common faults that can
occur, like force overloads and drive faults.
The full memory map on the following pages is based on all I/O options being turned on in the MotionPRO
Software. Each page represents one type of input or output. If some of the options are selected and others
are not, or if only parts of some of the options are selected in Version 2, the map will be appended to keep a
numeric order of the bytes. Example: If the only output options selected are Digital Outputs and Real
Outputs, and Integer Outputs are not used, the Real Outputs will be assigned to Bytes 4 -67, instead of Bytes
68 131 where they would be if Integer Outputs were also used. See the pictures below as further example.
Also, please contact Promess for a Fieldbus Memory Map Layout Calculator.
Notes: The first picture below shows the Promess standard memory map configuration. The inputs and
outputs shown on the memory map represent the default Promess configuration.
Byte 0 Byte 191
Bytes 0-3 ---- Bytes 4-11 ---- Bytes 12-23 ---- Bytes 24-47
Byte 0 Byte 183
Bytes 0-3 ---- Bytes 4-23 ---- Bytes 24-47


Byte 0 Byte 183
Bytes 0-3 ---- Bytes 4-55 ---- Bytes 56-183 Unused
Byte 0 Byte 183
Byte 0 Byte 183
Byte 0 Byte 183
Byte 0 Byte 191
Byte 0 ---- Bytes 1-3 ---- Bytes 4-31 ---- Bytes 32-71----Bytes 72-107 Unused
Byte 0-1 ---- Bytes 2-13 ---- Bytes 14-61 ---- Bytes 62-73
Byte 0 Byte 183


Outputs from MotionPRO Digital Outputs

Signal Data Type MotionPRO Index Bit Byte Word Description
Set when MotionPRO
Field Out #1 Ready Boolean Digital Output #1 0 is ready to receive
command input
Set when the end of the
Field Out #2 Cycle End Boolean Digital Output #2 1 program has been
reached
Set when the last
Field Out #3 Pass Boolean Digital Output #3 2 program part status was
Passed
Set when the last
Field Out #4 Fail Boolean Digital Output #4 3 program part status was
Byte 0 Failed
Set when the program is
Field Out #5 Cycle Stop Boolean Digital Output #5 4 in a cycle stop state
Field Out #6 Home Req Boolean Digital Output #6 5 Homing required

Field Out #7 User Boolean Digital Output #7 6 General purpose field
Field Out #8 User Boolean Digital Output #8 7 outputs. Usage depends
Field Out #9 User Boolean Digital Output #9 0 Word 0 on system User outputs
Field Out #10 User Boolean Digital Output #10 1 configuration in the
MotionPRO software.
Field Out #11 User Boolean Digital Output #11 2
Boolean 3 Byte 1 Set when there is a
Field Out #12 Drive Fault Digital Output #12 servo amplifier fault.
Field Out #14 User Boolean Digital Output #14 5 General purpose
Field Out #15 User Boolean Digital Output #15 6 field outputs
Field Out #17 Binary Out #1 Boolean Digital Output #17 0
Field Out #18 Binary Out #2 Boolean Digital Output #18 1 The Binary Outputs
allow the current
Byte 2 part program
number to be
output.
Field Out #25 User Boolean Digital Output #25 0 Word 1
Field Out #27 User Boolean Digital Output #27 2 General purpose
Field Out #28 User Boolean Digital Output #28 3 Byte 3 field outputs


Outputs from MotionPRO Error Bit Outputs

Error Bit Boolean Error Bit #1 0 F4 Feedback Error
Error Bit Boolean Error Bit #2 1 F6 Motor Over Temperature
Error Bit Boolean Error Bit #3 2 F8 Overspeed
Error Bit Boolean Error Bit #4 3 F10 Signal Failure Digital Encoder Input
Error Bit Boolean Error Bit #5 4 BYTE 4 F11 Brake Error

Error Bit Boolean Error Bit #6 5 F15 I^2T Max Override
Error Bit Boolean Error Bit #7 6 F16 Mains BTB

