MultiProFL OperatingInstructions TD-3191011 V1 3 Lite

OPERATING INSTRUCTIONS
Incl. assembly instructions according to EC Machinery Directive 2006/42/EC, Annex VI

for incomplete machines.
Press-in control system
MultiPro FL
TD-3191011, Version 1.3
Translation of the original German
operating instructions
DSM Messtechnik GmbH

Dieselstraße 16
73431 Aalen
Germany
ENGLISH
Please read these operating instructions carefully to facilitate long-term
and safe working with the press-in control system.
WARNING
Read all safety notes and instructions. Store the safety notes, instructions and
information summarised in these operating instructions for future use.
PDF version of the operating instructions

Contents
Operating instructions Press-in control system MultiPro FL
Contents
Chapter Page
1 Important basic information .................................................................................................................................................................. 7

1.1 Scope of delivery .............................................................................................................................................................................................................7
1.2 Declaration of incorporation .............................................................................................................................................................................................8
1.3 Legal information .............................................................................................................................................................................................................9
1.4 Documentation .................................................................................................................................................................................................................9
1.5 Abbreviations .................................................................................................................................................................................................................12
1.6 Service address / contact ..............................................................................................................................................................................................13
2 Safety.................................................................................................................................................................................................... 14
2.1 Conventions for safety instructions ................................................................................................................................................................................14
2.2 Intended use ..................................................................................................................................................................................................................15
2.3 Application......................................................................................................................................................................................................................15
2.4 Requirements to the personnel......................................................................................................................................................................................15
2.5 Safety precautions .........................................................................................................................................................................................................15
2.6 Protective devices ..........................................................................................................................................................................................................16
2.7 Safety-relevant ambient conditions ...............................................................................................................................................................................16
2.8 Safety-relevant information ............................................................................................................................................................................................17
2.9 Observing the operating instructions .............................................................................................................................................................................19
2.10 Identification on the product ...........................................................................................................................................................................................20
3 Technical data ...................................................................................................................................................................................... 21

3.1 Data sheet MultiPro FL ..................................................................................................................................................................................................21
3.2 Type overview MultiPro FL ............................................................................................................................................................................................23
4 Design of the press-in control system ............................................................................................................................................... 24

4.1 Modular design ..............................................................................................................................................................................................................24
4.2 Front view of control module..........................................................................................................................................................................................25
4.3 Interfaces and CompactFlash slot on the control module .............................................................................................................................................26
4.3.1 Interfaces X6 PC / X7 Printer ....................................................................................................................................................................26
4.3.2 Interfaces X10 Profibus / X14 TCP ............................................................................................................................................................27
4.3.3 Interface X52...............................................................................................................................................................................................27
4.3.4 Interfaces X58 System bus IN / X59 System bus OUT ..............................................................................................................................28
4.3.5 Interface X53 Universal ..............................................................................................................................................................................28
4.4 Versions and interfaces of the basic module .................................................................................................................................................................29
4.4.1 Design DS-L................................................................................................................................................................................................30
4.4.2 Design DS-H ...............................................................................................................................................................................................31
4.4.3 Design DS-V ...............................................................................................................................................................................................32
4.4.4 Machine Safety Interface: Interface „X76 MSI“ ..........................................................................................................................................33
5 Functional description......................................................................................................................................................................... 34
5.1 Function principle of the press-in control system ..........................................................................................................................................................34
5.2 Protective device / Protection concept ..........................................................................................................................................................................36
5.3 Schema of the function principle....................................................................................................................................................................................36
5.4 Stroke measurement ......................................................................................................................................................................................................37
5.5 Linearisation, bending-up compensation .......................................................................................................................................................................38
5.5.1 Record "Overrun curve" graphic .................................................................................................................................................................39
5.5.2 Determining the linearisation values ..........................................................................................................................................................40
5.6 Force measurement .......................................................................................................................................................................................................41
6 Process control description ................................................................................................................................................................ 42

6.1 Introduction ....................................................................................................................................................................................................................42
6.2 Before starting the joining process ................................................................................................................................................................................42
6.3 Measurements during the joining process .....................................................................................................................................................................42
6.4 After reaching the switch-off criterion ............................................................................................................................................................................43
6.4.1 Travelling on force without overrun ............................................................................................................................................................43
6.4.2 Travelling on force with overrun time .........................................................................................................................................................44
6.5 Joining processes ..........................................................................................................................................................................................................45
6.5.1 Travel on stroke ..........................................................................................................................................................................................46
6.5.2 Travel on force ............................................................................................................................................................................................48
6.5.3 Travel on initiator ........................................................................................................................................................................................51
6.5.4 Empty travel on stroke ................................................................................................................................................................................54
6.5.5 Function diagram „Review stroke“ ..............................................................................................................................................................57
© DSM Messtechnik GmbH 2018. All rights reserved!

Translation of the original German operating instructions - TD-3191011 / V1.3
Contents
6.5.6 Function diagram "Relative stroke measurement" .................................................................................................................................... 58

6.5.7 Function diagram "Force progression in OK window" ............................................................................................................................... 59
6.5.8 Function diagram "Hold force" (option) ...................................................................................................................................................... 60
6.5.9 Envelope function ...................................................................................................................................................................................... 61
6.6 Go initial position ........................................................................................................................................................................................................... 64
6.7 Joining sequence (programme) .................................................................................................................................................................................... 67
6.7.1 Signal time response: Joining process with OK result .............................................................................................................................. 67
6.7.2 Signal time response: Joining process with system error during programme sequence.......................................................................... 68
6.7.3 Signal time response: Joining process after occurrence of a system error .............................................................................................. 68
6.7.4 Signal time response: Joining process with start termination ................................................................................................................... 69
6.7.5 Signal time response: Joining process with PG preselection and NOK result.......................................................................................... 69
6.7.6 Signal time response: Joining process with termination by removing the ext. release ............................................................................. 70
7 Delivery, in-plant transport, storage................................................................................................................................................... 71

7.1 Delivery ......................................................................................................................................................................................................................... 71
7.2 Unpacking / Transport damage..................................................................................................................................................................................... 71
7.3 Repacking / Temporary storage.................................................................................................................................................................................... 71
7.4 In-plant transport ........................................................................................................................................................................................................... 71
7.5 Handling of packaging material..................................................................................................................................................................................... 72
7.6 Storage conditions ........................................................................................................................................................................................................ 72
8 Setup requirements ............................................................................................................................................................................. 73

8.1 Safety ............................................................................................................................................................................................................................ 73
8.2 Logistics data ................................................................................................................................................................................................................ 73
8.3 Ambient conditions ........................................................................................................................................................................................................ 74
8.4 Supply connections ....................................................................................................................................................................................................... 74
8.5 Other information .......................................................................................................................................................................................................... 74
9 Initial operation .................................................................................................................................................................................... 75

9.1 Safety ............................................................................................................................................................................................................................ 75
9.2 Assembly and installation ............................................................................................................................................................................................. 75
9.3 Configuration ................................................................................................................................................................................................................. 76
9.4 Sequence programming ................................................................................................................................................................................................ 77
10 Assembly and installation................................................................................................................................................................... 78

10.1 Safety ............................................................................................................................................................................................................................ 78
10.2 Assembly ....................................................................................................................................................................................................................... 78
10.3 Electrical installation...................................................................................................................................................................................................... 80
10.4 Connection options ....................................................................................................................................................................................................... 81
10.5 Electrical connection of basic module........................................................................................................................................................................... 82
10.5.1 Wiring diagram basic module DS-L Type3 ................................................................................................................................................ 82
10.5.2 Wiring diagram basic module DS-H Type2, Type5 ................................................................................................................................... 83
10.5.3 Wiring diagram basic module DS-V Type5................................................................................................................................................ 84
10.5.4 Assignment Power cable 230 VAC ............................................................................................................................................................ 85
10.5.5 Assignment Power cable 400 VAC ............................................................................................................................................................ 85
10.5.6 Assignment Connecting cable SMP 300 ................................................................................................................................................... 86
10.5.7 Assignment Motor cable SMP 400, QMP 80 ............................................................................................................................................. 87
10.5.8 Assignment Motor cable SMP 500, QMP 100, QMP 140 ......................................................................................................................... 88
10.5.9 C-HS cable SMP 400, SMP 500, QMP 80, QMP 100, QMP 140 ............................................................................................................. 89
10.6 Electrical connection of control module ........................................................................................................................................................................ 90
10.6.1 Wiring diagram control module MultiPro FL .............................................................................................................................................. 90
10.6.2 Assignment PC connecting cable .............................................................................................................................................................. 91
10.6.3 Assignment Printer cable ........................................................................................................................................................................... 92
10.6.4 Assignment System bus cable................................................................................................................................................................... 93
10.7 Settings with PC / Printer connection ........................................................................................................................................................................... 94
10.8 System bus.................................................................................................................................................................................................................... 95
10.8.1 System bus wiring ...................................................................................................................................................................................... 95
10.8.2 Supply voltage 24V .................................................................................................................................................................................... 96
10.8.3 Settings at system bus ............................................................................................................................................................................... 97
10.9 Profibus ......................................................................................................................................................................................................................... 98
10.9.1 Settings on the Profibus Master (PLC) ...................................................................................................................................................... 98
10.9.2 Settings at Profibus (press-in control system) ........................................................................................................................................... 99
10.9.3 Functional integration of the Profibus into the press-in control system................................................................................................... 101
10.9.4 Telegram structure ................................................................................................................................................................................... 102
10.9.5 Signal exchange ...................................................................................................................................................................................... 117
10.9.6 Parameterisation via Profibus (option) .................................................................................................................................................... 120
10.10 Settings with TCP/IP (optional module) ...................................................................................................................................................................... 121
10.11 Inputs / outputs ............................................................................................................................................................................................................ 122
10.11.1 System inputs........................................................................................................................................................................................... 122
10.11.2 Free inputs ............................................................................................................................................................................................... 122

Contents
10.11.3 System outputs .........................................................................................................................................................................................123

10.11.4 Free outputs ..............................................................................................................................................................................................123
10.11.5 Inputs when Profibus I/O = On .................................................................................................................................................................124
10.11.6 Inputs when Profibus I/O = Off .................................................................................................................................................................125
10.11.7 Outputs .....................................................................................................................................................................................................125
11 Operation............................................................................................................................................................................................ 126
11.1 Safety ...........................................................................................................................................................................................................................126
11.2 Operating controls ........................................................................................................................................................................................................127
11.3 Display functions ..........................................................................................................................................................................................................127
11.3.1 LED status display (limit value monitoring) ..............................................................................................................................................128
11.3.2 LCD display (production screen) ..............................................................................................................................................................128
11.4 Operating functions ......................................................................................................................................................................................................137
11.5 Operation: Configuration control unit ...........................................................................................................................................................................138
11.5.1 PG Start ....................................................................................................................................................................................................138
11.5.2 Linearisation table.....................................................................................................................................................................................144
11.5.3 SBUS-Start ...............................................................................................................................................................................................144
11.5.4 Status outputs ...........................................................................................................................................................................................145
11.5.5 Graphic settings ........................................................................................................................................................................................145
11.5.6 LCD contrast .............................................................................................................................................................................................145
11.5.7 LCD continuous light .................................................................................................................................................................................145
11.5.8 Date and Time ..........................................................................................................................................................................................146
11.5.9 Language ..................................................................................................................................................................................................146
11.5.10 Abort mode ...............................................................................................................................................................................................146
11.5.11 External release ........................................................................................................................................................................................147
11.5.12 Station number .........................................................................................................................................................................................147
11.5.13 Statistics about X-values ..........................................................................................................................................................................147
11.5.14 Red print ...................................................................................................................................................................................................147
11.5.15 Input NOK interlock ...................................................................................................................................................................................147
11.5.16 Access control...........................................................................................................................................................................................147
11.5.17 Statussignal ..............................................................................................................................................................................................148
11.5.18 External test mode ....................................................................................................................................................................................148
11.6 Operation: User administration ....................................................................................................................................................................................148
11.7 Operation: Configuration communication interfaces ...................................................................................................................................................150
11.8 Operation: Configuration press-in unit .........................................................................................................................................................................150
11.8.1 Auto-parameterisation ..............................................................................................................................................................................151
11.8.2 Unit of force (=Auto-parameter) ................................................................................................................................................................151
11.8.3 Calibration value (=Auto-parameter) ........................................................................................................................................................151
11.8.4 Max. feed (=Auto-parameter) ...................................................................................................................................................................151
11.8.5 Direction reversal (=Auto-parameter) .......................................................................................................................................................151
11.8.6 Feed ramp .................................................................................................................................................................................................151
11.8.7 Correction factor force ..............................................................................................................................................................................151
11.8.8 Correction factor stroke ............................................................................................................................................................................152
11.8.9 Maximum ramp time .................................................................................................................................................................................152
11.8.10 Starting position ........................................................................................................................................................................................152
11.8.11 Starting position (Vmax) ...........................................................................................................................................................................152
11.8.12 Starting position (only comp.) ...................................................................................................................................................................152
11.8.13 Service cycle .............................................................................................................................................................................................152
11.9 Operation: Sequence programming ............................................................................................................................................................................153
11.9.1 Create new program .................................................................................................................................................................................154
11.9.2 Enter / edit comment (program name) .....................................................................................................................................................155
11.9.3 Enter / edit program ..................................................................................................................................................................................155
11.9.4 Program instructions .................................................................................................................................................................................157
11.9.5 Programming example..............................................................................................................................................................................177
11.9.6 Copy program ...........................................................................................................................................................................................181
11.9.7 Delete program .........................................................................................................................................................................................181
11.9.8 Test program.............................................................................................................................................................................................182
11.10 Operation: Accessing system information ...................................................................................................................................................................185
11.11 Operation: Display tool data memory ..........................................................................................................................................................................186
11.12 Operation: Display measurements ..............................................................................................................................................................................187
11.12.1 Statistics ....................................................................................................................................................................................................187
11.12.2 Measurements ..........................................................................................................................................................................................188
11.12.3 PG protocol ...............................................................................................................................................................................................188
11.13 Operation: Creating a screenshot ................................................................................................................................................................................189
12 Error state detection, system verification ........................................................................................................................................ 190

12.1 Error state detection.....................................................................................................................................................................................................190
12.1.1 Description of error ...................................................................................................................................................................................190
12.1.2 Error display „Origin“.................................................................................................................................................................................191

Contents
12.1.3 Error display “Description” ....................................................................................................................................................................... 191

12.2 System verification, error analysis .............................................................................................................................................................................. 194
12.2.1 System test: Press-in unit ........................................................................................................................................................................ 194
12.2.2 Test system bus ....................................................................................................................................................................................... 198
12.2.3 Test control unit ....................................................................................................................................................................................... 199
12.3 Test mode / simulation of the inputs and outputs at the press-in control system ...................................................................................................... 204
13 Service, fault correction, maintenance, cleaning ............................................................................................................................ 205

13.1 Safety .......................................................................................................................................................................................................................... 205
13.2 Service menu .............................................................................................................................................................................................................. 206
13.2.1 Service Break fuse ................................................................................................................................................................................... 206
13.2.2 Storage administration ............................................................................................................................................................................. 207
13.2.3 Factory settings ........................................................................................................................................................................................ 208
13.2.4 Restart service counter ............................................................................................................................................................................ 208
13.2.5 Correction value stroke ............................................................................................................................................................................ 209
13.2.6 Service DCM-Extension ........................................................................................................................................................................... 210
13.2.7 Service DSM ............................................................................................................................................................................................ 210
13.3 Maintenance and Cleaning ......................................................................................................................................................................................... 211
13.4 Disassembly of the control module ............................................................................................................................................................................. 212
13.5 Service address .......................................................................................................................................................................................................... 212
13.6 Return shipment to DSM ............................................................................................................................................................................................. 212
13.7 Firmware update ......................................................................................................................................................................................................... 213
13.7.1 Firmware update CPU 4.54: Updating with CF card ............................................................................................................................... 213
13.7.2 Firmware update CPU 4.50: Updating with PC software UpdateCenter................................................................................................. 215
13.7.3 Boot loader CPU 4.54 .............................................................................................................................................................................. 218
13.8 Activation of chargeable options ................................................................................................................................................................................. 220
13.9 Remote maintenance .................................................................................................................................................................................................. 221
14 Dismantling and disposal ................................................................................................................................................................. 223

14.1 Safety .......................................................................................................................................................................................................................... 223
14.2 Dismantling sequence ................................................................................................................................................................................................. 223
14.3 Disposal ....................................................................................................................................................................................................................... 223
15 Supporting documents ..................................................................................................................................................................... 224

15.1 System bus device IO-Extension (optional module) ................................................................................................................................................... 224
15.1.1 Extension modules overview ................................................................................................................................................................... 224
15.1.2 Presentation IO-Extension ....................................................................................................................................................................... 224
15.1.3 Electrical specification.............................................................................................................................................................................. 225
15.1.4 Adressing in press-in control system ....................................................................................................................................................... 226
15.1.5 Dimensions .............................................................................................................................................................................................. 226
15.1.6 Switching principle IO Extension ............................................................................................................................................................. 227
15.2 System bus device Status Indication (optional module) ............................................................................................................................................. 228
15.2.1 Execution: Status Indication .................................................................................................................................................................... 228
15.2.2 Execution: Status Indication Key Switch ................................................................................................................................................. 228
15.2.3 Execution: Status Indication Selector ONE / TWO.................................................................................................................................. 228
15.2.4 Execution: Status Indication Selector ONE S / TWO S........................................................................................................................... 228
15.2.5 Execution: Status Indication Selector ONE KS / TWO KS ...................................................................................................................... 229
15.2.6 Required settings on the MultiPro FL ...................................................................................................................................................... 229
15.3 Software tool: CFG Data Converter ............................................................................................................................................................................ 230
16 Authorised DSM partners.................................................................................................................................................................. 231
17 Index ................................................................................................................................................................................................... 232

Important basic information
1 Important basic information
1.1 Scope of delivery
 Basic configuration Press-in control system MultiPro FL
• Control module MultiPro

· Firmware integrated in the control module (standard: 3200 Pro-E)
· Profibus module
• Basic module, design depending on the press-in unit used
• CF card
• Power cable
• Operating instructions MultiPro FL
· CD-ROM: MULTI CD with Parameterisation and programming software MultiControl4;
Profibus GSD files, firmware; UpdateCenter; CFG data converter; Documentation (PDF)
 Accessories and Options
• Ethernet module (TCP/IP)

• Machine Safety Interface
• IO-Extension 1, extension of inputs and outputs
• Status Indication1, status display, optionally with start button, program selection,
NOK key switch
• Serial module for connection of a barcode scanner
• DSM radio clock1
• DCM-Extension1, for the selection of an external DC motor
• DSM printer PR-II, to document the measuring results
• PC software with integrated database
• ToolControl1, tool management, monitoring of tool removal, assigns corresponding processes
to the respective tools
• LineManager software, client-server solution for central management of several
DSM control systems on a single computer
• LineControl software to control and monitor several DSM control systems and their periphery in
connection with the DSM MultiBusController
1
Optional module for connection to the press-in control system, via system bus interface.

Translation of the original German operating instructions - TD-3191011 / V1.3 7
1.2 Declaration of incorporation
Declaration of Incorporation in the meaning of Machinery Directive 2006/42/EC, Annex II, Part B
Hereby we declare that the following named incomplete machine as defined by article 2 g is only intended for integration into or
for assembly with another machine or equipment. The incomplete machine is only allowed to be started up, if it’s secured, that the
machine or line, in which this incomplete machine shall be integrated, is confirm with the regulations of the EC Directive in the
each valid version.
Product designation: Control system (Press-in control system)
Type designation: MultiPro FL DS-S /-L /-H /-V
Machine type: Incomplete machine
Year of manufacture: 2018
Function: The press-in control system is used for the measurement of force / stroke, control and monitoring
of a connected DSM press-in unit of the QMP / SMP series. The configuration as well as
programming of the joining process are performed directly on the press-in control system. The
program is started through an assigned input and the process flow follows the integrated joining
process. The system represents the entire process up to the OK/NOK analysis on the display.
Relevant EC directives:
2014/30/EU Electromagnetic Compatibility
2014/35/EU Low-Voltage Directive
2006/42/EC EC Machinery Directive
The following basic requirements of the “2006/42/EC machinery directive” are executed; the unsettled requirements of the
machinery directive have to be implemented by the customer (system integrator) before the start-up of the incomplete machine:
A list of the basic requirements acc. to attachment I, EC machinery directive 2006/42/EC which are applied and complied for this
product is attached 2 (page 1 – 3) to this declaration.
Applied harmonized EN standards, particularly:

DIN EN ISO 12100-1, DIN EN ISO 12100-2
DIN EN 13849-1, DIN EN 13849-2
DIN EN 60204-1
DIN EN 61800
Applied national standards, laws and technical specifications, particularly:

EMVG
ProdSG
With this declaration of incorporation we commit, on reasonable request, to transfer the special technical documentations of the
incomplete machine in hardcopy form or electronic to the appropriate national agency. Thereby the special technical
documentations are created acc. to the specifications of the “2006/42/EC machinery directive” attachment VII part B. The
commercial industrial property rights of the manufacturer of the incomplete machine remain unaffected from this.
Authorised representative for the compilation of the technical relevant documents:

Michael Moll, Documentation
DSM Messtechnik GmbH, Dieselstraße 16, 73431 Aalen, Germany
Authorized representative for issuing of declaration of incorporation:
Aalen, 02/09/2016
Raimund Wilhelm, Managing Director
DSM Messtechnik GmbH, Dieselstraße 16, 73431 Aalen, Germany
2
You find the attachment to the declaration of incorporation (list in PDF format) on the CD-ROM „MULTI CD“(from version 6.4) in the file folder
"Documentation English / Forms". The CD is included in the manual of the control system on the side before the last side.
Of course we also can send you the document „Attachment to the declaration of incorporation – Control system“ by e-mail.