F25 Commutation Error (Runaway of the
Error Bit Boolean Error Bit #8 7 motor)
WORD 2
Error Bit Boolean Error Bit #9 0 N01 I2T Threshold Override
Error Bit Boolean Error Bit #10 1 N03 Lag Error

Error Bit Boolean Error Bit #11 2 N05 Line Phase Missing
Error Bit Boolean Error Bit #12 3 N08 Wrong Motion Task Started
BYTE 5 N11 Home Switch Activated
Error Bit Boolean Error Bit #13 4
Error Bit Boolean Error Bit #14 5 Q5 Negative Overload Limit Violated
Error Bit Boolean Error Bit #15 6 Q6 Positive Overload Limit Violated
Error Bit Boolean Error Bit #16 7 Currently Not Used

I1 Lost Cycle Start Input Before Cycle
Error Bit Boolean Error Bit #17 0 Was Finished
I2 Lost The Homing Input Before The
Error Bit Boolean Error Bit #18 1 Homing Was Finished
I3 Attempted to Perform a Command that
Error Bit Boolean Error Bit #19 2 Requires the System To Be Homed First
S10 Operation Cannot Be Performed
Error Bit Boolean Error Bit #20 3 BYTE 6 Because System Is Not Yet Homed
I5 A Command Is Not Recognized
Error Bit Boolean Error Bit #21 4 Because The System Is Not Ready
WORD 3 Currently Not Used

BYTE 7 Currently Not Used
Error Bit Boolean Error Bit #33 0 P9 Runtime Error In Program

P600 Move to Signal Step Not Allowed
Error Bit Boolean Error Bit #34 1 Because the Current Position Is Greater
Than Maximum
P601 Move to Signal Step Not Allowed
Error Bit Boolean Error Bit #35 2 Because the Current Position Is Less
Than Minimum
BYTE 8 WORD 4 P602 Move to Signal Step Not Allowed To
Error Bit Boolean Error Bit #36 3 Move In A Negative Direction
P603 Move to Signal Step Not Allowed To
Error Bit Boolean Error Bit #37 4 Move In A Positive Direction


Outputs from MotionPRO Error Bit Outputs




WORD 5 Currently Not Used
Error Bit Boolean Error Bit #60 3 BYTE 11 Currently Not Used



Outputs from MotionPRO Integer Outputs

Signal Data Type MotionPRO Index Byte Word Description
Numeric Value Integer Byte 12
Word 6
Numeric Value Integer
Integer Output #1 Byte 14
Word 7
Word 8
Word 9
Word 10
Word 11
Word 12
Word 13
Word 14
Word 15
Word 16
Word 17
Word 18
Word 19
Word 20
Integer Output #8 Used to send a
Word 21 numeric (Integer)
Numeric Value Integer Byte 44 value from
Word 22 MotionPRO to PLC
Word 23
Word 24
Word 25
Word 26
Word 27
Word 28
Word 29
Word 30
Word 31
Word 32
Word 33
Word 34
Word 35
Word 36
Numeric Value Integer Integer Output #16 Byte 74
Numeric Value Integer Byte 75 Word 37


Outputs from MotionPRO Real Outputs

Numeric Value Real Byte 76
Word 38
Numeric Value Real
Real Output #1 Byte 78
Word 39
Word 40
Numeric Value Real
Word 41
Word 42
Numeric Value Real
Word 43
Word 44
Numeric Value Real
Word 45
Word 46
Numeric Value Real
Word 47
Word 48
Numeric Value Real
Word 49
Word 50
Numeric Value Real
Word 51
Word 52
Numeric Value Real
Real Output #8 Byte 106 Used to send a
Word 53 numeric (Real)
Numeric Value Real Byte 108 value from
Word 54
Real Output #9 MotionPRO to PLC
Word 55
Word 56
Numeric Value Real
Word 57
Word 58
Numeric Value Real
Word 59
Word 60
Numeric Value Real
Word 61
Word 62
Numeric Value Real
Word 63
Word 64
Numeric Value Real
Word 65
Word 66
Numeric Value Real
Word 67
Word 68
Real Output #16
Numeric Value Real Byte 138 Word 69

Outputs from MotionPRO Character Output

ASCII String Char Character (ASCII) ASCII Character #1 Byte 140
Word 70
Word 71
Word 72
Word 73
Word 74
Word 75
Word 76
Word 77
Word 78
Word 79
Word 80
Word 81
Word 82 Used to send an
ASCII string from
Word 83 MotionPRO to PLC
Word 84
Word 85
Word 86
Word 87
Word 88
Word 89
Word 90
Word 91
Word 92
Word 93
Word 94
Word 95


Inputs to MotionPRO Digital Inputs

Command input to start
Field In #1 Cycle Start Boolean Digital Input #1 0 the program
Field In #2 User Boolean Digital Input #2 1
General purpose
field inputs
Command input to
Field In #5 Home Boolean Digital Input #5 4 home the system
Byte 0 Command input to reset
Field In #6 Reset Boolean Digital Input #6 5 the part status
Field In #9 User Boolean Digital Input #9 0 General purpose
field inputs. Usage
depends on system
Word 0 User input
Field In #12 User Boolean Digital Input #12 3 Byte 1
configuration in the
Field In #13 User Boolean Digital Input #13 4 MotionPRO
Field In #14 User Boolean Digital Input #14 5 software.
Field In #17 Binary In 1 Boolean Digital Input #17 0
The Binary Inputs
allow for the
Byte 2 remote selection of
different part
Field In #21 Binary In 16 Boolean Digital Input #21 4 programs.
Command input to open
Field In #23 Prog Strobe Boolean Digital Input #23 6 specified program
Word 1 Command input to set
Field In #24 Serial # Strobe Boolean Digital Input #24 7 the serial number
Field In #25 Jog Input Boolean Digital Input #25 0 Command inputs to
Field In #26 Jog Input Boolean Digital Input #26 1 manually jog the system
Field In #28 User Boolean Digital Input #28 3 Byte 3
Field In #29 User Boolean Digital Input #29 4 General purpose
Field In #30 User Boolean Digital Input #30 5 field inputs


Inputs to MotionPRO Integer Inputs

Word 2
Integer Input #1 Byte 6
Word 3
Word 4
Word 5
Word 6
Word 7
Word 8
Word 9
Word 10
Word 11
Word 12
Word 13
Word 14
Word 15
Word 16
Integer Input #8 Used to send a
Word 17 numeric (Integer)
Numeric Value Integer Byte 36 value from PLC to
Word 18 MotionPRO
Word 19
Word 20
Word 21
Word 22
Word 23
Word 24
Word 25
Word 26
Word 27
Word 28
Word 29
Word 30
Word 31
Word 32
Numeric Value Integer Integer Input #16 Byte 66
Numeric Value Integer Byte 67 Word 33


Inputs to MotionPRO Real Inputs

Word 34
Numeric Value Real
Real Input #1 Byte 70
Word 35
Word 36
Numeric Value Real
Word 37
Word 38
Numeric Value Real
Word 39
Word 40
Numeric Value Real
Word 41
Word 42
Numeric Value Real
Word 43
Word 44
Numeric Value Real
Word 45
Word 46
Numeric Value Real
Word 47
Word 48
Numeric Value Real
Real Input #8 Byte 98 Used to send a
Word 49 numeric (Real)
Numeric Value Real Byte 100 value from PLC to
Word 50
Real Input #9 MotionPRO
Word 51
Word 52
Numeric Value Real
Word 53
Word 54
Numeric Value Real
Word 55
Word 56
Numeric Value Real
Word 57
Word 58
Numeric Value Real
Word 59
Word 60
Numeric Value Real
Word 61
Word 62
Numeric Value Real
Word 63
Word 64
Real Input #16
Word 65

Inputs to MotionPRO Character Input

Word 66
Word 67
Word 68
Word 69
Word 70
Word 71
Word 72
Word 73
Word 74
Word 75
Word 76
Word 77
Word 78 Used to send an
ASCII string from
Word 79 PLC to MotionPRO
Word 80
Word 81
Word 82
Word 83
Word 84
Word 85
Word 86
Word 87
Word 88
Word 89
Word 90
Word 91