8 Translation of the original German operating instructions - TD-3191011 / V1.3
1.3 Legal information
 We have reviewed the contents of the operating instructions for compliance with the press-in control system described.
Nonetheless, deviations cannot be ruled out. The information in this publication is regularly reviewed and necessary corrections
are documented in the change history section.
> Change history, Page 10
 The content of these operating instructions is not part of an earlier or existing agreement, promise or legal relationship nor does
it alter such. All obligations of DSM Messtechnik GmbH result from the respective order confirmation.
 The texts, graphic illustrations and photos of these operating instructions are subject to copyright protection and other laws for
the protection of intellectual property. Technical changes are reserved. We appreciate any suggestions for improvement.
 These documents are protected by copyright. They are the property of DSM Messtechnik GmbH who reserves all rights to
them. In particular, these documents may not be replicated, copied, published or passed on to their parties nor may their content
be made known to third parties without prior written consent of DSM Messtechnik GmbH. Contraventions will involve the
obligation to compensate. All right for the case of patent registration or utility patent registration are reserved. Note the right to use
reference according to VG 95 034.
 DSM Messtechnik GmbH is not liable for damages resulting from partial or non-compliance with the function instructions.
 DSM Messtechnik GmbH grants a warranty of 24 months in multi-shift operation, except for wearing parts. If damages arise
that do not affect the delivery subject itself, our liability will not exceed the value of the order. This excludes production loss and
lost revenue.
The warranty can only be fulfilled at the manufacturer's factory. In the event of repair, the press-in control system must be
delivered FOB to DSM, Aalen. The return shipment is free of charge in case of a warranty claim. Goods not shipped FOB cannot
be accepted. Travel costs are charged as incurred when handling warranty claims at the customer site or outside Germany.
 Unauthorized hardware changes on the press-in control system void the warranty. Repair is permitted only upon approval of
DSM. In the event of repair, ship the press-in control system together with the completed service form to DSM, Aalen.
> Chapter 13.6 Return shipment to DSM, Page 212
1.4 Documentation
The scope of the functions described in the operating instructions of the press-in control system MultiPro FL may differ from the
scope of the functions of the press-in system supplied. The press-in system may contain additional operable functions not
explained in this documentation and/or hardware components not shown. However, these functions cannot be claimed at a new
delivery.
 Operating instructions
These present operating instructions describe the functionality of the incomplete machinePress-in control system MultiPro FL so
that the target group knows the functionality. In conjunction with the operating instructions of the DSM system components it
enables the target group to commission the functions. If you would like to obtain additional information or if a problem should
occur which is not treated in the operating instructions of the DSM press-in system you may request the required information from
our parent plant in Aalen.
If the operation (configuration, programming etc.) of the press-in control system MultiPro FL is made by the
MultiControl4 software, the operating instructions of the press-in control system MultiClassic FL describes the
corresponding procedure. The operating instructions can be found on the included CD-ROM "MULTI CD" in PDF
format. We will be glad to send you a printed copy on request.
 Press-in system documentation

To commission and operate the press-in control system, the following documentation components are needed in addition to this
manual:
Documentation Standard Option
Operating instructions press-in control system MultiPro FL x
Functional description special firmware x
Operating instructions of the press-in unit of the QMP series / SMP series x
Safety data sheet lubricant Klüberplex BE 31-102 x
Operating instructions socket box ToolControl x
Integrate the documentation of the DSM press-in system or the DSM components used into the documentation of the
overall plant.

 Target group
The operating instructions for the press-in control system MultiPro FL addresses project planners and authorised persons
according to these instructions.
> Chapter 2.4 Requirements to the personnel, Page 15
 Issue key
The table shows the latest version (=marked in bolt) and the version of the issues published so far.
Status A B B C D E F 1.0 1.1 1.2
Date 30/06/2010 07/10/2010 22/11/2010 12/06/2014 10/03/2015 02/09/2016 30/09/2016 01/03/2017 29/05/2017 08/06/2017
Status 1.3
Stand 05/12/2017
Version management
A-F Basic version; issue status in combination with the Doc.-no. BA1910-e-1005-x
1.xx Revised version with new issue date. If the technical facts change compared to the previous issue date, this is
indicated by the changed version number.
 Change history
Status Date Firmware version Last modified
A 30/06/2010 3200 Pro-E V 1.06
B 07/10/2010 3200 Pro-E V 1.06 (3200.02) Parameterisation via Profibus (activation required)
B 22/12/2010 3200 Pro-E V 1.10 Various changes, use of SMP press-in units
C 06/06/2013 3200 Pro-E V 1.18 Revision according to EC Machinery Directive 2006/42/EC, Annex VI
Basic modules performance data integrated, various changes and adaptations
C 12/06/2014 3200 Pro-E V 1.25 (3200.05) Access control via PB
D 16/12/2014 3200 Pro-E V 1.28 (3200.05) Redesign
D 10/03/2015 Description of the procedure for updating firmware optimised
E 08/06/2016 3200 Pro-E V 1.31 (3200.06) Profibus, Extended configuration 3
E 02/09/2016 Declaration of incorporation updated
F 30/09/2016 3200 Pro-E V 1.33 (3200.07) Correction value stroke (activation code is required); Instruction Offset adjustment
1.0 01/03/2017 3200 Pro-E V 1.35 (3200.08) Doc. no. deleted, only article number and new versioning
1.1 29/05/2017 3200 Pro-E V 1.25 (3200.05) Envelope, mode "relative", "absolute", "retrospective"
1.2 08/06/2017 3200 Pro-E V 1.35 (3200.08) Normal position travel (only compelling)
1.3 05/12/2017 3200 Pro-E V 1.40 (3200.09) New parameter: "Evaluation force" and "Evaluation length" for all procedures,
except "Move empty"

 Identification - Article number

The article number with indication of the version is listed on each page of the operating instructions as well as in electronic media
in the file name. In addition, the article number is printed on the back as bar code.
*ATD-3191011*
A: Article, classification of the bar code
TD-3191011: Article number of the operating instructions
 Conventions regarding the presentation

• Headings are shown in bold.
• Sections are shown in bold and numbered and structured hierarchically according to the following pattern:
1, 1.1, 1.1.1, 1.1.1.1
• Sub-headings are shown in bold and numbered and structured hierarchically according to the following pattern:
a), b), c) …
• Enumerations are marked by a dot "•". Subitems of an enumeration are shown with a hyphen "-".
• Cross-references are shown in light blue; in addition, the reference is preceded by an arrow symbol ">" .
A cross-reference is structured as follows:
- Within a document
> Chapter 1.1 Scope of delivery, Page 6 (sample values)
Chapter, section number, section text, page number
- To another DSM document
> Operating instructions DS44 series / 4.5 / P.32 (sample values)

Document / Chapter / Page number
• An information note is identified as follows:
The text of the note is delimited by horizontal lines above and below the text.
Information notes contain usage tips and particularly useful information but no warnings against hazards.
• Operating controls and function keys are shown in pointed <angle brackets>.
• Additional information about a function is listed via a footnote "1" at the end of the page.

1.5 Abbreviations
 Product designation of the press-in control system

The MultiPro FL is designed for the DSM press-in units of the QMP series and SMP series direct force measurement / stroke
measurement. The design of the respective press-in control system can be seen by the type designation noted, amongst others,
on the type plate on the outside of the device.
3
The designation is made up of the following key: Basismodul
MultiPro FL PB ET CPU 4.54 DS-H Type 5
3
Basic module version
Hardware version control module
Integrated Ethernet (TCP/IP) module (option)
Integrated Profibus module
Variant FL (F: Force; L: Length)
Control module version
3
Basic module: Because of the different performance requirements of the press-in units, the basic module (=power supply integrated in press-in
control system) is available in various basic versions.

1.6 Service address / contact
SERVICE
Telephone +49 7361 5717 0
E-Mail info@dsm-messtechnik.de
Address DSM Messtechnik GmbH
Service
Dieselstraße 16
73431 Aalen
Germany
SALES
Contact Florian Wilhelm, Sales manager
Phone +49 7361 5717 43
E-Mail fwilhelm@dsm-messtechnik.de
Michael Gold, Sales

Phone +49 7361 5717 51
E-Mail gold@dsm-messtechnik.de
Marc Bartjen, Sales

Phone +49 7361 5717 45
E-Mail bartjen@dsm-messtechnik.de
DOCUMENTATION Contact Michael Moll

Phone +49 7361 5717 44
E-Mail moll@dsm-messtechnik.de
DSM PARTNER
> Chapter 16 Authorised DSM partners, Page 231
Please have all necessary information ready for the communication with our service department, amongst
others, the exact product name, serial number.

Safety
2 Safety
2.1 Conventions for safety instructions
 These present operating instructions use the following symbols for the safety information:
The signal word field "DANGER" warns of an immediately threatening danger for the health and life of persons. Disregarding this danger
notice may result in serious injuries and possibly death.
The signal word field "WARNING" warns of a potentially dangerous situation for the health of persons. Disregarding this warning may
result in serious injuries.
The signal word field "CAUTION" warns of a potentially harmful situation for the health of persons or of property and environmental
damages. Disregarding this warning may result in injuries, property or environmental damages.
The signal word field "NOTICE" warns of possible property damages. Disregarding this warning may result in property damages.
Caution, danger of electric current
Caution, warning of a danger zone
Warning of hot surface
Use safety goggles
Use protective footwear

Safety
2.2 Intended use
 The operating company is responsible for the intended use of the press-in control system. When assembling the incomplete
machine "press-in control system MultiPro FL", the following conditions must be ensured to allow it to be correctly assembled
together with other parts into a complete machine and without compromising safety and the health of persons.
2.3 Application
 The press-in control system is used for the force / stroke measurement, control and monitoring of a connected DSM press-in
unit of the QMP or SMP series.
The press-in control system was designed exclusively for pressing, joining and shaping tasks in assembly technology as well as
specific applications from pressing / joint technology (pushing and pulling forces).
Make sure when using a MultiPro FL press-in control system that the design of the integrated basic module is compatible with the
press-in unit.
> Chapter 3.2 Type overview MultiPro FL, Page 23
Unauthorized conversions, repair and modifications are prohibited for reasons of safety and product liability.
2.4 Requirements to the personnel
 Commissioning and operation of a press-in control system may be done only by qualified personnel. Qualified personnel
according to the safety notes of this documentation are persons authorised to commission devices, systems and electrical circuits
in accordance with the standards of safety technology.
The trained and instructed technicians of the operating company and the manufacturer constitute persons authorized for the
operating, setup and repair.
The operating company is responsible for

• instruction of the personnel
• compliance with the safety regulations
• following the operating instructions
The operator must:

• have received an orientation
• have read and understood the parts of the operating instruction(s) applicable to him before assuming his work activity
• know the safety devices and regulations
During work, depending on the type and use of the press-in unit, safety goggles against mechanical effects
(particle scattering) and non-skid safety shoes must be worn.
Wear suitable work clothing to prevent the risk of injury from being wound in and caught. Wearing personal
protective equipment reduces the risk of injuries.
The company operating the machine must make sure that new operating and maintenance personnel receive the same
orientation and conscientious instructions on the operation and repair of the press-in control system / press-in unit. Employees in
training may work only under the supervision of an authorized trainer with the press-in control system / press-in unit.
2.5 Safety precautions
 The safety requirements on the incomplete machine "Press-in control system MultiPro FL" must be defined by the manufacturer
of the overall machine who determines the production concept (single workstation, line assembly, manual loading, manual
operation, automatic production process) with the company operating the machine.
The fitting of the press-in control system with the MSI (machine safety interface) safety component and its integration into the
safety concept is determined on the basis of the required machine functions.
If for production-related reasons operators are occasionally or always present in the danger zone, the machine must be equipped
with a safety concept appropriate for this operating mode.
Operation with protective devices bypassed is principally prohibited.

Safety
2.6 Protective devices
The operating company must provide a suitable protective device to ensure that no person comes to harm during the operation of the
incomplete machine "Press-in control System MultiProFL".
Furthermore, the operating company must ensure that the interaction of all components does not create new hazards, the target group
does not change and the usage content is not altered.
The protective devices as well as the control systems must be installed correctly since hazardous movements may otherwise occur.
Furthermore, the complete and correct adjustment of the protective device must be ensured to prevent harm to the operator.
To ensure this fact, a DSM service technician or authorised technical personnel of the manufacturer / operating company must inspect
the protective devices (including checking the electrical safety). A corresponding test and acceptance protocol must be completed on
site
The connected press-in unit (QMP series / SMP series) is controlled and monitored by the press-in control system MultiPro FL.
For the connection to a safety device, this is equipped with the interface MSI.
The integrated Machine-Safety-Interface takes care of a safe disconnection of the servo controller (EN ISO 13849-1 Performance
Level e, EN IEC 62061 SIL3).
The above mentioned safety shutdown is a component, which is integrated into a protection device, i.e. which has to be activated
from the customer. The liability and the responsibility is by the customer/user. DSM does not take over any liability for perhaps
failures or their consequences.
Please observe that the reset after triggering the safety device may not result into an uncontrolled start of the drive. The drive
starts again when the "MSI" function is no longer triggered. To correspond to the EN 60204 standard external measures must
ensure that the drive only restarts after a confirmation.
Overrun of the drive may occur without mechanical brake; the motor runs down. Additional protective devices must be installed if
persons may be put at risk from this fact or property damage may occur.
If a risk to persons is present after shutting of the motor selection through MSI, access to the danger zone must remain blocked
until the drive has stopped.
> Chapter 4.4.4 Machine Safety Interface: Interface „X76 MSI“, Seite 33
 Standard EN ISO 12100-2 notes on selecting protective devices

If the hazards cannot be prevented or sufficiently limited by constructive measures, protective devices must be planned and
provided. The selection of a suitable protective device should be made either in accordance with an existing machine-specific
provision, e.g. a European C standard, or on the basis of a risk assessment of the respective machine.
The protective device should generally enable a simple and ergonomic operation of the machine and not obstruct its proper use.
If this is not the case this can lead to the protective devices being bypassed in order to achieve an easier operation of the
machine.
A fixed guard (e.g. a cover) should be used, where the access to the danger zone is not required by the operator during normal
operation. If the operation requires a more frequent access, an electro-sensitive protective equipment (e.g. Safety Light Curtain)
or a moveable guard (e.g. doors with Safety Switches) should be used.
The required protective measures are not part of the responsibility of DSM Messtechnik GmbH; they must be performed or
initiated by the customer. DSM does not assume any liability for possible faults or their consequences.
2.7 Safety-relevant ambient conditions
 The safety-relevant ambient conditions can be found in the following chapter.

> Chapter 8.3 Ambient conditions, Page 74

Safety
2.8 Safety-relevant information
Read all safety notes and instructions.

Neglecting to observe the safety notes and instructions may cause electrical shock, fire and/or serious injuries.
Store the safety notes and instructions (these operating instructions) for future use.
 Workplace safety
a) The press-in control system must be fastened at the intended location using the mounting holes according to the ambient and
operating conditions. All cable connections must be plugged and locked.
> Chapter 2.3 Application, Page 15
Risk of injury, damage of the control system during assembly

Because of its weight (10 - 15 kg) mount the press-in control system with the help of 2 persons at the intended location. Wear safety
shoes!
b) Keep your workplace clean and well illuminated. Clutter and dark work areas may lead to accidents.
c) Do not work with the press-in control system MultiPro FL in explosion-hazard environments where combustible liquids, gases
or dusts are present. The components may generate sparks that may possibly ignite the dust or vapours.
> Chapter 8 Setup requirements, Page 73
d) Keep other persons away while using the press-in control system. Errors may develop from being distracted, which may result
in accidents and property damages.
 Electrical safety
a) Establish the cable connections as described in these operating instructions. The connector must fit in the respective
connection socket on the device side. Plugs must not be changed in any way. Original unchanged plugs reduce the risk of electric
shock.
b) Avoid physical contact with earthed surfaces such as pipes, heaters, etc. Your earthed body presents an increased risk for
electric shock.
c) Keep electrical devices away from rain or wetness. Penetration of water into an electrical tool increases the risk of electric
shock.
d) Do not abuse the cable by pulling the plug out of the connection socket. Keep the cables away from heat, oil, sharp edges or
moving device parts. Damaged or entangled cables increase the risk of electric shock.
 Safety of persons
a) Be always attentive! Pay attention to what you are doing and approach work with reason. Do not operate the press-in control
system if your are tired or under the influence of drugs, alcohol or medication. A moment of inattention when using a control
system in connection with an electrical tool may cause serious injuries.
b) Avoid unintentional start-up. Verify that the installed press-in control system is switched off before connecting it to the power
supply.

Safety
 Use and handling of the press-in control system MultiPro FL

a) Do not overload the press-in unit. You will work better and safer in the specified recommended output range. Do not use any
press-in units with low performance for joining processes not designed for them.
Make sure that the calibration values shown on the type plate of the press-in unit are always set in the control system or that the auto-
parameterisation function is set (factory setting = ON). A wrong calibration value falsifies the measuring result and destroys the
press-in unit.
> Chapter 11.8.1 Auto-parameterisation, Page 151
b) Do not use a press-in control system if its switch of plug are defective.
c) Disconnect the connection to the installed electrical tool (On/Off switch on the press-in control system / Safety PLC) before
performing device settings or changing tools on the press-in unit. This precaution prevents the unintentional start of the electrical
tool.
Make sure to disconnect power to the press-in unit when performing maintenance tasks. When measuring cables for
continuity, resistance and short-circuit they must be absolutely disconnected from the press-in control system and
press-in unit.
Disregard means risk of life from electrical shock.
Other persons must be prevented from reactivating the system when working on electrical equipment. The electricians and instructed
electrical personnel must post the sign with the safety symbol well visibly at eye level for their own safety.
Work in progress!
Location: Date:
Removal of the sign
only by:
Electrical systems marked with the safety symbol may not be operated or switched no. This safety identification may only be removed
by the person who has posted it.
d) Do not allow persons not familiar with the device or not having read these instructions (operating instructions) to use the
device. Electrical tools are dangerous when used by inexperienced persons.
e) Before using the press-in unit with the control system, you must check all interacting components for their flawless and
intended function. Check if the function of movable parts is intact, whether they are not jammed, no parts are broken, whether all
other parts are working flawlessly, have been correctly mounted and all other conditions that may affect the operating of the
control system / press-in unit are correct.
f) Use only accessories and options specified in the Technical Documentation or offered in the respective product descriptions.
Use the press-in control system according to these instructions (these operating instructions). Take the working conditions and
tasks to be performed into consideration. Using electrical tools for other applications than those intended may lead to dangerous
situations.
g) The press-in control system MultiPro FL complies with the relevant safety regulations.

Safety
 Service
a) Have the press-in control system MultiPro FL repaired only by qualified skilled personnel using only original spare parts. This
ensures that the safety of the press-in control system is preserved.
Damaged system components, switches or plugs represent danger to life from electrical shock.
Repairs may be performed only by a DSM technician or accidents / damages may occur to the operating company for which DSM
cannot be held liable.
b) Make sure to disconnect power to the press-in unit before changing tools (On/Off switch on press-in control system / Safety
PLC).
c) Introduce a safety-compliant maintenance program which takes the local regulations for repair and maintenance for all
operating phases of the joining system into account.
When dismantling the press-in unit remember that the drive motor becomes hot and may cause burns.
2.9 Observing the operating instructions
 The operating instructions of the press-in control system MultiPro FL must always be followed completely. The information of
these operating instructions must be stored in the immediate vicinity of the overall machine and available to the entire personnel
of the overall machine at all times.
Start operating the press-in control system only after you have read the safety information and all relevant documents and have fully
understood them.
When using press-in units with the press-in control system MultiPro FL, the safety information listed in these operating instructions as
well as in the operating instructions of the press-in unit must always be observed to prevent injuries as well as property and
environmental damages.
Read and follow also all applicable, generally valid and local safety and accident prevention regulations as well as the safety information
of the overall machine.

Safety
2.10 Identification on the product
 The DSM plate contains order-specific data. The type plates contains information about the technical design (control module,
basic module).
C
A
a) DSM sign 1 2
12-12-2012 / 2508
Dieselstraße 16, D-73431 Aalen
1 Delivery date (Day-Month-Year DD-MM-YY)
2 DSM KOMM-No. (Commission number)
b) Type plate control module

3 4 5 6
Type: SM MultiPro FL mA PB DS-H/2

7
S.-Nr: 16 Q 00012 /4.54
Art-Nr DSM-300010 G B 8
9 10
3 Designation of control module
4 Transmission of measuring signal mA, optional mV/V
5 Options: PB Profibus, ET Ethernet (TCP/IP) > Chapter 1.5 Abbreviations, Page 12
6 Integrated basic module
7 Integrated CPU
8 Quality assurance G:VDE test (protective measures) B:Burn-In (Thermal test)
9 Item number 10 Serial number
c) Type plate basic module

11
Type: BM DS/H /2
S.-Nr: 17 Q 0011
Art.Nr. DSM-300663 G B 12
13 14
11 Designation of basic module
12 Quality assurance G:VDE test (protective measures) B:Burn-In (Thermal test)
13 Article number 14 Serial number

Technical data
3 Technical data
3.1 Data sheet MultiPro FL
Product designation MultiPro FL

Characteristic
4
Number of programs 255
Number of max. instruction lines per program / total 200 / 3000
Command set (programming commands) 31 instructions
Maximum number of joint steps per program 199
Sequence log (with command execution times. program run times) 

5
Internal ring buffer for measurements 500 data records
Mobile memory with backup function, CF card 128 MB 
Statistics memory (OK analysis, mean value, machine and process capability. 2 per program
Available joining methods (standard) 9
- Travel to force (switch-off force) 
- Travel to stroke (switch-off stroke) 
- Travel to initiator (switch-off input) 
- Review stroke 
- Force progression in IO window 
- Hold force 
- Empty travel on stroke 
- Normal position travel 
- Redundant voltage circuit F (additional monitoring of force) 
- Envelope monitoring 
- Customer-specific procedures, monitoring parameters 
Travel stroke measurement with digital absolute angle sensor 
Travel stroke resolution 0,01 mm
Force measurement with digital force transducer 
Force measurement according to VDI / VDE 2862 
Sampling rate 1 kHz
Input / output of strokes [mm, degree] 
Input / output of forces [N / kN] 
Input / output of velocities [mm/s] 
Access control, access journal integrated in the device 
User management integrated in the device 
Single step operation integrated in device (testing the program sequence) 
Firmware update via PC 
Firmware update with CF card 
Firmware bilingual, changeable 
Explanation of symbols:  (Series);  (Option);
4
255 programs are available which can be divided by the user into directly startable programs (program location 1 to 128) and into subroutines
(program location 129 to 255). Subroutines (macros) provide the user with the option of programming frequently recurring process sequences. The
subroutine can be integrated into any program and called from there. A subroutine cannot be started directly.
5
Ring buffer of production data (force, path, date, time, joining method, programme no., assessment) stored non-volatile.