17.7 Sending the MotionPRO a Serial Number

Note: Sending a serial number to the MotionPRO controller requires an optional Fieldbus module.
Sending a serial number to the MotionPRO is done using the Character input section of the Fieldbus memory
map and the Serial Number Strobe input, which is configured on the Inputs tab of the System Settings
screen, under the Setup pulldown menu. To send a serial number, follow the steps below.
1. From the PLC, put the serial number into the Character input section of the MotionPRO Fieldbus
memory map. Each byte should contain one character, as shown below. In the example, the serial
number would be set to 1234_567A.
2. Make sure the MotionPRO Ready signal is on.
3. Turn on the Serial Number Strobe input until the Ready signal drops low.
4. Once the Ready signal goes high again, the serial number has been processed and the MotionPRO
is ready to run the next cycle. See the timing diagram in section 8.9 for more information.
Character Signal Data Type Byte Word

1 ASCII String Char Character (ASCII) Byte 132 Word 66
2 ASCII String Char Character (ASCII) Byte 133
_ ASCII String Char Character (ASCII) Byte 136 Word 68
A ASCII String Char Character (ASCII) Byte 140 Word 70
ASCII String Char Character (ASCII) Byte 141
ASCII String Char Character (ASCII) Byte 142 Word 71
ASCII String Char Character (ASCII) Byte 162 81 - 91
ASCII String Char Character (ASCII) Byte 163 -183


17.8 Live Sensor Readings/Exchanging Data Between MotionPRO and a PLC

Note: Exchanging data/live sensor readings from the MotionPRO controller requires an optional
Fieldbus module.
Exchanging data values and/or live sensor readings from the MotionPRO to a PLC is done using either the
Integer or Real Fieldbus inputs and/or outputs. The setup is done on the FieldBus tab of the System
Settings screen, under the Setup pulldown menu.
To exchange data, click on the Linking button next to the desired type of input or output. Use the pulldown
menu next to the Fieldbus input or output you want to use to select the type of data you want to transfer.
For linking outputs, all sensor values and variable values will appear in the list. Selecting a sensor name
(such as Force, shown above) will output a live reading of that sensor to the selected Fieldbus output.
Selecting a variable name will output the live value of that variable to the selected Fieldbus output.
Linking an input can be used to send a variable value from the PLC to the MotionPRO, such as for
dynamically changing a value that is used for a Positioning move or other command. Select the desired
variable from list. The value for that variable can then be changed by writing the desired value to the
corresponding memory location in the Fieldbus memory map.
Once the data exchange is configured, the FieldBus Values In and FieldBus Values Out tabs on the
Service screen can be used for troubleshooting and verification.


18.0 PRO-MC Installation Instructions

This section describes the PRO-MC, using Promess MotionPRO S70101-S72401 series digital servo
amplifiers (standard version: 1.5A ...24A rated current, single or dual channel STO).
18.1 About the PRO-MC

The PRO-MC uses enclosed Type 1, AC adjustable speed drives that convert 3-phase, 50/60 Hz input
voltage to an adjustable output frequency and voltage for controlling the speed, torque, and position of
electrical motors intended to be used to control the motion of a Promess EMAP, TorquePRO, REMAP
(Rotational Electro-Mechanical Assembly Press), or any other Promess motion-controlled device. The drive
includes power conversion components, power and control logic devices, and regulator circuitry provided with
integral overload and over speed protection for the motor.
A microprocessor is used to control the drive regulators and power semiconductors which generate a pulse
width modulated (PWM) output wave form. The drive may include control options and/or external main circuit
options. Options can be internally mounted or can be installed in the field.
RATINGS The units are rated as follows;
PRO-MC Drive Amps HP

Size Model Voltage [VAC]
Part Number Part Number [A] [KVA]
1 PRO-MC-S701 8500400700 S70101-NA-024 3 x 208V-10% 3 x 480V+10%, 50/60 Hz 1.5 1.1
2 PRO-MC-S703 8500400700 S70301-NA-024 4 x 208V-10% 3 x 480V+10%, 50/60 Hz 3 2.2
3 PRO-MC-S706 8500400700 S70601-NA-024 5 x 208V-10% 3 x 480V+10%, 50/60 Hz 6 4.5
4 PRO-MC-S712 8500400700 S71201-NA-024 6 x 208V-10% 3 x 480V+10%, 50/60 Hz 12 9
5 PRO-MC-S724 8500400700 S72401-NA-024 7 x 208V-10% 3 x 480V+10%, 50/60 Hz 24 18
Short Circuit Rating The drive is suitable for use on a circuit capable of delivering not more than 42 kA
symmetrical amperes (rms) at 500V Maximum
Environmental Ambient Temperature Rating - 40C for Type 1 enclosure.
Duty Cycle Note: When Operating the PRO-MC enclosure at an ambient temperature of 40C, there must
be a minimum 2 second delay between cycles to maintain a safe operating temperature inside the PRO-MC.
The drive will trip and send an over temperature fault if this delay is not maintained.
18.2 Installation Instructions

The PRO-MC must be installed in clean air according to enclosure classification. Cooling air must be clean,
and free from corrosive materials and electrically conductive dust.
When connecting wires to all terminals, make sure no power is on any of the wires before the wires are
connected to the terminals. Failure to do so could result in injury or death.
18.3 Target Group

These instructions address personnel with the following qualifications:
Transport : only by personnel with knowledge of handling electrostatically sensitive components.
Unpacking: only by electrically qualified personnel.
Installation : only by electrically qualified personnel.
Setup : only by qualified personnel with extensive knowledge of electrical engineering and drive
technology
The qualified personnel must know and observe the following standards:
IEC 60364 and IEC 60664 national accident prevention regulations


During operation there are deadly hazards, with the possibility of death, severe
injury or material damage. The operator must ensure that the safety instructions in
this manual are followed. The operator must ensure that all personnel responsible
for working with the servo amplifier have read and understood the product manual.
17.4 Safety Instructions
During operation there are deadly hazards, with the possibility of death, severe
injury or material damage. Do not open or touch the equipment during operation.
Keep all covers and cabinet doors closed during operation. Touching the
equipment is allowed during installation and commissioning for properly qualified
persons only.
During operation, servo amplifiers may have uncovered live components,
depending on their level of enclosure protection.
Control and power connections may be live, even though the motor is not
rotating.
Servo amplifiers may have hot surfaces during operation.
Surface can reach temperatures above 80C.
There is a danger of electrical arcing with damage to contacts and personal injury.
Never undo any electrical connections to the servo amplifier while it is live.
Wait at least eight minutes after disconnecting the servo amplifier from the main
supply power before touching potentially live sections of the equipment (e.g.
contacts) or undoing any connections.
Capacitors can still have dangerous voltages present up to eight minutes
(5 min @ 1.5A to 12A types, 8 min @ 24A type) after switching off the supply power.
To be sure, measure the voltage in the DC Bus link and wait until it has fallen
below 40V.
Incorrect handling of the servo amplifier can lead to personal injury or material
damage. Read this documentation before carrying out the installation and
commissioning. It is vital that you keep to the technical data and information on
connection requirements (nameplate and documentation).
Only properly qualified personnel are permitted to carry out activities such as
transport, installation, commissioning and maintenance. Properly qualified persons
are those who are familiar with the transport, assembly, installation,
commissioning and operation of the product, and who have the appropriate
qualifications for their job. The qualified personnel must know and observe the
following standards:
IEC 60364 and IEC 60664
national accident prevention regulations
The manufacturer of the machine must produce a hazard analysis for the machine
and take appropriate measures to ensure that unforeseen movements do not result
in personal injury or material damage.