Technical data
Continuation Data sheet MultiPro FL
Graphical charting and presentation of the measurements 
Traceable calibration of the transducers 
Parameterisation and programming directly on the device 
Parameterisation and programming via PC software 
Upload of programs and parameters from the CF card 
Control module and basic module (servo controller) in one housing > Chapter 3.2, Seite 23 
Display (LCD display) 320 x 240 pixels
Keyboard 22 keys
Dimensions, version of basic module DS-S Type 1 (W x H x D) 201 x 280 x 128
Dimensions, all other standard versions (W x H x D) 201 x 280 x 231
Mains voltage (basic module Type DS-S, DS-L, DS-LH, DS-H) 220-240 V / 50-60 Hz
Mains voltage basic module Type DS-V) 3x 400 VAC / 50 Hz
Protection class, standard Protection class, optional IP40 IP54
Weight control module MultiPro FL approx. 1,5 kg
Weight control module MultiPro FL with basic module DS-S Type 1 / 2 approx. 6,5 kg
Weight control module MultiPro FL with basic module DS-L Type 1 approx. 11,0 kg
Weight control module MultiPro FL with basic module DS-H Type 2 / 3 / 4 approx. 10,0 kg
Weight control module MultiPro FL with basic module DS-H Type 5 approx. 10,0 kg
Weight control module MultiPro FL with basic module DS-V Type 4 / 5 approx. 10,5 kg
V24 interface for PC 
V24 interface for printer 

6
Operating equipment interface (interface), 4 inputs / 4 outputs 
Expansion of inputs and outputs (modules up to 128 I/O) 6 
DSM system bus interface (to connect DSM accessories) 
Profibus interface 
Ethernet port (TCP/IP) 
MSI interface (Machine-Safety Interface) 
Explanation of symbols:  (Series);  (Option);
6
24 V / 100 mA, DC, potential-free

Technical data
3.2 Type overview MultiPro FL

Press-in unit
QMP series, SMP series
Control module Basic module Power data
MultiPro FL DS-L Type 3 > Page 30 SMP 300 / 005, SMP 300 / 01, SMP 300 / 02
SMP 400 / 05, SMP 400 / 10

DS-H Type 2 > Page 31
(QMP 80 / 025, QMP 80 / 05, QMP 80 / 10) 7
DS-H Type 5 > Page 31 QMP 80 / 025, QMP 80 / 05, QMP 80 / 10, QMP 80 / 20
SMP 500 / 20, SMP 500 / 30, SMP 500 / 50, SMP 500 / 70
DS-V Type 5 > Page 32 QMP 100 / 30, QMP 100 / 40, QMP 100 / 50, QMP 100 / 60
QMP 140 / 70, QMP 140 / 100, QMP 140 / 120
In addition, the power electronics (servo controller) controls and monitors the drive motor of the press-in unit. It checks, amongst
others, voltage and condition of the hall sensor as well as temperature, current and voltage of the servo motor.
Supply
· Mains voltage basic module Type DS-L, DS-H: 220-240 V / 50 Hz
The permissible input voltage range of the DSM basic modules in 230 VAC version lies between 198 VAC and 253 VAC =>
230 VAC (-14 % / +10 %); it must be maintained even when using series transformers.
· Mains voltage basic module Type DS-V): 3 x 400 VAC / 50 Hz

The permissible input voltage range of the DSM basic modules in 400 VAC version lies between 344 VAC and 440 VAC =>
400 VAC (-14 % / +10 %); it must be maintained even when using series transformers.
> Chapter 4.4 Versions and interfaces of the basic module, Page 29
7
Basic module for the press-in unit up to 2015; from 2016 the version DS-H Type 5.

Design of the press-in control system
4 Design of the press-in control system
4.1 Modular design
 The press-in control system MultiPro FL is a device with programmable control electronics (control module) and power
electronics (basic module) in one housing.
Control module
Basic module
Thanks to the modular design, the control module, for example, can be replaced by a MultiClassic module or the basic module
can be exchanged if the process conditions change (e.g. greater force).
Furthermore, a press-in control system can be generated from a press-in control system through a firmware update 8.
> Chapter 13.4 Disassembly of the control module, Page 212
8
The enclosed CD contains the program "UpdateCenter2" to update / modify the firmware.

4.2 Front view of control module
Bedienung Display Produktionsbildschirm Frontansicht
LCD display
- Production screen
Function keys 9
- F-keys
- Reset function
9 10
Kontext Grenzwert
Keypad LED status display 10

- Numeric keypad - Limit value monitoring
- ESC key
- Arrow keys
- RET key
- Screenshot function
> Chapter 11.2 Operating controls, Page 127

> Chapter 11.3.1 LED status display (limit value monitoring), Page 128
> Chapter 11.3.2 LCD display (production screen), Page 128
9
Because of the context-sensitive menu navigation additional functions can be performed using the F-keys. They are indicated on the respective
screen or described in the corresponding chapter of this documentation.
10
The designations Torque/Angle refer to the "TA" (press-in control system) version of the MultiPro control module.

4.3 Interfaces and CompactFlash slot on the control module
 The underside of the press-in control system accommodates the interfaces of the control module MultiPro FL as well as the slot
for the mobile long-term memory (CompactFlash card).
1 2 3 4
5 6 7 8
Compact flash slot

with CF card in format: FAT32; size: 128 MB (standard)
• Mobile long-term memory (settings, parameters and programs)

• The CF card may be inserted only without voltage (=device off).
• The CF card must be logged off the system before removing it by pressing the <Remove CF>
function key (production screen).
Actuate the lever of the ejection mechanism to remove the storage medium.
1) X125 UNI (universal interface); (2) X52 INTERFACE (I/O); (3) X7 Printer; (4) X10 PB (Profibus interface);
(5) X59 SBOUT (System bus output); (6) X58 SBIN (System bus input); (7) X14 TCP; (8) X6 PC
4.3.1 Interfaces X6 PC / X7 Printer
X6 | PC X7 | Printer
Connectors (pins) 9-pin Sub-Min-D Connectors (pins) 9-pin Sub-Min-D
V24 interface PC V24 interface printer
Assignment Assignment
PIN I/O Designation PIN I/O Designation
1 - - 1 - -
2 In RxD 2 In RxD
3 Out TxD 3 Out TxD
4 - - 4 - -
5 - GND 5 - GND
6 - - 6 - -
7 Out RTS 7 Out RTS
8 In CTS 8 In CTS
9 - - 9 - -
> Chapter 10.6.1 Wiring diagram control module MultiPro FL, Page 90
> Chapter 10.7 Settings with PC / Printer connection, Page 94

4.3.2 Interfaces X10 Profibus / X14 TCP
11
X10 | PB X14 | TCP
Socket 9-pin Sub-Min-D Socket for standard plug RJ45
Profibus interface Ethernet (TCP/IP) port
PIN Designation PIN Designation
1 -
1 TD+
2 -
2 TD-
3 Profibus P
3 RX+
4 -
4 -
5 -
5 -
6 -
6 RX-
7 -
7 -
8 Profibus N
8 -
9 -
> Chapter 10.9 Profibus, Page 98
> Chapter 10.10 Settings with TCP/IP (optional module), Page 121
For connection via TCP/IP between control unit MultiPro FL and PC please use a crossover cable.
4.3.3 Interface X52
X52 | INTERFACE
Socket 15-pin Sub-Min-D
12
Inputs / Outputs for use with the program start, for status outputs or free use in the program sequence (4 inputs, 4 outputs ,
24V / 100 mA DC potential-free). Customer connection 13
Assignment
PIN I/O Designation
1 In 0V feed
2 - -
3 In Input 1
Bridge13
4 In Input 2
5 In Input 3
6 In Input 4
7 - -
8 Out GND supply
9 In 24 V feed
10 Out Output 1
11 Out Output 2
Bridge13
12 Out Output 3
13 Out Output 4
14 - -
15 Out 24 V supply
> Chapter 10.11 Inputs / outputs, Page 122
11
The interface is integrated into the device as standard feature; the function of the connection is ensured by purchasing the option module.
12
Expandable to up to 128 I/O through DSM expansion module "IO Extension".
13
When manufacturing a connecting able to the X52 interface, please note that a shielded cable is used and the shield is connected at the device
side (MultiPro). The X52 interface requires a 24 V voltage supply. Bridging can be done as follows if no 24 V is available: "PIN 1 with PIN 8" and
"PIN 9 with PIN 15".

4.3.4 Interfaces X58 System bus IN / X59 System bus OUT
X58 | SBIN
Connectors (pins) 5-pin M12 snap-in pin
System bus interface input, external 24V feed for system bus, control system connection
Assignment
PIN I/O Designation Colour
1 In 0V feed brown
2 In 24V feed white
3 I/O C-L blue
4 I/O C-H black
5 In Release grey
X59 | SBOUT
Socket 5-pin M12 snap-in pin
System bus interface output, options module connection
Assignment
PIN I/O Designation Colour
1 Out 0V feed brown

2 Out 24V feed white
3 I/O C-L blue
4 I/O C-H black
5 In Release grey
> Chapter 10.8 System bus, Page 95
4.3.5 Interface X53 Universal
X53 | UNI 14
Socket 25-pin Sub-Min-D
Universal interface (reserved for special solutions)
Assignment
PIN I/O Designation
1 Out + 15 V
2 Out - 15 V
3 In W1
4 In W2
5 Out KAL
6 - -
7 In IN 1
8 In IN 2
9 In IN 3
10 I/O RES 1
11 I/O SDA
12 Out SCL
13 Out GND
14 In Tiefe
15 In INT
16 I/O RES 2
17 Out OUT 3
18 - -
19 Out OUT 2
20 Out OUT 1
21 In MD –
22 In MD +
23 In W3
24 Out +5V
25 Out AGND
14
The interface is installed in the device as standard feature; the function of the connection depends on the firmware (special method) integrated in
the control module and the periphery planned for it.

4.4 Versions and interfaces of the basic module
 Because of the different performance requirements of the press-in units (SMP / QMP Series) the basic module is available in
several versions. The basic versions with the designations DS-L, DS-H, DS-V are divided into different types and permanently
assigned to press-in units.
The equipment with the respective interfaces depends on the design of the basic module. They are located on the bottom side of
the press-in control system where the On/Off switch of the MultiPro FL is located.
Design DS-L Design DS-H, DS-V
1 2 3 1 2 3
6 5 5 4
(1) Mains connection X21 AC (220 – 240V / 50 Hz) or X61 AC (3 x 400 VAC / 50 Hz);
(2) Interface motor (designation depends on the type); (3) X76 MSI (option)15; (4) X75 C-HS;
(5) On / Off-switch; (6) device protection
Please refer to the respective chapter for the designation and assignment of the electrical connection and the technical data:
MSI 15
> Chapter 4.4.1 Design DS-L, Seite 30
> Chapter 4.4.2 Design DS-H, Seite 31
> Chapter 4.4.3 Design DS-V, Seite 32
15
The connection "X76 MSI (Machine-Safety Interface)" is not a default interface and in not installed in the series version.
> Chapter 4.4.4 Machine Safety Interface: Interface „X76 MSI“, Page 33

4.4.1 Design DS-L
 Technical Data
Basic module Mains voltage Dimensions for press-in unit Max. F Max. vel. Item number
SMP 300 / 005 0,5 kN 350 mm/s
DS-L Type 3 230 V / 50-60 Hz SMP 300 / 01 1 kN 350 mm/s ML-1000330
SMP 300 / 02 2 kN 350 mm/s
Basic module
Max. rated Max. peak Max. rated Max. peak Internal fuse Intermediate
Series fuse
current current output output (slow) circuit voltage
Type C (K) in A
I Mains rated I Mains Peak I Mains rated P Mains peak Uzk / V
max / A max / A max / W max / W
DS-L Type 3 2,6 A 9,5 A 598 W 2185 W 6,3 A 6,3 A 60 V
Series transformers must be thermally designed for the max. rated current / the max. rated output. The actual rated current / rated output will lie
below the maximum values according to the machine load.
At the max. peak current / max. peak output, series transformers must absolutely (temperature, input voltage fluctuations, etc.) provide an output
voltage greater than 198 VAC for the basic module. The actual peak current / peak output will lie below the maximum values according to the
machine load.
 Interfaces
X21 | AC 220-240 V / 50-60 Hz

Connectors (pins) 4-pin
Harting with lock, mains connection 230 VAC
Assignment The permissible input voltage range of the DSM basic modules
PIN Designation in 230 VAC version lies between 198 VAC and 253 VAC => 230
VAC (-14 % / +10 %); it must be maintained even when using
1 Phase L1 series transformers.
2 NC
3 Neutral conductor N
4 Earth conductor PE
X70 | Motor
Socket 12-pin ITT Cannon
Power supply of the press-in unit, electrical control / regulation of the servo motor,
monitoring of the drive, digital signal transmission
Assignment
J Phase 1 C HSC
L Phase 2 D ϑ Motor
K Phase 3 B GND
M PE A +15 V
F HSA G C High
E HSB H C Low
> Chapter 10.5.1 Wiring diagram basic module DS-L Type3, Page 82

4.4.2 Design DS-H
 Technical Data
SMP 400 / 05 5 kN 200 mm/s
SMP 400 / 10 10 kN 200 mm/s

16
DS-H Type 2 230 V / 50-60 Hz QMP 80 / 025 2,5 kN 220 mm/s ML-1000820
16
QMP 80 / 05 5 kN 220 mm/s
QMP 80 / 1016 10 kN 220 mm/s
QMP 80 / 025 2,5 kN 220 mm/s
QMP 80 / 05 5 kN 220 mm/s

DS-H Type 5 230 V / 50-60 Hz ML-1000850
QMP 80 / 10 10 kN 220 mm/s
QMP 80 / 20 20 kN 220 mm/s
Basic module
Series fuse
Type C (K) in A
DS-H Type 2 7,4 A 39,0 A 1693 W 8961 W 16 / 0,5 A 16 A 325 V
DS-H Type 5 11,9 A 77,7 A 2732 W 17866 W 16 / 0,5 A 16 A 325 V
machine load.
 Interfaces
X21 | AC 220-240 V / 50-60 Hz

Assignment The permissible input voltage range of the DSM basic

PIN Designation modules
in 230 VAC version lies between 198 VAC and 253 VAC
1 Phase L1 => 230 VAC (-14 % / +10 %); it must be maintained even
2 NC when using series transformers.
3 Neutral conductor N
4 Earth conductor PE
X50 | Motor X75 | C-HS

Socket 8-pin Amphenol Socket 9-pin Sub-Min-D
Power supply of the nutrunner Monitoring of the drive, digital signal transmission
1 HSA
A Phase 1
2 HSB
B NC
3 HSC
C Phase 2
4 UHS
D NC
5 GND
E Phase 3
6 ϑ Motor
F NC
7 C High
G Ground conductor monitoring
8 C Low
H Earth conductor PE
9 NC
> Chapter 10.5.2 Wiring diagram basic module DS-H Type2, Type5, Page 83
16
Press-in unit manufactured in or before 2015; Basic module DS-H Type 5 as of 2016

4.4.3 Design DS-V
 Technical Data
SMP 500 / 20 20 kN 150 mm/s
SMP 500 / 30 30 kN 150 mm/s
SMP 500 / 50 50 kN 150 mm/s
SMP 500 / 70 70 kN 150 mm/s
QMP 100 / 30 30 kN 200 mm/s

3x 400 VAC
DS-V Type 5 QMP 100 / 40 40 kN 200 mm/s ML-1000950
50-60 Hz
QMP 100 / 50 50 kN 200 mm/s
QMP 100 / 60 60 kN 200 mm/s
QMP 140 / 70 70 kN 100 mm/s
QMP 140 / 100 100 kN 100 mm/s
QMP 140 / 120 120 kN 100 mm/s
Basic module
Series fuse
Type C (K) in A
DS-V Type 5 4,3 A 32,8 A 3114 W 23956 W 3x16 / 0,5 A 3x 16 A 565 V
machine load.
 Interfaces
X61 | AC 3 x 400 VAC / 50-60 Hz

Assignment The permissible input voltage range of the DSM basic

PIN Designation modules in 400 VAC version lies between 344 VAC and
440 VAC => 400 VAC (-14 % / +10 %); it must be
1 Neutral conductor N maintained even when using series transformers.
2 L3
3 L2
4 L1
PE Earth conductor PE
X60 | Motor X75 | C-HS

Socket 6-pin Socket 9-pin Sub-Min-D
Power supply of the press-in unit Monitoring of the drive, digital signal transmission
1 HSA
2 HSB
1 Phase B
3 HSC
2 Phase A
4 UHS
PE Select ground conductor
5 GND
4 Ground conductor monitoring
6 ϑ Motor
5 Phase C
7 C High
6 NC
8 C Low
9 NC
> Chapter 10.5.3 Wiring diagram basic module DS-V Type5, Page 84

4.4.4 Machine Safety Interface: Interface „X76 MSI“
X76 | MSI
Connectors (pins) 15-pin Sub-Min-D

Machine Safety Interface (EN ISO 13849-1 Performance Level e, EN IEC 62061 SIL3), supply and monitoring by customer
> Chapter 5.2 Protective device / Protection concept, Page 36
Assignment
PIN Designation
1 0V supply for K1
2 Not used, do not connect!
3 24V supply for K2
5 Return circuit Y2 17
7 Feed of auxiliary output 18
8 NC contact auxiliary output 18
9 Relay K1, 24V active
10 Relay K2, 0V active
12 Return circuit Y1 19
15 NO contact auxiliary output 18
E-Stop
7
Application circuit C3
via X76 MSI 12
Y1
9
K1
Resetting
10
K2
S2
5
Y2
3
Emergency-off A1
switchgear 1
Pilz PNOZ s5 24 VDC 14 S34 38 48 A2
with approx. 150 ms (750 105)
up to 250 ms delay
47
mode
A2
t(s)
X76 MSI
n
In2+ In2-
15
13 N03
37
0,1
A1
6
IN4
S11 S21 S22 S12
X52 Interface
S1 9
24V
Feed
24V ± 10% 1
0V
by customer Feed
Emergency
Stop 24V 0V
IN4 must be defined as input for the "External Release" in the menu "Control unit settings"!
> Chapter 11.5.11 External release, Page 147
17
Connected with Y1 when relays K1 and K2 are released
18
No secure output!
19
Connected with Y2 when relays K1 and K2 are released

Functional description
5 Functional description
5.1 Function principle of the press-in control system
 After activation, the press-in control system MultiPro FL displays the version of the firmware installed and the address of DSM
Messtechnik GmbH for approx. 5 seconds. The operating system now performs a system test and after the test is without fault it
reads the parameters stored in the press-in unit. The parameter Auto-Parameterisation, which is activated by default, is
responsible for the automatic reading of the appropriate setting.
After the final testing of the programs, the press-in control system switches to the production mode with the status "Waiting for
START...". The MultiPro FL is operational. If a new connected press-in unit is detected during initialisation, the MultiPro FL will
show it on the display.
Standard software 2G (3200)

RDY PGF OK NOK HA GSE PC- - - PB C: A: Program: xxx
New press-in unit detected!

The settings of the press-in unit are adopted.
Any key to continue. . .
After pressing any key, the control system reads the parameters stored into the press-in unit and checks the existing programs for
compatibility. The parameters entered in the joining process must match the new press-in unit in regard to force and velocity or
the message "Program error" will be displayed. The affected programs must be edited and adapted to the new process
conditions. The MultiPro FL is operational when the performance data of the connected press-in unit is compatible with the
programme data.
The integrated basic module is responsible for the power supply of the control module and the connected screw press-in unit.
Furthermore, it assumes the control as well as monitoring of the servo motor (tension / state of Hall sensor, max. motor current,
motor voltage, max. temperature, cable break).
You may parameterise and program the MultiPro FL press-in control system either on the device or with the MultiControl4 PC
software (included with delivery). A PC is required to use the PC software which will be connected with the MultiPro via zero
modem cable or TCP/IP.
The joining sequence programs can be created individually directly on the device (free programming environment) and changes
on the process sequence can be quickly adapted.
Edit program 1
RDY PGF OK NOK HA GSE PC- - - PB C: A: Program: xxx
001 Graphic start TAB = 2 ms

002 Travel to F = 5.0 kN
003 Measurements to intermediate memory
004 Measurements to long-term memory
005 Measurements display
006 Graphic stop
007 Transmit graphic data to PC
008 Normal position travel
009 End
Additional function through F-keys ...

Done Edit Ins. Del.
> Chapter 11.9 Operation: Sequence programming, Page 153

You can control access to the press-in control system via user management and thereby ensure that system-relevant settings are
made only by authorised persons.
The instructions Travel / Empty Travel / Normal Position Travel enable the integration of the joining processes stored in MultiPro
FL into the programme sequence.
> Chapter 6.5 Joining processes, Page 45
> Chapter 11.5.16 Access control, Page 147
In addition, MultiPro FL offers a variety of settings for the optimal configuration of the press-in control system and the press-in
unit; they can be easily located because of the context-sensitive menu navigation.
> Chapter 11.3.2.3 Menu navigation and menu overview, Page 136
> Chapter 11.5 Operation: Configuration control unit, Page 138
> Chapter 11.8 Operation: Configuration press-in unit, Page 150
The MultiPro is operational and displays the status message "Wait for START..."; a previously created joining program can now
be started. The start signal is applied directly to one of the available inputs of the X52 INTERFACE or one of the available inputs
of a connected IO extension.
The first start after ramping up the press-in control system always causes a normal position travel. The programme
sequence starts only with the subsequent start.
The press-in control system also provides the option of manually preselecting the program to be started directly on the unit by
entering a number (PG No.) and to start it via input 1 of the X52 interface. This requires that the parameter "Manual",
Preselection, E1" is set in the "Control unit settings" menu and the MultiPro is operational.
PG No. = 1 █
The selected joining program is carried out according to the programmed sequence and performs constant measurements during
the entire joining process. This way the limit values entered as well as additional parameters (joining time, start-up time, current
consumption) are monitored.
The joining process is analysed after a joining run has been completed. The end force and the end stroke are displayed.
The assessment of the joining process is displayed on the production screen with OK (in order) or NOK (not in order). In case of
NOK the stopping reason is displayed in an inverted field and the outputs for OK or NOK are set.
Joining station 0001

RDY PGF OK NOK HA GSE PC - - PB C: A: Preselection:
Test (PG001)
OK Step 2 OK
( TPG = 11877 ms )
F / [kN] = 20.15
S / [mm] = 160.73
Wait for start ...
Setting System info Remove CF
The production screen can be switched to the graphic mode (curve progression) to visualise the joining process.
An additional statement on the measuring result is indicated by the Led's of limit value monitoring on the press-in control system
(force / length (stroke) too small, unchanged, too large) as well as the status indication on the press-in unit (SMP without status
indication).
The measuring values are stored in the internal ring buffer.
Two statistic memories are available per program for the statistic recording. You can access the recorded values directly on the
press-in control system in the "Measuring data" menu.
You can transfer the measurements for detailed analysis either to the PC, CF card or via Profibus.

5.2 Protective device / Protection concept
 The press-in control system is suitable for connection to a protective device.

The integrated Machine-Safety-Interface (interface X76) takes care of a safe disconnection of the servo controller (EN ISO
13849-1 Performance Level e, EN IEC 62061 SIL3). The above mentioned safety shutdown is a component, which is integrated
into a protection device, i.e. which has to be activated from the customer. The liability and the responsibility is by the
customer/user. DSM does not take over any liability for perhaps failures or their consequences.
Please observe that the reset after triggering the safety device may not result into an uncontrolled start of the drive. The drive
starts again when the "MSI" function is no longer triggered. To correspond to the EN 60204 standard external measures must
ensure that the drive only restarts after a confirmation.
> Chapter 2.6 Protective devices, Page 16
5.3 Schema of the function principle
 The following figure shows the signalling (communication) of the MultiPro FL press-in control system.
20 21 22 23 24
PG Start Status output PB TCPIP MSI
PG-StartStatusausg. PBTCPI MSI
Power supply System bus
DSM SBUS units

Start / Stop - IO-Extension
- Status Indication
press-in unit - DCM-Extension
- Tool Control
- P Control
Drive - Synchronisation of
monitoring control systems
- Max. motor current Program start 20

- Max. temperature
- Cable break - 4 inputs (24V)
4 PG, 7 PG (BCD)
Permanent
Press-in measurements Status outputs 21
unit
- 4 outputs (24V)
- Force MultiPro FL
- Stroke RS232 (PC)
SMP series / - Current consumption
QMP series - Starting time
- Press-in time - Program and process data
Extern
as per DSM standard
Force (Push / Pull)
RS232 (Drucker)
Stroke - Printing the measurement results
(Relative / Absolute)
Profibus 22
Auto-parameterisation Ethernet 23
(TCP/IP)
The parameters of the
press-in unit are read
Machine safety 24
when the system starts.
20
4PG: Direct start of 4 programs possible. 7-PG: Start of 7 programs possible with binary encoded preselection. The number of the program inputs
can be expanded via the IO Extension.
21
Operational, OK, NOK, PG-ready, hold active, outputs not needed are freely available
22
Process data (DSM standard), parametrisation (DSM standard), customer-specific adaptation (option)
23
Program and process data as per DSM standard or optionally as per customer-specific adaptation
24
MSI: E-Stop, supply and monitoring by customer

5.4 Stroke measurement
 The press-in control system uses a relative stroke measuring system and an absolute measuring system when measuring the
travel stroke. The stroke measuring system is set in the joining parameter "Stroke measurement relative". Both systems work with
a resolution of 0.01 mm. The strokes / positions are entered and displayed in millimetres [mm].
Stroke
measurement
system "Absolute
Offset zero point
Lower edge press-in unit
S0 25
AE:
Stop retracted
BE:
Break fuse retracted S0 25
EE
Stroke KMGS:
measurement EE: Smallest possible
system "Relative" End range normal position
retracted
Start
position
Working range (example)
EA:
End range
extended
BA: EA
Break fuse extended
AA: 25
Stop extended
S0
> Chapter 13.2.5 Correction value stroke, Page 209
25
The value "S0" describes the dimension from the lower edge of the press-in unit to the zero point of the absolute measurement system. The value
is shown on the type plate of the press-in unit.

5.5 Linearisation, bending-up compensation
 With pressing/ joining processes each pressing/ joining system exhibits a load-dependant bending-up. This physical
characteristic is made up of the elastic bending-up of the machine, the tool and the work piece. The bending-up of the component
may amount to several tenths or a millimetre, depending on the application, also several millimetres.
Example
A pressing / joining system has a bending-up of: 0,15 mm at 10 kN
0,20 mm at 15 kN
0,25 mm at 20 kN
1,00 mm at 50 kN
With the extension to stroke without bending-up compensation the following result, shown in the table, is obtained:
Nominal stroke Force Bending-up

Effectively extended stroke [mm]
(displayed value) [mm] [kN] [mm]
10,0 mm 10 kN - 0,15 mm 9,85 mm
10,0 mm 15 kN - 0,20 mm 9,80 mm
10,0 mm 20 kN - 0,25 mm 9,75 mm
10,0 mm 50 kN - 1,00 mm 9,00 mm
You can see from the table with the sample values that the stroke of the bending-up is short at the impression depth.
To compensate for the bending-up of the components several linearisation values can be entered into press-in control system.
The bending-up compensation allows correcting the pressing / joining stroke in these force ranges.
To be able to enter the linearisation values they must first be calculated. Bending-up is determined with the overrun curve
(graphic recording with the MultiControl4 PC software). You can take the following approach when determining the values.
a) Prerequisites
The mechanical installation and setup of the tool as well as the programming and parameterisation of the press-in control system
must have been completed. The MultiControl4 software is installed on a PC. The press-in control system was connected with the
PC using a zero-modem cable.
b) Procedure
Start the MultiControl4 software.
Verify the program sequence whether graphic recording was programmed. In addition, the 'Overrun time' parameter should be
increased with the 'Travel' instruction. This is necessary to capture the overrun in detail, i.e. to visualise the resilient properties of
the overall system (machine, tool, work piece).
The parameter "Linearisation table" must be disabled in the settings (=Off).
Menu navigation
Production screen  <Settings>  <Settings/Test>  <Settings>  <control unit>  Linearisation table

5.5.1 Record "Overrun curve" graphic

Record the graphic (instruction: Graphic start) and transfer to the PC (instruction: Transfer graphic data to PC). Use the
programme sequence here intended for production. The overrun time should be chosen long enough (approx. 1000 ms) for the
overrun curve to come as closely as possible to the base line (F=0).
To determine the auxiliary points 'HP' the curve discussion ("Discussion" button) can be used. The last auxiliary
point (HPn) should be located here at the end of the overrun curve above the idle force (Fempty).
a) Determination of S0
The overrun curve with the graphics recording will never be able to drop to the baseline; the theoretic intersection of the overrun
curve with the baseline (S0), e.g., must be determined through an auxiliary line.
b) Auxiliary points determination

Various auxiliary points must now be measured from the overrun curve (see note on 'Curve discussion'). Several auxiliary points
should be set here in the non-linear areas of the overrun curve. Two auxiliary points are usually sufficient in the linear areas.
c) Determine auxiliary points

The auxiliary points (HP) measured with the curve discussion should be noted, for example, in a table.
Overrun curve Intersection NK: Overrun curve
Auxiliary point Force HP Stroke HP NK / GL GL: Baseline

HP1 F1 S1 S0
HP2 F2 S2
HPn Fn Sn

5.5.2 Determining the linearisation values

The values for the linearisation table are determined as follows:
• The forces are taken directly from the auxiliary points (F1 .. Fn).
• The strokes are calculated from the stroke of the auxiliary point (S1 .. Sn) minus the theoretic intersection of the overrun curve
with the baseline (S0).
Overrun curve Intersection Linearisation table

Auxiliary point Force HP Stroke HP NK / GL Item F [kN] S [mm]
HP1 F1 S1 S0 01 F1 S1 - S0
HP2 F2 S2 02 F2 S2 - S0
HPn Fn Sn n Fn Sn - S0
a) Test run
Linearisation table After entering the values in the linearisation table the
RDY PGF OK NOK HA GSE PC- - PB C: A: Program: xxx linearisation is activated and the graphics recorded
again. When analysing the curve progression the
Pos F [kN] S [mm]
overrun curve will ideally run almost vertically.
01 0.000 0.000
If the result of the bending-up compensation is not
02 0.000 0.000
satisfactory, the linearisation values may need to be
03 0.000 0.000
corrected or additional auxiliary points added in the
04 0.000 0.000
non-linear areas.
05 0.000 0.000
b) Production operation setup

If the result of the bending-up compensation is satisfactory the graphic recording / transfer may possibly be disabled (shortening
the cycle time). Furthermore, adapting the overrun time (approx. 200 ms) to the respective production requirements is useful.

5.6 Force measurement
 The press-in control system MultiPro FL is designed for the direct force measurement for pushing (QMP, SMP) and pulling
(only QMP). The highly precise digital force measurement sensor (KMDi) has been installed in the stamp of the press-in unit for
this purpose. The accuracy of force measurement (nominal force) lies around 1 % of the end value. The resolution is 1631 digits
on the calibration value (max. force) of the press-in unit.
Depending on the setting, the force can be entered or displayed in N or kN.
Force measurement
sensor (KMDi)
Plunger

Process control description
6 Process control description
6.1 Introduction
 A joining process can be performed in several ways. For this reason, the press-in control system MultiPro FL is equipped with
different joining processes. The joining process is defined by a method using specific parameters. The individual joining
processes hereby differ primarily in their main switch-off criteria. The respective method is integrated into the joining program and
parameterised with the help of an instruction.
• Travel until switch-off stroke has been reached • Empty travel

• Travel until switch-off force has been reached • Normal position travel
• Travel until initiator responds
6.2 Before starting the joining process
 To ensure that a program can only be run with an no-fault system, a "minor" system test is performed before each start of the
process control. Contrary to the "major" system test which is performed after switching on the joining control system only some
operating voltages, the offset and the calibration value are measured and checked. In addition, the system checks the operational
readiness of peripheral devices (e.g. IO Extension) when accessing them. If the controller detects one or several faults during the
"minor" system test, they are displayed and the output for operational readiness is reset. The operating personnel must confirm
each fault that has occurred individually. The output for operational readiness is afterwards set again.
6.3 Measurements during the joining process
 With all joining methods, regardless whether travel or empty travel, the following measurements are always verified and used to
assess the joining method.
Measured value Limit value Comment

Min value Max value
F F Min F Max The max. force (F) occurring during the joining process (F) 26.
The stroke measured until reaching the switch-off criterion26.

S S Min S Max
With relative measurement from threshold force FS.
The joining time is the period measured from the start of the
tF 0 tF max
joining process until reaching the main switch-off criterion.
The starting time is the period from the start of the joining
tAn 0 tAn max
process until a position change has been registered 27.
Current consumption of the press-in unit during the joining

I 0 I max
process.
The joining process is rated OK only when the measurements of the current joining process lie within these limits 28. If one of
these measuring values exceeds the limit value stored in the joining process, the process will be terminated with NOK (not in
order). The stop reason for the NOK joining process will be displayed.
26
Please note here: > Chapter 6.4 After reaching the switch-off criterion, Page 43
27
Serves to monitor whether the plunger is moving.
28
The limit values will be rated as OK (in order).

6.4 After reaching the switch-off criterion
 Once the main switch-off criterion of the joining process is reached, the press-in unit is generally switched of. However, if a
joining process in the program sequence is followed by a second joining process, the press-in unit is not stopped.
To be able to capture the torsion processes occurring after switch-off, an overrun time can be entered so that the measurement of
force and stroke can be continued even after the press-in unit is switched off.
To determine the actual results of a joining process, the overrun time must definitely be recorded as well. The
larger the press-in unit the greater the overrun time is be chosen.
> Chapter 6.4.1 Travelling on force without overrun, Page 43

> Chapter 6.4.2 Travelling on force with overrun time, Page 44
> Joining parameters: Overrun time, Page 163
6.4.1 Travelling on force without overrun
Force [N] / [kN]
Emergency switch-off
F Block
F Max
OK band
force (F)
F Res
F Stop
F Min
Emergency
switch-off
OK band
stroke (S)
Stroke
[mm]
S Min S Res S Max S Block
t [ms]
 Start t F
 Start t On
PG Switch-off
Start press-in unit
F Block Max. blocking force S Min Limit value min. stroke

F Max Limit value max. force S Res Result, stroke to switch-off time
F Res Result, stroke to switch-off time S Max Limit value maximum stroke
F Stop Switch-off force S Block Max. blocking dimension
n Min Limit value min. force tF Joining time
t Start Starting time
With the start of the joining process the force gradually increases from the time the plunger makes contact. The stroke
measurement starts from the threshold force and once the switch-off force (MStop) has been reached the press-in unit is switched
off.
The force (FRes) and the stroke (SRes) at the switch-off time are shown as result.

6.4.2 Travelling on force with overrun time
Force [N] / [kN]
F Block
F Max
OK band force (F)
F Res
F Stop
F Min
Emergency
switch-off
OK band
stroke (S)
Stroke
[mm]
t [ms]
 Start t F
 Start t On  Start t N  End t N
PG Switch-off
Start press-in unit
F Block Max. blocking force S Res Result, stroke to switch-off time

F Max Limit value max. force S Max Limit value maximum stroke
F Res Result, stroke to switch-off time S Block Max. blocking dimension
F Stop Switch-off force tF Joining time
F Min Limit value min. force t On Starting time
S Min Limit value min. stroke tN Overrun time
With the start of the joining process the force gradually increases from the time the plunger makes contact. The stroke
measurement starts from the threshold force and once the switch-off force (MStop) has been reached the press-in unit is switched
off. After switch-off the press-in unit it does not stop immediately but overruns due to physical aspects.
The force acting during the period from switch-off to standstill of the press-in unit as well as the characteristics of the stroke are
recorded through the overrun time N.
The peak force (FRes) during the overrun time and the stroke (SRes) after the overrun time has elapsed are shown as
result.

6.5 Joining processes
 The joining process is integrated into the program sequence with the instruction "Travel" or "Empty travel". Furthermore, the
instruction "Normal position travel" lets the plunger travel to a defined point.
The press-in control system MultiPro FL needs precise information for the joining process "Travel" and "Empty travel" about the
switch-off values, the limit values, the direction of travel, the velocity etc.
This information is referred to as parameters and differs according to the joining process selected (main switch-off criterion). The
parameters are entered by the user directly after the instruction (Travel, Empty travel) is called.
Function Joining process
TS TF TI ETS
Measurement
Assessment
Travel on Travel on Travel on Empty travel
Monitoring
stroke force initiator on stroke
Control
Parameter Page 46 Page 48 Page 51 Page 54
Switch-off stroke [mm] Sstop Page 158 x  
Switch-off force [N] / [kN] Fstop Page 158 x 
Switch-off input (INstop) Page 158 x 
Direction of travel (Dir.) Page 159 x    
Stroke measurement relative (Srel) Page 159 x    
Threshold force [N] / [kN] (Fs) Page 159 x   
Stroke min [mm] (Smin) Page 160 x x    
Stroke max [mm] Smax Page 160 x x    
Review stroke [mm] (Sdelta) Page 160 x x   
Blocking dimension max [mm] Sblk Page 161 x   
Force min [N] / [kN] (Fmin) Page 161 x x   
Force max [N] / [kN] (Fmax) Page 161 x x   
Blocking force max [N] / [kN] (Fblk) Page 162 x    
Entry in OK window (IOF) Page 162 x x   
Joining time [ms] (TP) Page 162 x    
Holding time [ms] (TH) Page 162 x   

Overrun time [ms] (TN) Page 163 x    
Ramp time [ms] (TR) Page 163 x    
Plunger velocity [mm/s] (V) Page 163 x    
Envelope number (HUKnr) Page 163 x x x   
Envelope switching (HUKsw) Page 164 x x x   
Motor current max [%] (Imax) Page 164 x    
Measurands add-on memory Page 165    

Delay [mm/s²] (Del.) Page 166 x 
Evaluation force (EF) Page 167 x   
Evaluation length (EL) Page 168 x   
X = Included in joining process.

 = Option, the parameters are available after activation.
> Chapter 13.8 Activation of chargeable options, Page 220

6.5.1 Travel on stroke

With the joining process "Travel on stroke" the main switch-off criterion is reaching a desired target position (switch-off stroke)
"SStop", that is, travelling a defined distance. This stroke can be specified as absolute but also as relative stroke to the starting
position. Contrary to the absolute measurement a threshold force is specified when travelling to a relative position. The threshold
force starts the relative stroke measurement. When the switch-off criterion has been reached the measured force can be held for
a parametric period (hold time) using the "Hold force" function.
Different parameters are available for monitoring the joining process, for example, the limit values of the stroke (min / max /
block), the limit values of the force (min / max / block), the starting time and the joining time as well as the max. motor current.
Exceeding one of these parameters leads to a termination of the joining process and is analysed with NOK.
29
The quality assessment of the joining process uses the max. force recorded during overrun as well as the current
position at the end of the overrun time.
The parameter 'Stroke review' is used to determine the analysis position in the force-stroke progression, i.e. pressing takes place
up to the switch-off stroke followed by a review on the defined stroke (review stroke). This stroke represents the stroke result as
well as the force result at this stroke point. The overrun is not taken into account here!
If monitoring of the force-stroke course within the OK window is desired, this can be activated with the parameter 'Force
progression in OK window'. The entrance of the force-stroke progression into the OK window must take place here from the left
and then remain in the OK window.
a) Diagram of the joining process "Travel on stroke (TS)"
Force [N] / [kN]
F Block
F Max
OK band force (F)
F Res
F Min
Emergency
switch-off
OK band
stroke (S)
Stroke
[mm]
S Min S Stop S Res S Max S Block
t [ms]
 Start t F
PG Switch-off
Start press-in unit

F Res Result, stroke to switch-off time S Block Max. blocking dimension
F Min Limit value min. force tF Joining time
S Min Limit value min. stroke t On Starting time
S Stop Switch-off stroke tN Overrun time
29
The overrun time begins when the cut-off criterion has been reached and the motor of the joining unit is stopped. The joining process is only
finished when the overrun time has elapsed.

b) Assessing the joining process "Travel on stroke (TS)"
The press-in unit is switched off if one of the following conditions is met.
 The switch-off stroke SStop has been reached.

 The force is greater equal FBlock.
 The position is greater equal SBlock.
 The joining time has elapsed.
 The plunger has not started within the permissible starting time.
The joining stage is rated OK if all of the following conditions are met.
 Switch-off took place through SStop.

 The switch-off point lies within the OK window, i.e. FMin ≤ FRes ≤ FMax and SMin ≤ SRes ≤ SMax.
 No error message from the basic module is present.
 No termination of the press-in unit took place.
c) Parameter overview "Travel on stroke (TS)"
Function
Measurement
Parameter of
Assessment
Monitoring
the joining
process
Control
Page
Switch-off stroke [mm] (Sstop) x 158
Direction of travel (Dir.) x 159
Stroke measurement relative (Srel) x 159
Threshold force [N] / [kN] (Fs) x 159
Stroke min [mm] (Smin) x x 160
Stroke max [mm] Smax x x 160
Review stroke [mm] (Sdelta) x x 160
Blocking dimension max [mm] (Sblk) x 161
Force min [N] / [kN] (Fmin) x x 161
Force max [N] / [kN] (Fmax) x x 161
Blocking force max [N] / [kN] (Fblk) x 162
Entry in OK window (IOF) x x 162
Joining time [ms] (TP) x 162

30
Holding time [ms] (TH) x 162
Overrun time [ms] (TN) x 163
Ramp time [ms] (TR) x 163
Plunger velocity [mm/s] (V) x 163
Envelope number (HUKnr) x x x 163
Envelope switching (HUKsw) x x x 164
Motor current max [%] (Imax) x 164
Measurands add-on memory 30 165
Evaluation force (EF) x 167
Evaluation length (EL) x 168
30
The parameter is available after respective activation.

6.5.2 Travel on force

With the joining process "Travel on force" the main switch-off criterion is reaching a predefined force "FStop". Stroke monitoring
takes place as additional check; the optional choices here are absolute or relative stroke measurement. With relative position
recording, contrary to the absolute measurement, a threshold force FS must be specified. The threshold force starts the relative
stroke measurement. When the switch-off criterion has been reached the measured force can be held for a parametric period
(hold time) using the "Hold force" function.
Different parameters are available for monitoring the joining process, for example, the limit values of the force (min / max / block),
the stroke (min / max / block), the starting time and the joining time as well as the max. motor current. Exceeding one of these
parameters leads to a termination of the joining process and is analysed with NOK.
31
a) Diagram of the joining process "Travel on force (TF)"
Force [N] / [kN]
F Block
F Max
OK band force (F)
F Res
F Stop
F Min
Emergency
switch-off
OK band
stroke (S)
Stroke
[mm]
t [ms]
 Start t F
PG Switch-off
Start press-in unit

F Res Result, peak force during overrun time S Block Max. blocking dimension
F Stop Switch-off force tF Joining time
31
The overrun time begins when the switch-off criterion has been reached and the motor of the press-in unit is stopped. The joining process is only

The diagram depicted on page 48 shows the force-stroke progression by way of example.
The options in regard to the review stroke, relative stroke measurement, force progression in OK window as well as
hold times can be seen symbolically from the diagrams on pages 57 to 59.
> Chapter 6.5.5 Function diagram „Review stroke“, Page 57

> Chapter 6.5.6 Function diagram "Relative stroke measurement", Page 58
> Chapter 6.5.7 Function diagram "Force progression in OK window", Page 59
> Chapter 6.5.8 Function diagram "Hold force" (option), Page 60
b) Diagram of the joining process "Travel on force (TF)"
 The switch-off force FStopp has been reached.

 Switch-off took place through FStop.


c) Parameter overview "Travel on force (TF)"
Function
Measurement
Parameter of
Assessment
Monitoring
the joining
process
Control
Page
Switch-off force [N] / [kN] (Fstop) x 158

32
32

6.5.3 Travel on initiator

With the joining process "Travel on initiator" the joining process is closed by an external signal (e.g. from an external initiator).
The main switch-off criterion is the predefined freely selectable switch-off input "INStop".
Stroke monitoring takes place as additional check; the optional choices here are absolute or relative stroke measurement. With
relative position recording, contrary to the absolute measurement, a threshold force FS must be specified. The threshold force
starts the relative stroke measurement. When the switch-off criterion has been reached the measured force can be held for a
parametric period (hold time) using the "Hold force" function.
Different parameters are available for monitoring the joining process, for example, the limit values of the force (min / max / block),
the stroke (min / max / block), the starting time and the joining time as well as the max. motor current. Exceeding one of these
33
a) Diagram of the joining process "Travel on initiator (TI)"
Force [N] / [kN]
F Block
F Max
OK band force (F)
F Res
IN Stop
F Min
Emergency
switch-off
OK band
stroke (S)
Stroke
[mm]
t [ms]
 Start t F
PG Switch-off
Start press-in unit

F Res Result, peak force during overrun time S Block Max. blocking dimension
IN Stop Switch-off input (= 1) tF Joining time
33

The diagram depicted on page 48 shows the force-stroke progression by way of example.
The options in regard to the review stroke, relative stroke measurement, force progression in OK window as well as
hold times can be seen symbolically from the diagrams on pages 57 to 59.

b) Assessment of the joining process "Travel on initiator (TI)"
 The switch-off input INStop = 1.

 Switch-off took place via the switch-off input.


c) Parameter overview "Travel on initiator (TI)"
Function
Measurement
Parameter of
Assessment
Monitoring
the joining
process
Control
Page
Switch-off input (INstop) x 158

34
Stamp velocity [mm/s] (V) x 163
34

6.5.4 Empty travel on stroke
With the joining process "Travel on stroke" the main switch-off criterion is reaching a desired target position (switch-off stroke)
"SStop", that is, travelling of the stamp to a defined position without force. The parameter "Stroke measurement relative"
determines how to travel with relative (=On) or absolute (=Off) stroke measurement.
Relative: The plunger is moved in relationship to the current position and in accordance with the chosen direction of travel.
Absolute: The plunger is moved in relationship to the zero point of the press-in unit and in accordance with the chosen direction
of travel.
> Chapter 5.4 Stroke measurement, Page 37
Depending on the application a delay (negative acceleration) can be entered parametrically. The delay specifies the value of how
much the stamp is slowed down from the brake point "SBrake" till reaching the target position "SStop".
a) Velocity / stroke progression with acceleration and delay
Velocity
[mm/s]
 Start S Brake S Stop

V0 t Ramp
Stroke [mm]
Time [s]
Acceleration Delay
PG-
Start
V0 Stamp velocity S Brake Braking point

t Ramp Ramp time S Stop Switch-off stroke
From braking point "SBrake" the attempt is made to slow down the stamp with the parametric delay.
If the delay is chosen too large, the stamp cannot come to stop at the target position "SStop" for physical reasons.
b) Velocity / stroke progression when delay is chosen too large
Velocity
[mm/s]
Delay
V0
Actual
Theoretic progression
progression
Stroke [mm]
Time [s]
S Brake S Stopp TH S Stop ACT
V0 Stamp velocity S Stop TH Theoretic switch-off stroke

S Brake Braking point S Stop TAT Actual switch-off stroke
Different parameters are available for monitoring the joining process, for example, the limit values of the stroke (min / max /
block), the max. blocking force, the starting time and the joining time as well as the max. motor current. Exceeding one of these
The current position at the end of the overrun time 35 is used to rate the quality of the joining process.
35

c) Diagram of the joining process "Empty travel on stroke (ETS)"
Force [N] / [kN]
F Block
Emergency
switch-off
OK band
stroke (S)
Stroke
[mm]
S Min S Stop S Res S Max S Block

t [ms]
 Start t F
PG Switch-off
Start press-in unit
F Block Max. blocking force S Block Max. blocking dimension

S Min Limit value min. stroke tF Joining time
S Stop Switch-off stroke t On Starting time
S Res Result, stroke to switch-off time tN Overrun time
S Max Limit value maximum stroke
d) Assessment of the joining process "Empty travel on stroke (ETS)"

 The switch-off stroke SStop has been reached.

 Switch-off took place through SStop.

 The switch-off point lies within the OK window, i.e. SMin ≤ SRes ≤ SMax.

e) Parameter overview "Empty travel on stroke (ETS)"
Function
Measurement
Parameter of
Assessment
Monitoring
the joining
process
Control
Page
Switch-off stroke [mm] (Sstop) x 158
Delay [mm/s²] (Dely) x 166

36
Measurands add-on memory 165
36

6.5.5 Function diagram „Review stroke“
The illustration symbolically shows the function on the joining process "Travel on stroke".
Force [N] / [kN]
F Block
OK band
stroke (S)
Emergency
switch-off
F Max
OK band force (F)
F Res
F Min
Review
stroke
Stroke
[mm]
S Min S Res S Max S Stop S Block
t [ms]
 Start t F
 Start t On
PG Switch-off
Start press-in unit
F Block Max. blocking force S Max Limit value maximum stroke

F Max Limit value max. force S Stop Switch-off stroke
F Res Result, force on stroke point SRes S Block Max. blocking dimension
S Res Result, stroke point after deducting the defined review stroke of SStop
After the program start pressing is first performed up to the switch-off stroke SStop, this is followed by a review of the defined
stroke (review stroke). This calculated stroke represents the stroke result SRes as well as the force result FRes at this stroke point.
When using the review stroke a max. block dimension as well as max. block force must be entered to secure the switch-
off criterion. The overrun time is not considered when using the review stroke.
Example:
The switch-off stroke SStop lies at 100 mm, the defined return stroke is 5 mm, this produces the resulting way result SRes of 95 mm.
The force result FRes is the force measured at the 95 mm.
> Joining parameter: Review stroke, Page 160

6.5.6 Function diagram "Relative stroke measurement"
Force [N] / [kN]

F Block
F Max
OK band force (F)
F Min
Emergency
switch-off
FS
OK band
stroke (S)
Stroke
[mm]
Start
relative Stroke
stroke 
[mm]
measurement S Min S Stop S Res S Max S Block
0 mm
t [ms]
 Start t F  Start t N  End t N
 Start t On
PG Switch-off
Start press-in unit
F Block Max. blocking force S Res Result, stroke after overrun time has elapsed
F Min Limit value min. force S Block Max. blocking dimension
FS Threshold force tF Joining time
S Stop Switch-off stroke tN Overrun time
When activating the joint parameter "Stroke measurement relative" the relative stroke measurement is started from the defined
threshold force FS The limit values for the position analysis refer thereby to the way stroke from which relative stroke
measurement was started.

> Joining parameter: Relative stroke measurement, Page 159

6.5.7 Function diagram "Force progression in OK window"

When activating the joint parameter "Entry to OK window the entry of the force/stroke progression into the OK
window must take place from the left and during the further progress remain within this window until the switch-off
point has been reached.
> Joining parameter: Entry in OK window, Page 162
The following illustrations show different joint progressions at active progression monitoring "Force progression in OK window".
OK case NOK case 1
Force [N] / [kN] Force [N] / [kN]
Emergency switch-off Emergency switch-off

F Block F Block
F Max F Max
OK band OK window OK band OK window
Emergency Emergency
force (F) force (F)
switch-off switch-off
F Min F Min
OK band OK band
stroke (S) stroke (S)
Stroke Stroke
[mm] [mm]
PG S Min S Max S Block PG S Min S Max S Block

Start S Stop Start S Stop
NOK case 2 NOK case 3
Force [N] / [kN] Force [N] / [kN]
Emergency switch-off Emergency switch-off

F Block F Block
F Max F Max
OK band OK window OK band
force (F) Emergency force (F) Emergency
OK
switch-off switch-off
window
F Min F Min
OK band OK band
stroke (S) stroke (S)
Stroke Stroke
[mm] [mm]
PG S Min S Max S Block PG S Min S Max S Block

Start Start S Stop
F Block Max. blocking force S Min Limit value min. stroke

F Max Limit value max. force S Res Switch-off stroke
F Min Limit value min. force S Max Limit value maximum stroke
S Block Max. blocking dimension

6.5.8 Function diagram "Hold force" (option)
Force [N] / [kN]

F Block
OK band
stroke (S)
F Max
OK band force (F)
Hold time
F Res
F Min
Emergency
switch-off
Stroke
[mm]
S Stop S Min S Res S Max S Block
t [ms]
 Start t F  Start t Hold  Start t N  End t N
 Start t On
PG Switch-off
Start press-in unit
F Block Max. blocking force S Res Result, stroke after hold and overrun times have elapsed
F Res Force result S Block Max. blocking dimension
S Stop Switch-off stroke t On Starting time
S Min Limit value min. stroke t Hold Hold time S Min Limit value min. stroke
The joining process is started After the switch-off criterion SStop has been reached the force measured at the switch-off time via
current hold is held for the hold time (max. 3000 ms) defined in the joint parameters. The press-in unit is switched off after the
hold time has elapsed. The force acting during the period from switch-off to standstill of the press-in unit as well as the
characteristics of the stroke are recorded through the overrun time N.
The peak force (FRes) during the overrun time and the stroke (SRes) after the overrun time has elapsed are shown as result.
The hold mode "Hold force" can be enabled with an activation code.
> Joining parameter: Holding time, Page 162

6.5.9 Envelope function

The envelope monitoring is a additional monitoring of the joining stage. A envelope describes a curve band that checks at all the
points of the joining stage the deviations to the recorded reference curve. The parameter "Envelope switching" specifies the
behaviour of the control system when exiting the upper or lower envelope during the press-in process.
The selection of the press-in process and their parameterisation must been completed before the reference curve will be recorded
(with the exception of the envelope parameters "Envelope number = 0"). Please particularly note the selection of the stroke
measurement, the function "Entry in OK window" as well as the function "Hold".
The envelope will then defined with the "MultiControl4" PC software and stored globally into the control system (max. 10
envelopes).
The generated envelope curve based on the recorded reference curve will be selected later with the parameter "Envelope
number". With this parameter the function will be integrated into the joining stage and activated.
Of course, the envelope must be suitable for the respective application / joining stage. Note that a envelope refers always only to
one stage in the program sequence. This means that in a sequence program with several stages a suitable envelope must be
assigned to the process (joining stage) which shall be monitored.
a) Recording / choosing a reference curve
Are no suitable graphics (curves) available it is necessary that the user program a sequence with the respective procedures (main
cut off criterion) and the associated parameters. In addition it is essential, the instruction "Graphics" and "Transfer graphics data
to the PC" must be integrated into the program sequence. Next, start the respective program under the same conditions as later
with envelope monitoring. It is recommended to execute the program and record graphic data until you recorded a suitable
reference curve.
For choosing a reference curve open the menu <Edit> of the MultiControl4 software and select the menu item <Envelope>.
(2) Selection list „Graphic data“ (1) Maximise window
(4) Mode
(3) Selection stage (6) Designation
(7) Save (5) Memory location
(1) Maximise the window for a better overview. Now highlight a suitable graphics in the selection list (2) and select the stage (3)
that shall be used for the definition of the envelope. Set the mode (4) for the envelope monitoring. With the setting "relative" the
envelope monitoring starts when the threshold force is reached, with the setting "absolute" the stroke value of a point refers to the
absolute stroke measurement system, with the setting "reviewing" the envelope will be checked in retrospect after switch-off
stroke is reached (the following applies for the mode "reviewing": Only the setting "non switching" in the parameter "Envelope
switching" is plausible).
Determine a memory location (max. 10 envelopes) in the "Selection" list field (5) and assign a designation for the envelope with
the input field "Name" (6). Finally click on the button <Save> (7).

b) Create an envelope
An envelope always consists of an upper and lower band. Each band can be defined freely with up to 10 points 37. The points are
thereby automatically arranged in ascending order when saving.
First, press the button <Edit> to define the upper envelope. Then place the first point of the envelope in the graphic area. Starting
from the first point all further positions of the upper band will be placed by using a multipoint line. The drawing of the multipoint
line is completed by double-clicking (left mouse button).
By pressing the button <Points> already placed points can be edited. When selecting a point it receives a red highlight.
A highlighted point can be moved (position) with the left mouse button pressed or deleted with right mouse button. Adding of
points can also be done with the right mouse button.
In addition, the window "Envelope" show the value pair "Force / Stroke" of the marked point. It is possible to adjust (optimize) the
force value as well as the stroke value of a point in the corresponding field.
Note when setting the first point that the envelope can begin no earlier than with the threshold value.
Edit Edit points
Add / delete points

optimise values
After all points of the upper band (envelope)

have been set the points of the lower band
are subsequently arranged.
Click on <Edit> in the area "Lower envelope".
Now set the points relevant for monitoring the
lower area.
Arrange the points so that the area of the curve relevant for your application is monitored.
37
One point consist of a value pair (force / stroke).

Finally, click on <Save>. When saving the envelope is saved in the current order and sent automatically to the control system
connected.
The upper and lower envelope defines the limit values of the master curve. The analysis of the envelope thereby
always takes place from the first to the last point.
For this reason, the points set are verified after completing the input and sorted automatically in the correct order.
The following message is displayed:
c) Edit envelope
Using the <Edit> button (upper / lower envelope) the respective envelope can be moved with the left mouse button pressed.
You can edit the points of the selected envelope using the "Points" button. The software offers two options here: Move the
marked point with the mouse or by entering the value pair. A marked point can be removed with the button "Delete".
Enter value pair
d) Parameterisation of the envelope
The integration of the envelope function is done in the programming environment. Select the program line with the instruction
"Turn in" / "Turn out" and then select in the input screen the parameter "Envelope number". Next, enter the number of the
envelope to be used.
> Joining parameter: Envelope number, Page 163
Then define with the parameter "Envelope switching" how to travel when the envelope has been fallen below / exceeded.
> Joining parameter: Envelope switching, Page 164
Finally save the parameters.

6.6 Go initial position
 The procedure "Go initial position" is used to move the plunger of the press-in unit to the starting position that is stored global in
the settings "Press".
The initial position is approached during the first program start after switching on (compelling drive to initial position). This serves
to check the stroke measurement system. This means that by program start the procedure "Go initial position" will be run and not
the pre-selected program will be started. The MultiPro FL sets the two status outputs "Press-in procedure was OK" and "Press-in
procedure was NOK" for signalling to a higher-level control system.
In addition, the programming environment of the control system offers the possibility to drive to the starting position from each
program with the instruction "Go Initial Pos". The procedure "Go initial position" can be used for example as position for tool
replacement.
> Chapter 11.9.4.1 Go Initial Pos (instruction), Page 157
The drive to initial position will be run compelling (= exclusively after switching-on the control system), if the parameter "Starting
position (only comp.)" is enabled. Otherwise – a drive to initial position will be run in the event of any modification of the
parameters as well as in the event of measures that the plunger was not moved by a program.
When moving to starting position, depending on the distance of the starting point "S Start" of the plunger until reaching the starting
position "S GS", the velocity "G Vmax" is controlled.
The function is implemented in such way that the movement "go initial position" always be finalized in driving direction
"move in".
The associated parameters "Starting position", "Starting position (Vmax)" and "Starting position (only comp.) are set in the "Press"
menu of the press-in control system MultiPro FL.
Menu navigation
Production screen  <Settings>  <Settings/Test>  <Settings>  <Press>
> Chapter 11.8.10 Starting position, Page 152

> Chapter 11.8.11 Starting position (Vmax), Page 152
> Chapter 11.8.12 Starting position (only comp.), Page 152

Continuation Go initial position
(1) If the starting point "S Start" lies below the starting position "S GS" the stamp is retracted with the corresponding control of the
velocity up to the starting position "S GS".
(2) If the starting point "S Start" lies above the starting position "S GS" it is first travelled past by delta "∆ S GS", the direction of travel
is subsequently changed to „move in“. The stamp is retracted with the corresponding control of the velocity (V3 = 6% from G Vmax)
to the starting position "S GS".
V1 G Vmax = Parameter "Starting position (Vmax)" S Start Starting point

V2 50 % von G Vmax S GS Initial position = Parameter "Starting position"
V3 6 % von G Vmax

Continuation Go initial position
Value range "Starting position Vmax"
0,2 · Vmax ≤ G Vmax ≤ Vmax
Max. feed of the press-in unit

Vmax
(configuration press-in unit)
G Vmax Starting position Vmax (parameter)
No OK / NOK assessment is performed after reaching the initial position; however, you can set the status output "Initial position
reached" in the "Control unit" menu.
Menu navigation
Production screen  <Settings>  <Settings/Test>  <Settings>  <Control unit>
> Chapter 11.5.4 Status outputs, Page 145
No measured and graphics data is saved with the "Go initial position".

6.7 Joining sequence (programme)
 A program is a list of instructions used to determine how a joining process proceeds. If a joint step shall be carried out, the user
selects the joining process with the instruction "Travel" or "Empty travel" or "Normal position travel" and defines the criteria the
press-in unit shall use to work with. This allows realising multi-step processes in a programme
However, a program is not only limited to calling joining processs. It allows the user to adapt the process to his application by
using different instructions (programme commands).
The press-in control system MultiPro FL waits for the start signal. A system test is first carried out if a program (PG input) is
assigned to the start signal. The respective program is selected, initialised and started when the measured parameters lie within
the limit values. A normal position travel always takes place at the first start after the system was started up. Next, the start must
be entered once more to start the programme.
A failed system test is indicated by an error message which the user must acknowledge. Next, the press-in control system moves
to the ready mode and shows the "Wait for START ..." message on the display. The start signal must be applied again.
After a program is started, the instructions are processed line by line following the sequence entered. The program is completed
when the END command is executed or a start termination is detected. A start termination is present if the start signal is removed
during the joining process.

> Chapter 11.5.1 PG Start, Page 138
> Chapter 11.5.10 Abort mode, Page 146
6.7.1 Signal time response: Joining process with OK result
By applying input 1, the sequential program with the number 1 (PG 1) is started as shown in the example. No later than after "t
D1" milliseconds are the status outputs OK, NOK as well as PG Complete reset.
If the first program instruction is a joining process, the drive of the press-in unit is started no later than after "t Start" milliseconds.
If the sequence was normally completed, the corresponding status output OK or NOK is set and then the output PG Complete.
Input 1 must remain set for at least "t H min" milliseconds after setting the status output PG Compete; otherwise, the sequence is
handled as with a start termination.
A restart can take place no earlier than after "t NS" milliseconds.

6.7.2 Signal time response: Joining process with system error during programme sequence
By applying input 1, the sequential program with the number 1 (PG1) is started as shown in the example. A system error occurs
during the program sequence, e.g. caused by the overload of an output of an IO Extension.
The drive of the press-in unit is stopped no later than after "tD2" milliseconds. The status output Ready is reset after "tD3"
milliseconds.
6.7.3 Signal time response: Joining process after occurrence of a system error
After a system error has been removed and acknowledged the next start always leads to the stamp travelling to the normal
position. This is indicated in that the OK output and NOK output are set simultaneously.
Once normal position travel was performed without faults the system outputs OK and NOK are simultaneously at zero.

6.7.4 Signal time response: Joining process with start termination
6.7.5 Signal time response: Joining process with PG preselection and NOK result

6.7.6 Signal time response: Joining process with termination by removing the ext. release
The program is terminated if the external release is removed during a program sequence. Because this is an irregular stop, the
status outputs OK and NOK are set simultaneously.
This indicates that a normal position travel is performed with the next programme start.

Delivery, in-plant transport, storage
7 Delivery, in-plant transport, storage
7.1 Delivery
 The component "Press-in control system MultiPro FL" is supplied as individual packing unit.
The components of the total scope of delivery are delivered either as individual packing units or combined into one or several
packing units.
7.2 Unpacking / Transport damage
 The press-in control system MultiPro FL is inspected before shipment and carefully packaged by our shipping staff. If you
should still receive a damaged device please have the package forwarder issue a damage confirmation claim
Concealed transport damages must be reported to DSM within 5 working days after receiving the goods. Transport
damages reported later will not be acknowledged by the transport companies.
Please inspect the goods immediately upon receipt. Please call us in case of damages:
Phone +49 07361 5717 - 36.
Alternatively you can also send an e-mail to info@dsm-messtechnik.de. We will then discuss the appropriate procedure. Please
do not return any goods without authorisation.
7.3 Repacking / Temporary storage
Transport and store the press-in control system MultiPro FL in the original DSM
packaging or equivalent.
 After you have inspected the goods, repackage the scope of delivery and store temporarily, if applicable, until the time of
installation.
> Chapter 7.6 Storage conditions, Page 72
7.4 In-plant transport
 Transporting the packaged shipment 38 to the installation location. Remove the press-in control system MultiPro FL only from
the package if it will be installed soon.
> Chapter 10 Assembly and installation, Page 78
38
Logistics data
Carton dimensions:
430mm (W) x 330mm (D) x 430mm (H);
Weight of carton:
MultiPro FL DS-L Type 3 approx. 12,5 kg;
MultiPro FL DS-H Type 2 approx. 11 kg;
MultiPro FL DS-V Type 5 approx. 11,5 kg

Delivery, in-plant transport, storage
7.5 Handling of packaging material
 Dispose of the packaging material in conformity with the respective applicable statutes and local regulations.
Environmental damages from improper disposal!

Packaging materials are valuable raw materials and in many cases can be used further or reused and recycled.
For this reason:
• Dispose of packaging materials in an environmentally compatible manner.
• Observe the local applicable disposal regulations. If necessary, commission a speciality company with the disposal.
7.6 Storage conditions
Improper storage may cause damage to the press-in control system MultiPro FL!
The following conditions must be observed for secure and careful storage of the press-in control system.
Preparatory measures
• In case of extended storage, regularly check the general condition of the

press-in control system and the packaging.
• Store the press-in control system in the original packaging or equivalent.
Permissible environmental conditions

• Storage temperature range: +5 °C to +40 °C
• Relative humidity: max. 60 %.
• Store dry and dust-free.
• Do not store outside.
• Protect from direct sunlight.
• Do not expose to aggressive media.

Setup requirements
8 Setup requirements
8.1 Safety
 The press-in control system MultiPro FL may be operated only in interior areas. Consider the ambient influences.
Do not use the press-in control system in moist or wet locations. Penetration of liquids into an electrical device
increases the risk of electrical shock.
Avoid body contact with grounded parts / surfaces such as pipes, radiators and other connected machines.
Increased risk from electrical shock if your body is earthed.
Do not use the press-in control system in explosion hazard environments. The press-in control system is not designed for this
purpose.
Electrical devices may generate sparks which may then ignite flammable liquids, gases or dusts.
Keep your workplace clean and uncluttered. Provide sufficient space and adequate lighting at the location intended for the
installation of the press-in control system.
Disarray and dark work areas may lead to accidents.
> Chapter 2.3 Application, Page 15
8.2 Logistics data
• Packaged shipment
- Carton dimensions:
(W x D x H) 430 x 330 x 430 mm
- Weight of carton:
MultiPro FL DS-L Type 3 approx. 12,5 kg;
MultiPro FL DS-V Type 5 approx. 11,5 kg
• Unpackaged delivery unit

For dimensions and weights please refer to:
> Chapter 3.1 Data sheet MultiPro FL, Page 21

Setup requirements
8.3 Ambient conditions
It is imperative to operate the press-in control system at a vibration-free location. The ambient influences listed below must always be
observed.
Ambient temperature Ambient air temperature according to VDE 0113 Part 1 (EN 60204-1)
Working temperature between +5 °C and +40 °C, provided that the average temperature of the
Working temperature
air does not exceed +35 °C over a period of 24 hours.
Adequate cooling must be provided if the average temperature is exceeded (air conditioner,
Average temperature heat exchanger).
> 35 °C When installing several devices make sure that a distance of approx. 1 - 2 cm is observed
between the individual devices to allow for air circulation.
Relative humidity Relative humidity between 30% and 90% (non-condensing).
Protection class Protection class IP40 according to VDE 0470 Part 1 (EN 60529)
8.4 Supply connections
 The mains connection is integrated in the basic module of the press-in control system.
Mains voltage (basic module Type DS-L, DS-H) 230 VAC / 50-60 Hz
Mains voltage (basic module Type DS-V) 3x 400 VAC / 50-60 Hz
8.5 Other information
 The press-in control system must be mounted with 4 screws to a suitable mounting surface / device. The mounting holes are
located in the rear wall of the housing.
> Chapter 10.2 Assembly, Page 78

Initial operation
9 Initial operation
9.1 Safety
Risk of injury or property damage from faulty installation and commissioning!

Installation and commissioning require trained technical personnel with sufficient experience. Errors during installation can lead to life-
threatening situations or cause significant property damages.
For this reason:
• Have the installation and initial commissioning carried out only by the manufacturer or technical personnel.
9.2 Assembly and installation
• Remove the press-in control system from its packaging and mount to the intended mounting device. Save the packaging
material or dispose of in an environmentally compatible manner.
> Chapter 7 Delivery, in-plant transport, storage, Page 71
> Chapter 8 Setup requirements, Page 73
> Chapter 10.2Assembly, Page 78
• Make sure before beginning with the electrical connection that in addition to the press-in control system also the press-in unit,
possible optional module as well as other relevant components are installed. Make sure that the On/Off switch is set to "OFF".
• First connect the press-in unit to the basic module. Select the appropriate wiring diagram. The designation of the basic
module is noted on the type plate (Page 20).
> Chapter 10.3 Electrical installation, Page 80
> Chapter 10.5 Electrical connection of basic module, Page 82
• The MSI interface must be connected in accordance with the customer safety concept. When integrating the MSI interface the
wiring diagrams of the system documentation must be observed.
> Chapter 2.6 Protective devices, Page 16
• The connection of the control module depends on the customer requirements.

It is noted in the documentation of the overall plant. Connect the control module accordingly. The assignments as well as the
necessary settings for the interfaces can be found at:
Determine whether the program start as well as the output of the status outputs takes place via the I/O level or
Profibus.
When using the PC software MultiControl4 the PC can be connected with the press-in control system either in series
or via TCP/IP. Choose a connection type.
Standard cable:
The connection of the computer to the X6 interface of the press-in control system is made with the PC connecting cable from
DSM or a commercially available zero modem cable.
> Chapter 10.6.2 Assignment PC connecting cable, Page 91
If a printer of the type Multisystem PR-II is integrated into the press-in system then connect the two devices with the DSM printer
cable. When using a third party make (serial) the printer is connected in accordance with the interface assignment (Page 26).
> Chapter 10.6.3 Assignment Printer cable, Page 92
The DSM systembus devices 39 are connected with the systembus cable.
> Chapter 10.6.4 Assignment System bus cable, Page 93
39
IO Extension, Status Indication, ToolControl, P Control, DCM Extension

Initial operation
9.3 Configuration
• Switch on the press-in control system on the on/off switch after the assembly and installation work has been completed. The
MultiPro checks the connected press-in unit during the initialisation. If a new press-in unit is detected this is shown on the display.
After confirmation the data of the press-in unit stored in the digital parameter memory is read.
• First configure the communication interfaces; open the following menu for this purpose:
Production screen  <Settings>  <Settings/Test>  <Settings>  <Communication>
Set the relevant interfaces.
> Chapter 10.8.3 Settings at system bus, Page 97
> Chapter 10.9.2 Settings at Profibus, Page 99
• If you would like to perform all additional settings with the MultiControl4 software then install the software (Application
"SetupMultiControl4_Vx_xx.exe" on the CD-ROM "MULTI CD") and start the "MultiControl4" program. First, set the parameters
for the PC interface.
The procedure of parameterisation and programming using the MultiControl4 software is outlined in the MultiClassic
FL operating instructions.
The PDF file of the instructions is available on the CD-ROM "MULTI CD".
• Next, switch to the menu „Press-in unit settings“:

Production screen  <Setting>  <Settings/Test>  <Settings>  <Press-in unit>
Verify whether the parameter "Auto- parameterisation" was set to the factory setting "On". Check the parameters "Force
correction factor" and "Stroke correction factor" by comparing the set values with those on the type plate of the press-in unit. The
respective factor can also be adjusted while auto parameterisation is switched on. The parameters "Maximum ramp-time",
"Normal position", "Normal position Vmax" and "Service cycle" can also be set in this context.
• Finally, configure the control unit; switch to the following menu for this purpose:
Production screen  <Setting>  <Settings/test>  <Settings>  <Control unit>
Define the programme start (PG Start) and also include the parameter "SBUS start".
> Chapter 11.5.3 SBUS-Start, Page 144
Set the status outputs or verify the factory settings and change them if necessary.
- Optional settings:
· External release, when using the optional module MSI interface this parameter must be activated by setting an input. The
selected input must be connected with the emergency-off switchgear/the safety PLC.
> Chapter 11.5.11 External release, Page 147
· NOK interlock, the NOK interlock is activated by setting an input. This means, the program sequence can only be restarted
by a release after an NOK joining process. The defined input must be selected accordingly (24 V signal).
> Chapter 11.5.15 Input NOK interlock, Page 147
· Access control, when activated, the user can make settings to the press-in control system MultiPro FL according to the
defined authorisation.
> Chapter 11.5.16 Access control, Page 147
> Chapter 11.6 Operation: User administration, Page 148

Initial operation
9.4 Sequence programming
 After the configuration has been completed programming of the joint process can be begun.
> Chapter 6.7 Joining sequence (programme), Page 67
• To program the sequence open the following menu: Production screen  <Settings>  <Programs>
• Define the joining process(s) as well as the programme sequence and begin programming. For your support and to illustrate
the program structure refer to the following two examples.
Joint program 1 (example)

Z No. Instruction Explanation
001 Graphic start TAB = 2 ms Starts the graphic recording
002 Travel to F = x N Joining process
Step
003 Measurements to intermediate memory Measurements of the step are saved
004 Measurements Display Presentation of measurements on the display
005 Graphic stop Stops the graphic recording
006 Transmit Graphic data to PC Transfers the recorded values
007 Normal position travel Stamp moves back to the normal position
008 End Programme end
Joint program 2 (example)

Z No. Instruction Explanation
001 Graphic start TAB = 2 ms Starts the graphic recording
002 Travel to S = x N Joining process
Step 1

006 Jump if result OK - > 008 Program branch if results OK
008 Graphic continue Continues the graphics recording
009 Travel to F = x N Joining process
Step 2

014 Transmit Graphic data to PC Transfers the recorded values
015 End Programme end
> Chapter 11.9.5 Programming example, Page 177
It is possible to check the functionality of the used inputs and outputs by the help of the MultiControl4 software (menu
bar "Online", Setting "IO simulation").
Please take care, that no safety-related actions/processes will be triggered by the simulation of the inputs/outputs. The non-observance
can result into a defect as well as into a possible dangerous situation for the health of persons!
> Chapter 12.3 Test mode / simulation of the inputs and outputs at the press-in control system, Page 204

Assembly and installation
10 Assembly and installation
10.1 Safety
a) Improper installation
Risk of injury or property damage from faulty installation and commissioning!

Installation and commissioning require trained technical personnel with sufficient experience. Errors during installation can lead to life-
threatening situations or cause significant property damages.
For this reason:
• Have the assembly and installation carried out only by the manufacturer or technical personnel.
b) Accidental commissioning
Risk of injury from unintentional starting!

Unintentional starting of the press-in control system during installation may cause serious injuries.
For this reason:
• Before beginning to work, switch off the power supply on the press-in control system (On/Off switch)
and secure against switching-on again.
c) Liability
Damage to the press-in control system through assembly!

DSM Messtechnik GmbH cannot be held liable for damages and malfunctions to the press-in control system due to incorrect assembly
or installation.
For this reason:
• Have the assembly carried out only by trained technical personnel.
10.2 Assembly
a) Mounting the press-in control system

Mount the press-in control system with 4 screws to a suitable mounting surface / device. The mounting holes are located in the
rear wall of the housing.
Dimension A: 128 mm MultiPro DS-S Type 1

231 mm all other versions
Back side

M5 thread (customer) Screws M5 (4x)
Mounting surface / device at

customer location
(example figure)
Plan at least 140 mm

space for cable!
Depending on the weight of the press-in control system 2 persons need to mount the device.
Tighten the screws M5 8.8 (4x) with a torque of 5.5 Nm.
Please refer to the technical data of these instructions for the weight of the press-in control system.
> Chapter 3.1 Data sheet MultiPro FL, Page 21
b) Mounting the IO-Extension
The cut-outs on the IO-Extension are equipped with a hole for mounting the system bus device. Install the I/O extension with M4
screws an Schnorr washers.
2x Screws M4
2x Schnorr washers S4
(customer)
Hole
Ø 4,5 mm (2x)
> Chapter 15.1 System bus device IO-Extension (optional module), Page 224
Tighten the screws M4 8.8 (2x) with a torque of 2,8 Nm.

10.3 Electrical installation
a) Safety
Avoid unintentional switch-on.

You should make sure that all devices are switched off before beginning with the electrical installation. Set the On/Off switch to the
"OFF" position for this purpose. The On/Off switch is located at the bottom side of the press-in control system. Disconnect possible
accessories from voltage.
Make sure that the control system, the press-in unit and possible optional modules have been mounted in accordance with the
respective assembly instructions.
Do not abuse the cables. Keep the cables away from heat, oil, sharp edges or moving device parts.
Damaged or entangled cables or plugs increase the risk of electrical shock.
b) Scope
The extent of the electrical installation depends on the version of the MultiPro (optional modules) and the requirements placed on
the press-in control system. Below, all connection options of the press-in control system are demonstrated with the help of a
schematic presentation.
> Chapter 10.4 Connection options, Page 81
c) Basic module
The electrical connection of the basic module depends on the type of the screw tool. For this reason 4 different connection
versions are possible here. The name of the integrated basic module is listed on the type plate (page 20). Select the appropriate
wiring diagram.
> Chapter 10.5 Electrical connection of basic module, Page 82
d) Control module
The electrical connection of the control module depends on the periphery to be connected (systembus devices) and the extent of
functions (I/O Level or Profibus) of the control system. The wiring diagram of the control module shows all options. When
integrating the press-in control system into a system, all wiring diagrams of the overall documentation must be observed.
> Chapter 10.6 Electrical connection of control module, Page 90

10.4 Connection options
 The following figure shows the schematic presentation of the terminals and possible connections of the press-in control system
MultiPro FL.
So
Motor cable Pi DS-MOTOR AC So Power cable
40 40
Pi X X40 So Pi X
41
So Pi C-HS So
C-HS Cable MSI cable (customer)
Pi X74 X75 So Pi X76
MultiPro FL
QMP series Press-in control system
Control System bus PC cable
SMP series system / cable So SBIN PC So (Zero modem cable)
Press-in External X58 Pi Pi X6
unit feed Printer So Printer cable
System bus Pi X7
Pi Pi SBOUT
40 DSM cable PB
X72 Pi Profibus cable (customer)
HS data line 42
accessories X59 So
So X10
TCP Pi Ethernet cable (customer)
System bus So X14
UNI
External
DSM cable Pi
X7340 special X53 So INTERFACE Pi Connecting cable (customer)

So solutions So X52
Return stop /
Hold brake44
So Pi So Pi
Pi X99 INTERFACE
X52 So
24V ext.
So Pi
Motor
hold brake44
So Pi So Pi
Pi X98 INTERFACE
X52 So
24V
External
So Pi
So
Pi X91 or
Monitoring of break fuses 43, customer connecting cable
So
43
BRUSI module (standard)
So = Socket
40 41 42 43 44 Pi = Pins (connector)
Mot_BM und AC C-HS HS-Daten BRUSI Optionen = Control module
= Basic module
> Chapter 4.3 Interfaces and CompactFlash slot on the control module, Page 26
Optional configuration QMP series

> Operating instructions QMP series / 4.5 / P.33
> Operating instructions QMP series / 4.6.3 / P.37
> Operating instructions QMP series / 7.6.3 / P.51
40
The interface depends on the version of the basic module (BM).
41
The interface X75 "C-HS" is integrated only in the basic modules DS-H and DS-V. With the DS-L version the power supply of the motor as well as
the digital signal transmission takes place via an interface (motor).
42
The HS data line is omitted with the SMP 300 press-in units.
43
The "BRUSI" interface is integrated only in the press-in units of the QMP series.
44
Optional configuration only for press-in units of the QMP series.

10.5 Electrical connection of basic module
 First connect motor cable with the interface of the press-in unit and then with the interface on the basic module of the press-in
control system.
With the versions DS-H and DS-V the C-HS cable and must be installed in addition. To do so connect X74 (press-in unit) with
X75 (basic module).
Connect the supplied power cable first to the device. Make sure that the On/Off switch is set to "OFF" before connecting the
mains plug with the power supply.
If the basic module is equipped with the MSI interface, it takes care of the secure switch-off of the servo controller (EN ISO
13849-1 performance level e, EN IEC 62061 SIL3).
The MSI interface is a component which is integrated into a protective device, this means, it must be addressed by a customer
facility. The responsibility and liability rests with the operating company. DSM does not assume any liability for possible faults or
their consequences.
10.5.1 Wiring diagram basic module DS-L Type3
MultiPro FL / DS-L Type 3

230 VAC MSI DS-Motor

X21 X76 X70
Pi Pi So
Connectable press-in units:

So So Pi
Type 3: SMP 300 series
> Chapter 10.5.6 Assignment Connecting cable SMP 300, Page 86
Connection cable
> Chapter 10.5.4 Assignment Power cable 230 VAC, Page 85
Machine Safety Interface: Interface „X76 MSI“, Page 33

Mains connection 230 VAC / 50 – 60 Hz (customer)
Connection to customer's protective device
So
Pi Motor
Customer connecting cable
> Chapter 4.4.4

Power cable
So = Socket
Pi = Pins (connector)
The connector must fit in the connection socket on the basic module (servo amplifier) of the control system.
The Plug must not be changed in anyway. Do not use an adapter plug with ground protected power tools.
Original unchanged plugs reduce the risk of electric shock.

10.5.2 Wiring diagram basic module DS-H Type2, Type5
MultiPro FL / DS-H Type 2, Type 5

230 VAC MSI DS-Motor C-HS

X21 X76 X50 X75
Pi Pi So So
So So Connectable press-in units: Pi Pi
> Chapter 10.5.7 Assignment Motor cable SMP 400, QMP 80, Page 87
C-HS cable SMP 400, SMP 500, QMP 80, QMP 100, QMP 140, Page 89
Motor cable
Type 5: QMP 80 / 025 / 05 / 10 / 20
C-HS cable
Mains connection 230 VAC / 50 – 60 Hz (customer)
Bu
Machine Safety Interface: Interface „X76 MSI“,
St
transmission cable
Motor
St
Bu
HS data X94
Bu
St
X95
> Chapter 10.5.9

X74
> Chapter 4.4.4
St
Power cable
Bu
Page 33
So = Socket
Pi = Pins (connector)
Note when using a press-in unit of the QMP 80 series!

• The BRUSI Module is plugged in by default (QMP X91, plug housing motor).
• With the customer monitoring version the BRUSI Module is not plugged in. The output signals (pin 1/6) must be
monitored by the customer. The press-in unit of this version cannot be operated without 24 V supply!
Interface BRUSI, version with BRUSI module
> Operating instructions QMP series / 4.4.5.1 / P.31
Interface BRUSI, version with customer monitoring
HS data transmission cable, assignment

> Operating instructions QMP series / 7.6.8 / P.57 > Operating instructions SMP series / 7.5.10 / P.56

10.5.3 Wiring diagram basic module DS-V Type5
MultiPro FL / DS-V Type 5

3x 400 VAC MSI DS-Motor C-HS

X61 X76 X60 X75
Pi Pi So So
So So Connectable press-in units: Pi Pi
C-HS cable SMP 400, SMP 500, QMP 80, QMP 100, QMP 140, Page 89
Motor cable
C-HS cable
QMP 100 series
QMP 140 series
Assignment Motor cable SMP 500, QMP 100, QMP 140, Page 88
Machine Safety Interface: Interface „X76 MSI“, Page 33
So
Mains connection 3x 400 VAC / 50 Hz (customer)
St
Motor
transmission cable
Pi
So
X94
HS data
So
Pi
X95
> Chapter 10.5.8
> Chapter 10.5.9

> Chapter 4.4.4
X74
Power cable
Pi
So
So = Socket
Pi = Pins (Connector)
Note when using a press-in unit of the QMP 100 series / QMP 140 series!
• The BRUSI Module is plugged in by default (QMP X91, plug housing motor).
• With the customer monitoring version the BRUSI Module is not plugged in. The output signals (pin 1/6) must be
monitored by the customer. The press-in unit of this version cannot be operated without 24 V supply!
Interface BRUSI, version with BRUSI module
Interface BRUSI, version with customer monitoring
HS data transmission cable, assignment

> Operating instructions QMP series / 7.6.8 / P.57 > Operating instructions SMP series / 7.5.10 / P.56

10.5.4 Assignment Power cable 230 VAC
Article number MS-1009002 Sheath PVC

Length of cable approx. 1,5 m Sheath colour black
Number of wires / gauge 3 x 1,5 mm² Outside dia. approx. 6,4 mm
Wire insulation PVC Bending radius not specified
10.5.5 Assignment Power cable 400 VAC
When connecting a control system with integrated basic module of type DS-V to the power supply use only the
power cable 400 VAC (Art. No. MS-1009035) supplied. Observe the correct cable assignment!
Disregard may destroy the device and possibly lead to a harmful situation for the health of persons!
Article number MS-1009035 Sheath PVC

Length of cable approx. 5,0 m Sheath colour grey (RAL7001)
Wire insulation PVC Bending radius moving occasionally: 15x outside dia.
fixed installation: 4 x outside dia.
Thermal properties moving: -5° C to +70° C; fixed installation: -40° C to +80° C

Inflammability flame resistance as per IEC 60332-1-2
Conductor design fine-strand as per VDE 0295, Class 5 / IEC 60228 CI.5
Connect the supply line preferably with CEE plug 16 A to the power supply (400 VAC mains).

10.5.6 Assignment Connecting cable SMP 300
Article number see table below Sheath PUR

Length of cable 5,0 m / 10,0 m / 15,0 m Sheath colour black (RAL9005)
Number of wires / gauge 4 x 1,5 mm² / 8 x 0,14 mm² Outside dia. approx. 14,0 mm
Wire insulation PVC Bending radius application in E-Chains
10 x outside dia.

Conductor design Feindrahtiger Litzenleiter, besonders biegefester Ausführung aus blanken Kupferdrähten; Kupfergeflecht, verzinnt;
Type Cable length Article number

Interconnecting cable DS34 / DS44 / SMP300 5m MK-2409005
Interconnecting cable DS34 / DS44 / SMP300 10 m MK-2409010
Interconnecting cable DS34 / DS44 / SMP300 15 m MK-2409015
Interconnecting cable DS34 / DS44 / SMP300 - angled 90° right 5m MK-2409105
Interconnecting cable DS34 / DS44 / SMP300 - angled 90° right 10 m MK-2409110
Interconnecting cable DS34 / DS44 / SMP300 - angled 90° right 15 m MK-2409115
Interconnecting cable DS34 / DS44 / SMP300 - angled 90° left 5m MK-2409205
Interconnecting cable DS34 / DS44 / SMP300 - angled 90° left 10 m MK-2409210
Interconnecting cable DS34 / DS44 / SMP300 - angled 90° left 15 m MK-2409215

10.5.7 Assignment Motor cable SMP 400, QMP 80
Article number see table below Sheath PVC

Length of cable 5,0 m / 10,0 m / 15,0 m Sheath colour grey (RAL7001)
Wire insulation PVC Bending radius moving occasionally: 7,5 x outside dia.
Inside sheath PVC, grey fixed installation: 4 x outside dia.
Thermal properties moving: 0° C to +70° C; fixed installation: -40° C to +80° C

Conductor design finest-strand as per VDE 0295, Class 6 / IEC 228 CI.6; Ausführung mit Abschirmung: Kupfergeflecht, verzinnt
Swaying cycles designed for up to 5 million swaying cycles and for travel distances up to 10 m

Motor cable DS57 / QMP80 / SMP400 5m MK-0809605
Motor cable DS57 / QMP80 / SMP400 10 m MK-0809610
Motor cable DS57 / QMP80 / SMP400 15 m MK-0809615
Motor cable DS57 / QMP80 / SMP400 - with shielding 5m MK-0809705
Motor cable DS57 / QMP80 / SMP400 - with shielding 10 m MK-0809710
Motor cable DS57 / QMP80 / SMP400 - with shielding 15 m MK-0809715

10.5.8 Assignment Motor cable SMP 500, QMP 100, QMP 140

Inside sheath PVC, grey fixed installation: 4 x outside dia.
Thermal properties moving: 0° C to +70° C; fixed installation: -40° C to +80° C

Conductor design finest-strand as per VDE 0295, Class 6 / IEC 228 CI.6; Ausführung mit Abschirmung: Kupfergeflecht, verzinnt
Swaying cycles designed for up to 5 million swaying cycles and for travel distances up to 10 m

Motor cable DS80 / QMP100/140 / SMP500 5m MK-1009605
Motor cable DS80 / QMP100/140 / SMP500 10 m MK-1009610
Motor cable DS80 / QMP100/140 / SMP500 15 m MK-1009615
Motor cable DS80 / QMP100/140 / SMP500 - with shielding 5m MK-1009705
Motor cable DS80 / QMP100/140 / SMP500 - with shielding 10 m MK-1009710
Motor cable DS80 / QMP100/140 / SMP500 - with shielding 15 m MK-1009715

10.5.9 C-HS cable SMP 400, SMP 500, QMP 80, QMP 100, QMP 140

Thermal properties moving: -5° C to +70° C; fixed installation: -40° C bis +80° C
Inflammability Flame resistance as per IEC 60332-1-2
Conductor design Feinstdrähtige Litze aus blanken Kupferdrähten; Kupfergeflecht, verzinnt; Vliesbewicklung
Swaying cycles designed for 2 up to 8 million swaying cycles in the energy supply chain

C-HS cable DS57 / DS80 / QMP80/100/140 / SMP400/500 5m MK-0809505
C-HS cable DS57 / DS80 / QMP80/100/140 / SMP400/500 10 m MK-0809510
C-HS cable DS57 / DS80 / QMP80/100/140 / SMP400/500 15 m MK-0809515

90
10.6
10.6.1
External 24V
feed System bus cable
OR
Pin 1 / Pin 2
X58
X59
SBIN
> Chapter 10.6.4 Assignment System bus , Page 93
Pi
Pi
So
So
> Chapter 10.8.2 Supply voltage 24V, Page 96
MultiPro FL / DS- ...

Optional modules System bus cable

with systembus
X59
SBIN
interface > Chapter 10.6.4 Assignment System bus , Page 93
SBOUT
Pi
Pi
So
So
TCP/IP, cable by customer X14

Wiring diagram control module MultiPro FL
TCP
> Chapter 4.3.2 Interfaces X10 Profibus / X14 TCP, Page 27
Pi
So
> Chapter 10.10 Settings with TCP/IP (optional module), Seite 121
Electrical connection of control module
PC, connection to PC connecting cable, zero modem cable

X6
COM interface
PC
> Chapter 10.6.2 Assignment PC connecting cable, Page 91

Pi
So
So
Printer PR-II, RS232

other interfaces need to be accessed according to customer requirements.
Printer cable
connection or
X7
commercially
Printer
> Chapter 10.6.3 Assignment Printer cable, Page 92

Pi
Pi
available printer with
So
serial interface
Profibus, cable by customer
PB
X10

Pi
So
Operating equipment interface, cable by customer

E
X52
> Chapter 4.3.3 Interface X52, Page 27

Pi
INTERFAC
So
Pi
So
Special cable (option), cable by customer
X53
UNI
= Socket
> Chapter 4.3.5 Interface X53 Universal, Page 28
Pi
So
= Pins (connector)
 The electrical connection of the control module is made with DSM standard cables for the interfacesX6, X7, X59 and X58 . All

10.6.2 Assignment PC connecting cable
Zero modem cable
Article number MK-1001703 Sheath PVC

Length of cable 3,0 m Sheath colour pebble grey (RAL7032)
Wire insulation PVC Bending radius moving occasionally: 15 x outside dia.
Thermal properties Bewegt: -5° C bis +70° C; Fest verlegt: -25° C bis +80° C
Inflammability Flammwidrig nach IEC 60332-1-2
Conductor design Litze, feinstdrähtig nach VDE 0295
> Chapter 4.3.1 Interfaces X6 PC / X7 Printer, Page 26


10.6.3 Assignment Printer cable
When using the DSM printer Multisystem PR-II.
Article number DSM-200912 Sheath PVC

Length of cable 0,8 m Sheath colour grey (RAL7001)

Conductor design Feinstdrähtige Litze aus blanken Kupferdrähten; Kupfergeflecht, verzinnt; Vliesbewicklung
Swaying cycles designed for 2 up to 8 million swaying cycles in the energy supply chain
> Chapter 4.3.1 Interfaces X6 PC / X7 Printer, Seite 26


10.6.4 Assignment System bus cable

Length of cable 1,0 m / 2,0 m / 5,0 m Sheath colour grey
Wire insulation PVC Bending radius moving occasionally: 10 x outside dia.

Conductor design Litze, feinstdrähtig

System bus cable 1m MS-1003001
> Chapter 4.3.4 Interfaces X58 System bus IN / X59 System bus OUT, Page 28

10.7 Settings with PC / Printer connection
Menu navigation
Production screen  <Settings>  <Device service>  <Settings>  <Communication>  <PC/Printer>
The following screen opens after pressing the key <PC/Printer>.
Settings PC / Printer Select with arrow

RDY PGF OK NOK HA PC v IP C DFU x PB C: A: Program: xxx keys <> / <>.
Bit rate PC 57600 Bit/s
Bit rate Printer 9600 Bit/s
Set bit rate with function keys

<-> and <+>.
Press Up / Down keys to select …
Done - +
Bit rate PC Transfer rate for PC interface X6; Bit rate: 4800, 9600, 14400, 19200, 28800, 38400, 57600 Bit/s
Bit rate Printer Transfer rate for printer interface X7; Bit rate: 4800, 9600, 14400, 19200, 28800, 38400, 57600 Bit/s
The settings are saved with the <Done> function key and the menu is exited.
Simultaneous data transfer to all connected and registered interfaces by instruction "Transfer measurands to PC" and
"Transfer graphic data to PC" as well as by error. The synchronised parameterisation of the control unit via multiple
interfaces is not possible. This includes also the entry at the unit, via Profibus or via PC-connection.
The connection to the PC interface also requires setting the bit rate (baud rate) in the PC software.
Menu navigation
MultiControl4  <Settings>  <Communication>
Parameters for the

communication settings
of the PC interface

10.8 System bus
 The system bus is the internal DSM system for the connection of specific DSM optional modules.
When making the connection it must be noted that the systembus has been designed as linear bus system. To prevent reflections
it must be terminated with a resistor (120 Ohm, 200 mW) at both ends. Stub lines should be as short as possible and should not
extent a length of 2 m. The total length of the systembus should not exceed 30 m.
The press-in control system which represents one end of the system bus already contains an internal terminating resistor. It must
therefore be remembered to furnish the other end of the system bus with an external terminating resistor (Art. No. MS-1003030).
The system bus cable contains an activation line. A sequence program can only be carried out if the activation signal is applied here
(24 V). A running program is terminated with an error message if the voltage is removed from the activation line during the joining
process. The external terminating resistor (with activation bridge) connects the activation signal solidly with 24 V. It is available as
accessory and is plugged into the system bus output of the last systembus device.
a) System bus connection
The optional modules for the MultiPro is available in two different connection versions for the system bus.
Type 1 This version has only one connection for the system bus.
Type 2 This version has two connections for the systembus. As socket "SBOUT" and as plug (pins) "SBIN".
Devices of the Type 1 always require a T-connector (Art. No. DSM-200722) for the connection to the system bus; devices of
Type 2 loop the system bus signals through and therefore do not need an additional distributor.
When using one or several system bus devices it must be remembered that a system bus output "SBOUT" that is not used
receives a terminating resistor (Art. No. MS-1003030)
b) System bus cable
Typ Cable length Article number

10.8.1 System bus wiring

You should make sure that all devices are switched off before beginning with the wiring of the system bus. To do so, turn the
On/Off switch at the bottom side of the press-in control system to the "OFF" position. Disconnect possible accessories from
power. Install the optional modules as well as the control system and the press-in unit at the intended location. Connect the
optional modules according to the type of the system bus connection with the press-in control system. Apply the terminating
resistor to the last device on the system bus. The figure below shows the example of an arrangement.
Press-in control system with Y-piece

integrated terminating resistor (distribution device) Terminating
resistor
System bus cable System bus cable System bus cable
SBIN SBOUT SBIN SBOUT

SBIN
X59
Optional module Option module

Press-in control system Status Indication IO-Extension Option module
System bus Type 2 Type 2 ToolControl
> Connection Page 28 System bus is System bus is Type 1
> Wiring Page 90 looped through looped through System bus with Y-piece
(distribution device)

10.8.2 Supply voltage 24V

The internal 24 V supply of the press-in control system can provide a total current off max. 1 A. This 24 V is applied to the
interface SBOUT X59 (Pin1 / Pin2). If more current is required the 24 V can be supplied externally. The system bus can be
supplied with 24 V at the connector SBIN X58 (Pin 1 / Pin 2). Note that the maximum current may not exceed 3 A.
With external supply at the interface X58 the internal 24 V supply is disconnected via a relay. This also deactivates the internal
terminating resistor (MultiPro). For this reason the signal lines C-L (Pin3) and C-H (Pin 4) must be equipped with a resistor
(124 Ω, 1/4 Watt) at the X58 interface.
System bus
IN X58 X59 OUT IN OUT IN OUT Bridge
Terminating
resistor
Terminating External
resistor supply
> Chapter 4.3.4 Interfaces X58 System bus IN / X59 System bus OUT, Page 28

10.8.3 Settings at system bus
Menu navigation
Production screen  <Settings>  <Settings/Test>  <Settings>  <Communication>  <System bus>
The following screen opens after pressing the key <System bus>.
System bus settings Selection with arrow

RDY PGF OK NOK HA PC v IP C DFU x PB C: A: Program: xxx keys <> / <>.
Bit rate System bus 500 KBit/s
ID System bus 2
Value with function

keys <-> and <+>.
Press Up / Down key to select …
Done - +
Bit rate system bus Transfer rate for system bus interface X59; Bit rate: 10, 20, 50, 100, 125, 250, 500, 1000 KBit/s
ID system bus ID address of the press-in control system within the system bus.
ID: 1, 2, 3, 4, 5, 6, 7, 8, 9, A, B, C, D, E, F
Entry is, completed with the <Done> key and the following window or opens.
System bus settings

RDY PGF OK NOK HA PC v IP C DFU x PB C: A: Program: xxx
Bit rate system bus 500 KBit/s

ID system bus 2 Follow the screen
prompts.
Check if all SBUS devices are flashing
If YES: Push the Activation key
IF NO: Unable to set bit rate!
Push the Cancel key
Press Up / Down key to select …
Activation Cancel

10.9 Profibus
 The press-in control system MultiPro FL is equipped by default with the DSM Profibus module (registration at PNO, ID number
AFFE HEX). When the Profibus is activated the IO areas of Base 45 10 and 20 are available to the user. This allows transferring
the results of a joint step to the Profibus. The instruction "Transfer measurements to PB" are available for this purpose in program
sequence programming. With extended Profibus configuration error messages of the press-in control system as well as error
acknowledgements can also be done via the Profibus.
The quality statement (OK/NOK assessment) of a program sequence may be made only via status outputs.
Bus terminating resistor

For technical reasons (deactivating the press-in control system MultiPro FL at firmware updates, etc.) MultiPro does not support
the active supply of terminating resistors.
If the press-in control system MultiPro FL is used as last bus member an active bus terminating device must be set.
Active bus terminating devices are available from various manufacturers (Active RS485 bus terminator 24V DC, Art.No. 6ES7972-
0DA00-0AA0, Siemens; Active RS485 bus terminator 115V-230V AC, Art.No. 2SX5801-2BA10, SIPOS).

10.9.1 Settings on the Profibus Master (PLC)

To be able to integrate the press-in control system the Profibus master (PLC) requires a configuration file. It is included in the
scope of delivery 46. Because the control system supports two configurations, two configuration files are supplied. The user must
ensure that he uses the correct file for his scenario.
If the "Extended configuration" shall be used the extended GSD file must also be used.
Extended configuration = 0
i.e., file "3000.gsd" must be used (Standard configuration).
i.e., file "3000Plus.gsd" must be used (Extended configuration).
i.e., file "3000_Res.gsd" must be used (Extended configuration + results of the function "Measurands add-on memory").
i.e., file "3000_Num.gsd" must be used (Extended configuration 3, PLC  MultiPro FL: Function "Import number").
Furthermore, the station address as supplied in the Profibus parameters must be considered. All modules of the Profibus
configuration (GSD) are consistent.
> 10.9.2.1 Parameters, Page 99
45
Base 10, i.e. IO area 1 ...... 18; Base 20, i.e. IO area 21 ...... 28
46
The configuration files are located on the enclosed CD.

10.9.2 Settings at Profibus (press-in control system)
Menu navigation
Production screen  <Settings>  <Settings/Test>  <Settings>  <Communication>  <Other>  <Profibus>
The following screen opens after pressing the key <Profibus>.
Profibus settings
RDY PGF OK NOK HA GSE PC v PB C: A: Program: xxx
Profibus On
Inputs used of PB Off
Profibus station adr. 2
Extended configuration Off
Error transmission also to PB Off
Error acknowledgement also via PB Off
Access control via PB Off
10.9.2.1 Parameters
 Profibus
This parameter switches the Profibus on or off.
 Profibus inputs used

With this parameter the user decides whether the control system shall use the inputs of the base 47 10 and 20 of the Profibus or of
a connected IO Extension of the same base.
On: Profibus inputs
Off: Inputs of IO Extension
The outputs of base 1047 and 20 are connected in parallel to the Profibus as well as to a possibly existing IO Extension.
 Profibus station address

The Profibus address of the control system can be set here. Value range: 1 ... 255
 Extended configuration
To be able to utilise the functions of the extended measuring values of error transmission as well as error acknowledgement the
"extended configuration" must be activated.
If the "Extended configuration" shall be used the extended GSD file must also be used.
i.e., file "3000.gsd" must be used (Standard configuration).
i.e., file "3000Plus.gsd" must be used (Extended configuration).
i.e., file "3000_Res.gsd" must be used (Extended configuration + results of the function "Measurands add-on memory").
i.e., file "3000_Num.gsd" must be used (Extended configuration 3, PLC  MultiPro FL: Function "Import number").
 Error transmission also to Profibus (extended configuration only)

System errors are transmitted via Profibus when the parameter is activated. This requires that the parameter "extended
configuration" is also activated.
On: System errors are transmitted via Profibus
Off: No transmission of system errors via Profibus
Detailed explanation:
> Chapter 10.9.3.2 Transfer of system errors (extended configuration only), Page 101
47
Base 10, i.e. IO area 1 ...... 18; Base 20, i.e. IO area 21 ...... 28

 Error acknowledgement also via Profibus (extended configuration only)

A system error can be acknowledged via Profibus if the parameter is activated. This requires that the parameter "extended
configuration" is also activated.
On: Error acknowledgement via Profibus possible
Off: No error acknowledgement via Profibus
> Chapter 10.9.3.3 Acknowledging system errors (extended configuration only), Page 101
The integration of the Profibus can also be made by utilising the PC software MultiControl4 in the menu "User and
communication settings" (menu navigation: Edit  device configuration).
 Access control via Profibus (extended configuration only)

The access to the program settings as well as to the device settings at the control system can be enabled or disabled via Profibus
if the parameter is activated. This requires that the parameter "extended configuration" is also activated.
On: Access control via Profibus is possible
Off: No access control via Profibus

10.9.3 Functional integration of the Profibus into the press-in control system
48
When the Profibus is activated the outputs and optionally also the inputs of Base 49 10 and 20 are available. They can then be
used in all areas.
They are individually: - Program start 50: Program preselection + PG Start

- Program sequence: Setting an output; wait for input; joining until input = ON
51
- Status inputs : As abort input; ss input for NOK interlock
- Status outputs 52: Output OK; Output NOK; Ready; Program done; Hold active;
Normal position reached
In addition to the pure IO level the following functions can also be used:
• Transfer of the results of a joining step
• Transfer of system errors
• Acknowledgement of system error
10.9.3.1 Transfer of the results of a joining step

If the results of a joint step shall be transferred via the Profibus the sequence program must be extended by the instruction
"transfer measurements to PB". Note that the results of the intermediate memory are always transferred. This means, the user
must save the results he wants to transfer with the instruction "measuring values to intermediate memory". A handshake method
is used with the transfer.
> Chapter 10.9.5 Signal exchange, Page 117
10.9.3.2 Transfer of system errors (extended configuration only)

If error transmission is activated, the parameter 'Error transmission also to PB' = ON, system errors are also transferred to the
Profibus. A handshake method is used with the transfer.
A system error is transmitted in three parts:

1. Byte: FU = origin of error (who has caused the error)
2. Byte: FB = description of error (what kind of error)
3. Byte: FA = type of error (critical or uncritical)
An "uncritical error" can be acknowledged and the error window is closed. A "critical error" cannot be acknowledged. The control
system proceeds to a safe state, the motor is switched off. The control system does no longer accept any commands, the control unit
is stopped!
> Chapter 12.1.1 Description of error, Page 190
10.9.3.3 Acknowledging system errors (extended configuration only)

In the event of a system error the control system opens a so-called error window which contains the corresponding text for more
specific error definition. MultiPro then expects an acknowledgement of the error to ensure that the error was registered. The
acknowledgement can be made either by pressing a key on the press-in control system, through confirmation via the PC software
Multi Control4 or the Profibus. After acknowledgement the error window is closed and the press-in control system sends the error
telegram F0 (FU=0, FB=0, FA=0). The next error is displayed if additional errors are pending.
The output ready = 0 is set as long as an error is present. Principally, operational readiness is removed while the error window is
displayed (acknowledgement not yet made).
Operational readiness is restored after the error has been acknowledged and the error is no longer present. A handshake method
is used when acknowledging via the Profibus.
48
> Chapter 10.9.2.1 Parameters, Page 99 (Use inputs of Profibus)
49
Basis 10, i.e. IO area 11 ...... 18; Base 20, i.e. IO area 21 ...... 28
50
Setting in menu > Chapter 11.5.1 PG Start, Page 138
51
Setting in menu > Chapter 11.5.10 Abort mode, Page 146; > Chapter 11.5.15 Input NOK interlock, Page 147
52
Setting in menu > Chapter 11.5.4 Status outputs, Page 145

10.9.4 Telegram structure
10.9.4.1 Telegram structure MultiPro FL  PLC
Configuration Profibus settings GSD file Colour code
Standard configuration Extended configuration = 0 3000.gsd

Extended configuration 1 Extended configuration = 1 3000Plus.gsd
Extended configuration 2 Extended configuration = 2 3000_Res.gsd
Extended configuration 3 Extended configuration = 3 3000_Num.gsd
Options Colour code
Parameterisation via Profibus, option extended configuration 1 / 2

Cyclic values via Profibus, option extended configuration 1 / 2
Measurands add-on memory
Options
Adr. Description GSD modules
0 Status Multi (STM)
1 Outputs O11-O18 (as IO-Extension)
2 Outputs O21-O28 (as IO-Extension)
Header
3 Mirrored inputs I11-I18 8 Byte
4 Mirrored inputs I21-I28 consistent
5 Info Byte, Bit 0 = Maintenance flag
6 Reserve
7 Stage (Parameter transmission)
8 Date Day
9 Month
Standard configuration
10 Year 6 Byte
11 Time Hour consistent
12 Minute
13 Second
14 Force actual as floating comma value [N / kN]
15
16
17 8 Byte
18 Stroke actual as floating comma value [mm] consistent Extended configuration 1
Extended configuration 2
19
20
21
22 Program number
23 Joining stage 4 Byte
24 Result consistent
Result
25 Result
26 Result 6 Byte
28 Minimum force as floating comma value [N / kN]
29
30
31
32 Maximum force as floating comma value [N / kN]
33
34
35 16 Byte
36 Minimum stroke as floating comma value [mm] consistent
37
38
39
40 Maximum stroke as floating comma value [mm]
41
42
43

Continuation Telegram structure MultiPro FL  PLC
44 Reserve
45
46
47
48 Reserve
49
50
51
52 Effective force [N / kN] 16 Byte
consistent
Result
53
54
55
56 Effective stroke [mm]
57
58
59
60 Error FU = Error cause
61 FB = Error description
Error
4 Byte
62 FA = Error type consistent
63 Reserve
64 Joining stage
65 Reserve
66 Result
67 Result
68 Result
69 Result
70 Force actual as floating comma value [N / kN] 14 Byte
consistent
71
72
73
74 Stroke actual as floating comma value [mm]
75
76
77
79
80
Result
81
83
84
16 Byte
85
consistent
86 Minimum stroke as floating comma value [mm]
87
88
89
91
92
93
94 Reserve
95
96 6 Byte
97 consistent
98
99

100 Joining stage

101 Reserve
102 Result
103 Result
104 Result
105 Result
107 14 Byte
consistent
108
109
111
112
113
115
116
117
119
120
16 Byte
121
Result
consistent
123
124
125
127
128
129
130 Reserve
131
132 6 Byte
133 consistent
134
135
136 Joining stage
137 Reserve
138 Result
139 Result
140 Result
141 Result
14 Byte
consistent
143
144
145
147
148
149
151
152
16 Byte
153
consistent
155
156
157


159
160
161
163
164
165
166 Reserve
167
168
6 Byte
169
consistent
170
171
172 Joining stage
173 Reserve
174 Result
175 Result
176 Result
177 Result
178 Force actual as floating comma value [N / kN] 14 Byte
179 consistent
180
181
183
184
185
Result
187
188
189
191
192
193 16 Byte
194 Minimum stroke as floating comma value [mm] consistent
195
196
197
199
200
201
202 Reserve
203
204 6 Byte
205 consistent
206
207
208 Joining stage
209 Reserve
210 Result
211 Result
212 Result 14 Byte
215
216
217


219
220
221
223
224
225
227
228
229
Result
230 Minimum stroke as floating comma value [mm] 16 Byte
consistent
231
232
233
235
236
237
238 Reserve
239
240 6 Byte
241 consistent
242
243
10.9.4.2 Detailed description MultiPro FL  PLC
Byte 0 | Header
STM: Status Multi
Bit Designation Description

1: Results are current
0 STM_E
0: Results accepted
1 STM_F 2: New error occurs 0: Ready
2 STM_Q 3: Multi has assumed the error acknowledgement 0: Ready
3 STM_P 1: Parameter requirement 0: Parameter
4 Reserve
5 Reserve
6 Reserve
7 Reserve
Byte 1 | Header
O1: Outputs O11...O18
Bit 7 6 5 4 3 2 1 0
Output O18 O17 O16 O15 O14 O13 O12 O11
Byte 2 | Header
O2: Outputs O21...O28
Bit 7 6 5 4 3 2 1 0
Output O28 O27 O26 O25 O24 O23 O22 O21
The inputs set by the PLC (system constant: use inputs of PB = 1) or via the operating equipment interface
(system constant: use inputs of PB = 0) are mirrored here.
Byte 3 | Header
I1: Inputs I11...I18
Bit 7 6 5 4 3 2 1 0
Input I18 I17 I16 I15 I14 I13 I12 I11

Continuation Detailed description MultiPro FL  PLC
Byte 4 | Header
I2:Inputs I21...I28
Bit 7 6 5 4 3 2 1 0
Input I28 I27 I26 I25 I24 I23 I22 I21
Byte 5 | Header
Info Byte, Bit 0 = Maintenance flag
Byte 6 | Header
Reserve
Byte 7 | Header
Stage (Parameter transmission)
Byte 8 - 13
D1 - T3: Date and time
Date / time of the current result data record.
D1 Date: Day
D2 Date: Month
D3 Date: Year
T1 Time: Hour
T2 Time: Minute
T3 Time: Second
Byte 14 - 17
Force: Measured switch-off force of joining stage
Byte 14 Byte 15 Byte 16 Byte 17

Bit 31 28|27 24|23 20|19 16|15 12|11 6|7 4|3 0
v e f
Sign Exponent: e Mantissa: m

(1 Bit) (8 Bit) (23 Bit)
Byte 18 - 21
Stroke: Measured switch-off stroke of joining stage
Byte 18 Byte 19 Byte 20 Byte 21

Bit 31 28|27 24|23 20|19 16|15 12|11 6|7 4|3 0
v e f

(1 Bit) (8 Bit) (23 Bit)
Byte 22
PG: Program number
Byte 23
Number: Number of joining stage, corresponds to the line number in the sequence program

Byte 24
Result: OK result
Bit 7 6 5 4 3 2 1 0
Designation EL IM SA TP S> S< F> F<
Byte 25
Result: I1 result
Bit 15 14 13 12 11 10 9 8
Designation GS PA ST FM SM AN NIO IS
Byte 26
Result: I2 result
Bit 23 22 21 20 19 18 17 16
Designation GK RW BR EA EE EF SB FB
Byte 27
Result: I3 result
Bit 31 30 29 28 27 26 25 24
Designation R R R HU FI HG HK GP
Error flags 1
F< Force too small NOK NOK flag (0=OK, 1=NOK)

F> Force too large AN No start of press-in unit
S< Stroke too small SM Stop reason SMax
S> Stroke too large FM Stop reason FMax
TP Joining time exceeded ST Error system test
SA Start aborted PA Error program sequence
IM IMax is reached GS Error normal position travel
EL Error power supply FB Error, running on block (F>FBlk)
IS Irregular stop SB Error, running on block (S>SBlk)
EF Error, OK window monitoring GP Encoder fault position (stroke)
EE Error, limit switch driven-in HK Force has underrun the lower envelope
EA Error, limit switch driven-out HG Force has exceeded the upper envelope
BR Error, break fuse FI Stop reason F-Min
RW Error, Review stroke HU Stop reason envelope monitoring
GK Encoder fault force R Reserve
Byte 28 - 31
F-Min: Smallest permissible force, limit value for assessment of joining stage
Byte 32 - 35
F-Max: Largest permissible force, limit value for assessment of joining stage
Byte 36 - 39
S-Min: Smallest permissible stroke, limit value for assessment of joining stage
Byte 40 - 43
S-Max: Largest permissible stroke, limit value for assessment of joining stage
Coding of floating comma value

Byte 28 Byte 29 Byte 30 Byte 31 F-Min
Byte 32 Byte 33 Byte 34 Byte 35 F-Max
Byte 36 Byte 37 Byte 38 Byte 39 S-Min
Byte 40 Byte 41 Byte 42 Byte 43 S-Max
Bit 31 28|27 24|23 20|19 16|15 12|11 6|7 4|3 0

v e f

(1 Bit) (8 Bit) (23 Bit)

Byte 44 - 51
Reserve
Byte 52 - 55
F-current, current force value [N / kN]
Byte 56 - 59
S-current, current stroke value [mm]
Byte 60
Origin of error: Who has caused error, number between 101 ... 255
Byte 61
Description of defect: What kind of error is present, number between 101 ... 255
Byte 62
Error type: 1 = critical error 2 = uncritical error
Byte 63
Error: Reserve
Additional results of the function add-on memory
Byte 64 - 99 Add-on memory 1

Byte 64 | Byte 100 | Byte 136 | Byte 172 | Byte 208

Stage: Number of joining stage, corresponds to the line number in the sequence program

Reserve

Erg: OK result
Bit 7 6 5 4 3 2 1 0
Designation EL IM SA TP S> S< F> F<

Erg: I1 result
Bit 15 14 13 12 11 10 9 8
Designation GS PA ST FM SM AN NIO IS

Erg: I2 result
Bit 23 22 21 20 19 18 17 16
Designation GK RW BR EA EE EF SB FB

Erg: I3 result
Bit 31 30 29 28 27 26 25 24
Designation R R R HU FI HG HK GP
> Table Error flags, Page 110

Error flags 2
F< Force to small GS Error normal position travel

F> Force to large FB Error, running on block (F>FBlk)
S< Stroke to small SB Error, running on block (S>SBlk)
S> Stroke to large EF Error, OK window monitoring
TP Joining time exceeded EE Error, limit switch driven-in
SA Start aborted EA Error, limit switch driven-out
IM Current error, reached I Max BR Error, break fuse
EL Error power pack RW Error, Review stroke
IS Irregular stop GK Encoder fault force
NIO NOK flag (0=OK, 1=NOK) GP Encoder fault position (stroke)
AN No press-in unit start HK Force has underrun the lower envelope
SM Stop reason S-Max HG Force has exceeded the upper envelope
FM Stop reason F-Max FI Stop reason F-Min
ST Error system test HU Stop reason envelope monitoring
PA Error program sequence R Reserve
Byte 70 - 73 | Byte 106 - 109 | Byte 142 - 145 | Byte 178 - 181 | Byte 214 - 217
Force: Measured switch-off force of the joining stage
Byte 70 Byte 71 Byte 72 Byte 73 Add-on memory 1

Bit 31 28|27 24|23 20|19 16|15 12|11 6|7 4|3 0

v e f

(1 Bit) (8 Bit) (23 Bit)
Stroke: Measured switch-off stroke of the joining stage
Bit 31 28|27 24|23 20|19 16|15 12|11 6|7 4|3 0

v e f

(1 Bit) (8 Bit) (23 Bit)
F-Min: Smallest permissible force, limit value for assessment of joining stage
Bit 31 28|27 24|23 20|19 16|15 12|11 6|7 4|3 0

v e f

(1 Bit) (8 Bit) (23 Bit)

F-Max: Largest permissible force, limit value for assessment of joining stage
Bit 31 28|27 24|23 20|19 16|15 12|11 6|7 4|3 0

v e f

(1 Bit) (8 Bit) (23 Bit)
S-Min: Smallest permissible stroke, limit value for assessment of joining stage
Bit 31 28|27 24|23 20|19 16|15 12|11 6|7 4|3 0

v e f

(1 Bit) (8 Bit) (23 Bit)
S-Max: Largest permissible stroke, limit value for assessment of joining stage
Bit 31 28|27 24|23 20|19 16|15 12|11 6|7 4|3 0

v e f

(1 Bit) (8 Bit) (23 Bit)
Reserve

10.9.4.3 Telegram structure PLC  MultiPro FL
Configuration Profibus settings GSD file Colour code
Standard configuration Extended configuration = 0 3000.gsd

Extended configuration 1 Extended configuration = 1 3000Plus.gsd
Extended configuration 2 Extended configuration = 2 3000_Res.gsd
Extended configuration 3 Extended configuration = 3 3000_Num.gsd
Options Colour code
Parameterisation via Profibus, option extended configuration 1 / 2

Cyclic values via Profibus, option extended configuration 1 / 2
Options
Adr. Description GSD modules
0 Status PLC (STS)
Standard configuration
1 Inputs I11-I18
2 Inputs I21-I28
Header
3 Reserve 8 Byte
4 Reserve consistent
5 Access control via PB, Bit 0 = Access is locked, Bit 1 = Access
6 Reserve
7 Stage (Parameter transmission)
8 Switch-off value as floating comma value
9 (force, stroke, initiator)
10
11 8 Byte
12 Review stroke as floating comma value [mm] consistent
13
14
15
16 Minimum force (F-Min) as floating comma value [N / kN]
17
18
19
20 Maximum force (F-Max) as floating comma value [N / kN]
21
22
23 16 Byte
24 Minimum stroke (S-Min) as floating comma value [mm] consistent
25
26
27
28 Maximum stroke (S-Max) as floating comma value [mm]
29
30
31
32 Maximum blocking force (F-Block Max) as floating comma value [N / kN]
33
34
35
36 Blocking dimension maximum (S-Block Max) as floating comma value [mm]
37
38 16 Byte
39 consistent
40 Reserve
41 Byte 40 - 63
42
43
44
45

Continuation Telegram structure PLC  MultiPro FL
46
47
48
49
50
51
52
53
54
55 16 Byte
56 consistent
57
58
59
60
61
62
63
64 Reserve
65 Byte 64 - 95
66
67
68
69
70
71 16 Byte
72 consistent
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87 16 Byte
88 consistent
89
90
91
92
93
94
95
96 Number
97 (ASCII, max. 40 Byte, C conform, end detection 0x00)
98 Byte 97 - 135
99
100
101 16 Byte
consistent
102
103
104
105

Continuation Telegram structure PLC  MultiPro FL
106
107
108
109
110
111
112
113
114
115
116
117
118
119 16 Byte
120 consistent
121
122
123
124
125
126
127
128
129
130
131 8 Byte
132 consistent
133
134
135

10.9.4.4 Detail description PLC  MultiPro FL
Byte 0
STS: Status PLC
Bit Designation Description

0 STS_E 1: Results assumed 0: Ready
1 STS_F 1:Errors assumed 0: Ready
2 STS_Q 1: Error will be acknowledged 0: Ready
3 STS_P 1: Parameter ready 0: Ready
4 Reserve
5 Reserve
6 Reserve
7 Reserve
Byte 1
Bit 7 6 5 4 3 2 1 0
Input I18 I17 I16 I15 I14 I13 I12 I11
Byte 2
Bit 7 6 5 4 3 2 1 0
Input I28 I27 I26 I25 I24 I23 I22 I21
Byte 3 - 4
Reserve
Byte 5
Access control via PB, Bit 0 = Access is locked, Bit 1 = Access
Byte 6
Reserve
Byte 7
Stage (Parameter transmission)
Byte 8 - 11
Switch-off values as floating comma values (force, stroke, initiator)
Byte 12 - 15
Review stroke as floating comma value
Byte 16 - 19
F-Min as floating comma value
Byte 20 - 23
F-Max as floating comma value
Byte 24 - 27
S-Min as floating comma value
Byte 28 - 31
S-Max as floating comma value
Byte 32 - 35
F-Block Max as floating comma value
Byte 36 - 39
S-Block Max as floating comma value
Byte 40 - 63
Reserve

Continuation Detail description PLC  MultiPro FL
Byte 64 -95
Reserve
Byte 96 - 135
Number (ASCII, max. 40 Byte, C conform, end detection 0x00)
The number (max. 40 character, ASCII) is imported C-conform. If a number is smaller than 40 characters it's necessary to
use the end detection 0x00 (Hex 00).
Example
·
N Byte 96 ASCII
U Byte 97 ASCII
M Byte 98 ASCII
B Byte 99 ASCII
E Byte 100 ASCII
R Byte 101 ASCII
0x00 Byte 102 hexadecimal
·
·
The program start (PG_init) is the point in time to take over the number.

10.9.5 Signal exchange
As already indicated in the previous chapters the transfer of the measured value, the error messages as well as the
acknowledgement of the error messages take place in a so-called handshake procedure. This ensures that the data is correctly
accepted by the receiving entity.
So-called status bits are used for this purpose which are described below in detail.
Handshake is mandatory. Error message in case of non-compliance!
10.9.5.1 Signal exchange with transfer of measurements

If new measurements are available for the PLC to be fetched, the control system sets the status bit STM_E 53 (see detailed
description). The PLC now has 10 seconds to fetch the measured results. During this time the press-in control system waits until
the PLC has fetched the data and confirms this by setting the status bit STS_E 54. The press-in control system now sets back the
status bit STM_E and then the PLC the status bit STS_E.
Signal flow
STM_E
Byte 0,
Bit 0 t
STS_E
Byte 0,
Bit 0 t
tmax
= 10 s PLC resets status
Control system resets status
PLC has accepted measurements
Current measurements are available to be fetched
The control system continues to transmit measurements in the event of an aborted start. They must also be fetched with the
handshake procedure.
53
Bit 0 of the status byte MultiPro FL  PLC
54
Bit 0 of the status byte PLC  MultiPro FL

10.9.5.2 Signal exchange with transfer of error messages

(extended configuration only)
If a system error has occurred the press-in control system indicates this by setting the status bit STM_F. The PLC now has 10
seconds to fetch the error message. This is confirmed by the PLC by setting the status bit STS_F = 1. The press-in control
system now resets status bit STS_F.
Decoding of errors: > Table Error flags 1, Page 108; > Table Error flags 2, Page 110
Signal flow
STM_F
Byte 0,
Bit 1 t
STS_F
Byte 0,
Bit 1 t
tmax
PLC has fetched error message
Press-in control system signals system error
10.9.5.3 Signal exchange when acknowledging an error message

(extended configuration only)
If a system error has occurred this can be confirmed by the PLC. If the PLC shall confirm an error status bit STS_Q = 1 must be
set. The press-in control system then confirms the acknowledgement by setting the status bit STM_Q = 1. Resetting of status bits
then first takes place with the PLC and then with the press-in control system.
The error message F0 may not be acknowledged.

> Chapter 10.9.3.3 Acknowledging system errors (extended configuration only), Page 101
Signal flow
STS_Q
Byte 0,
Bit 2 t
STM_Q
Byte 0,
Bit 2 t
tmax
Press-in control system confirms the acknowledgement
PLC acknowledges error

10.9.5.4 Sample of signal exchange when a system error occurs
PLC MultiPro FL
An error is occurred
Profibus
Error window is displayed
Error bytes are set on

Profibus
An error message is available for retrieval

STM_F = 1
Read and display error

bytes
Acknowledging receipt of error

STS_F = 1
STM_F = 0
STS_F = 0
User confirms error User confirms error User confirms error

on PLC on Multi via PC
ja
User has acknowledged error Yes
Yes
STS_Q = 1
Error window is Error window is Error window is

closed closed closed
Quitting the error acknowledgement

STM_Q = 1
STS_Q = 0
STM_Q = 0
Set all error bytes of the

Profibus equal to zero
Error bytes are set on

Profibus
An error message is available for retrieval

STM_F = 1
Delete error display
Acknowledging receipt of error

STS_F = 1
STM_F = 0
STS_F = 0
End

10.9.6 Parameterisation via Profibus (option)
The function "Parameterisation via Profibus" is chargeable and can only be used after an activation code has been
purchased and entered.
The request of the parameters from MultiPro FL is made with the extended program command "Wait". The command is extended
by the addition "Wait parameter". In the program sequence this command must immediately precede a joint step, otherwise the
running program is terminated and set to NOK.
If the command is considered valid the step (line number) of the subsequent joint step is put on the bus (byte 7 Multi -> PLC) and
status bit STM_P is set. The PLC now puts the parameters on the bus and in turn sets the step (line number byte 7 PLC -> Multi)
and the status bit STS_P. If the PLC does not set the status bit within 10 seconds the program sequence is terminated with NOK
(error message will be generated).
If all parameters of the PLC are zero the program continues with the set parameters. The step number must still be correct and
the handshake performed.
If the step (line number) does not equal the step (line number) of the program step the running program is terminated with an
error message.
If the parameters are not plausible the running program is terminated with an error message.
If Multi now has verified and accepted the parameters the bit STM_P is reset. The PLC must now also reset its bit STS_P. If the
PLC does not set the bit STS_P within 10 seconds the running program is terminated with an error message.
If the program is terminated, for example, by start signal = 0 during parameter transfer (handshake) the handshake must still be
completed or an error message is issued.
10.9.6.1 Function requirements

• Can only be used with the extended configuration (3000Plus.gsd / 3000_Res.gsd).
• All parameters must always be met.
• When adding or deleting the line in the program sequence the step (line number) may change. This is especially to be noted
when several "Wait parameter" are supplied per program sequence.
• The PLC must make sure that it always transfers the correct parameter according to the joining process.
10.9.6.2 Parameter transmission
Parameter
STM_P
Byte 0, Bit 3
STS_P
Byte 0, Bit 3
PLC resets its status.

Control system has accepted the parameter and
continues its program sequence.
PLC has set parameter on bus. The control system shall now take over.
Parameter on the bus.
The control system requests parameter from the PLC.
The synchronised parameterisation of the control unit via multiple interfaces is not possible. This includes also
the entry at the unit, via Profibus or via PC-connection.
> Chapter 10.9.4.1 Telegram structure MultiPro FL  PLC, Page 102

> Chapter 10.9.4.3 Telegram structure PLC  MultiPro FL, Page 112

10.10 Settings with TCP/IP (optional module)
Please note that the TCP/IP module is not integrated in the press-in control system by default.
a) Settings TCP/IP on the press-in control system MultiPro FL
Menu navigation
Production screen  <Settings>  <Settings/Test>  <Settings>  <Communication>  <Other>  <TCP/IP>
The following screen opens after pressing the key <TCP/IP>.
TCP/IP settings
RDY PGF IO NIO HA GSE PC v DFU x PB C: A: Program: xxx
TCP/IP On
MAC address 00.50.C2.25.30.59
IP address 192.168.000.042
Subnet mask 255.255.255.000
Gateway
Socket 1
Socket 2
Socket 3
Socket 4
TCP/IP On: TCP/IP activated; Off: TCP/IP deactivated

MAC address Mac address of the press-in control system MultiPro FL.
IP address Own IP, must be determined by the network administrator.
Subnet mask Subnet mask, must be determined by the network administrator.
Gateway Gateway, must be determined by the network administrator.
Socket 1 Client, connection to MultiControl4. The following window opens after pressing the key <RET>.
Socket 1 settings
Own port: 1024

Target port: 1024
Target IP: 192.168.000.042
The parameter to be set is selected with the function keys and entered with a numeric
keypad and confirmed with the key <RET>.
Own Port Client port of the press-in control system MultiPro FL
Target Port Setting 1024 when connected with the software MultiControl4 (Server)
Target IP Target IP Server, PC on which the software MultiControl4 is installed.
When entering the IP it must be noted that after entering three numbers
the key <RET> must be pressed to enter the next numbers. After
entering the last three numbers this must also be concluded with <RET>.
The window " Socket settings" is left with<ESC>.
Socket 2 DSM
Socket 3 DSM
Socket 4 DSM
> Chapter 13.9 Remote maintenance, Page 221

b) Settings TCP/IP MultiControl4 software
The communication settings of the PC software must also be made for the TCP/IP connection.
Menu navigation
Parameters for the communication

settings of the TCP/IP connection
10.11 Inputs / outputs
10.11.1 System inputs

The inputs which are used to start or cancel a sequence program are referred to as system inputs.
System inputs can not be used in a sequence program. The system inputs are defined in the settings for the program
start.
55
The tables show the possible system inputs depending on PG Start :
Input X52 IO Extension 8/8

PG-Start 1 2 3 4 11 12 13 14 15 16 17 18
4 (direct) X X X X
7 X X X X
8 (direct) X X X X X X X X
7 X X X X
15 X X X X X
31 X X X X X X
63 X X X X X X X
127 X X X X X X X X
10.11.2 Free inputs

All inputs not used as system input are referred to as "free inputs".
A "free input" can be "freely" used in a sequence programme (instruction "jump" and "wait").
> Chapter 11.9.4 Program instructions, Page 170 and 172
55
The parameter "PG Start" specifies the number of programs that can be started as well as the start mode. When activating the parameter "SBUS
Start" the setting options of "PG Start" also change.

10.11.3 System outputs

The outputs used as status outputs are referred to as system outputs.
System outputs can not be used in a sequence program. Any output available in the system can be used as system
output.
The following table shows the possible system outputs:
Designation Function =1 when =0 when
... the system has completely ... the system is not operational
RDY Indicates the readiness of the
started up and all components (system is just starting up or an
Ready system.
are operational. error has occurred).
Indicates that a sequence ... the program was completed ... after switch-on or when the
OK
program was completed without errors and the jointing program is running or when the
Okay without error. process was assessed with OK. program was completed with OK.
Indicates that a sequence ... the program was completed ... after switch-on or when the
NOK
program was completed with errors and the jointing program is running or when the
Not Okay with error. process was analysed with NOK. program was closed with NOK.
PGF Indicates whether a sequence

... the program is not running. ... the program is running.
Program finished program is done.
HA
Indicates whether the hold
Hold active ... the hold time is running. ... the hold time is not running.
mode is active.
(Hold operating mode)
GSE ... the plunger has reached the

Indicates whether the plunger is in ... the initial position was not
Initial position initial position with observation
the initial position. travelled to.
reached of the limits (± 0.5 mm of NP).
A 24 V signal is output when ... the threshold force was ... the threshold force was not
FS Trigger
exceeding the threshold force. reached until program end. yet reached.
> Chapter 11.3.2.1 Info area, Page 129

10.11.4 Free outputs

All outputs not used as system output are referred to as "free outputs".
A "free output" can be "freely" used in a sequence programme (instruction "output").

> Chapter 11.9.4.7 Output, Page 171

10.11.5 Inputs when Profibus I/O = On

The following table shows the possible input sources interface X52, IO Extension and Profibus in the left column. The columns to
the right show the allocation of the input numbers to the respective connection, for example, the inputs 1 to 4 are allocated to the
X52 interface integrated in the press-in control system.
When using an IO Extension each module receives a basic address. Because 16 modules max. can be connected the basic
addresses 10 to 160 are possible. The input number of an IO Extension is derived from the basic address and the input of the I/O
module. The table shows the inputs of an IO Extension of the type 8/8 (8 inputs). An IO Extension of type 4/4 only has 4 inputs,
so that the respective 4 rear inputs of a column are obsolete. This means if the device with the base 80 is an IO Extension of type
4/4, only the inputs E81 – E84 can be used.
When using the inputs of the Profibus (Bases 10 and 20), as shown in the table, the inputs of the IO Extension of the same base
are locked (L=Locked).
Decoding of the possible inputs when Profibus I/O = On
Input 1 11 21 31 41 51 61 71 81 91 101 111 121 131 141 151 161

- - - - - - - - - - - - - - - - -
Connection 4 18 28 38 48 58 68 78 88 98 108 118 128 138 148 158 168
56
X52 X
IO-Extension 57
Base 10 L
Base 20 L
Base 30 X
Base 40 X
Base 50 X
Base 60 X
Base 70 X
Base 80 X
Base 90 X
Base 100 X
Base 110 X
Base 120 X
Base 130 X
Base 140 X
Base 150 X
Base 160 X
Profibus 58 X X
56
X52 Interface = operating equipment interface on the MultiPro FL
57
Optional module IO Extension
58
Inputs of Profibus (Base 10