18.5 Enclosure and Electrical Drawings












18.6 Approvals
18.6.1 Conformance with UL
The Pro-MC is listed under UL file number E350817.
UL-certified servo amplifiers (Underwriters Laboratories Inc.) fulfill the relevant U.S. standards
(in this case UL 840 and UL 508C).
This standard describes the fulfillment by design of minimum requirements for electrically
operated power conversion equipment, such as frequency converters and servo amplifiers,
which is intended to eliminate the risk of fire, electric shock, or injury to persons,
being caused by such equipment.
Apart from the notes on installation and safety in the documentation, the customer does
not have to observe any other points in direct connection with the UL-certification of the
equipment.
UL 508C
UL 508C describes the fulfillment by design of minimum requirements for electrically

operated power conversion equipment, such as frequency converters and servo amplifiers,
which is intended to eliminate the risk of fire being caused by such equipment.
UL 840
UL 840 describes the fulfillment by design of air and insulation creepage spacings for
electrical equipment and printed circuit boards.
18.6.2 UL Markings
Use 75C copper wire only for every model of this section.
Use Class 1 wire only or equivalent.
Tightening torque for field wiring terminals.
X0B, X9: 0.7 - 0.8Nm
Suitable for use on a circuit capable of delivering not more than 42kA rms symmetrical
amperes for a max. voltage of 480 Vac.
For circuit protection see table below.
Model Fuse Class Rating Max. Fuse Rating

S7010 RK5, CC, J, T 600VAC 200kA 6A (Time-Delay)


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1.0 Safety ............................................................................................................................ 4

11.0 EMAP Load Cell Calibration .................................................................................... 31

MotionPRO Technical Manual Revision 1.14 -3-

MotionPRO Technical Manual Revision 1.14 -4-

It is strictly forbidden to disconnect, bridge, or remove any safety devices or installations!

Put main switch in OFF position.

The Promess Electro Mechanical press unit may harm the

MotionPRO Technical Manual Revision 1.14 -5-

2.0 MotionPRO System

2.2 System Overview

MotionPRO Technical Manual Revision 1.14 -6-

2.3 System Installation Notes

MotionPRO Technical Manual Revision 1.14 -7-

MotionPRO Technical Manual Revision 1.14 -8-

2.3.2 Three-Phase Power in an E-Stop Condition

Preamplifier(s) Mounting Detail

2.3.5 Discrete I/O Power Supply

2.3.6 Computer Location

2.3.7 Servo Amplifier Environment

MotionPRO Technical Manual Revision 1.14 -9-

3.0 EMAP Mechanical Layout

MotionPRO Technical Manual Revision 1.14 -10-

4.0 Input Signals

Note: All inputs to the MotionPRO Controller are 24VDC / 20mA.

MotionPRO Technical Manual Revision 1.14 -11-

Input Signals Continued

Input Signal Description

5.0 Output Signals

Note: All outputs are 24VDC / 100mA

MotionPRO Technical Manual Revision 1.14 -12-

Ready (Contd) The Ready signal is NOT set if:

MotionPRO Technical Manual Revision 1.14 -13-

6.0 MotionPRO Controller Connections

6.1 MotionPRO Card

A1 Analog Input 1 A1 Analog Input 1

C Input Common 0VDC

MotionPRO Card w/ Profibus MotionPRO Card w/ DeviceNet

A1 Analog Input 1 A1 Analog Input 1

24V CF Supply Power 24VDC 24V CF Supply Power 24VDC

MotionPRO Technical Manual Revision 1.14 -14-

6.2 Servo Amplifier Connections

PROMESS E24 DrivePRO

X4A X4B X4A X4B

6.3 PRO-MC Connections

X3.1 X12 X11.2

AN_1- 24V AN_1- = DrivePRO Ana Input 1 Sig- Preamplifier)

Ain_1 I_3 AGND = DrivePRO Ana Input GND I_5 = Input #5

DI_1 DI_1 = MotionPRO Board Dig. In. 1 O_5 = Output #5

MotionPRO Technical Manual Revision 1.14 -15-

7.0 MotionPRO Input and Output Circuits

Internal to the MotionPRO controller

Internal to the MotionPRO controller

MotionPRO Technical Manual Revision 1.14 -16-

8.0 Timing Diagrams

1. The Home input must be set high for at least 50 ms.

Typical Homing Motion Sequence

The following motion occurs when the press is homed:

MotionPRO Technical Manual Revision 1.14 -17-

MotionPRO Technical Manual Revision 1.14 -18-

8.3 Cycle Start

Cycle Start Release Exceptions: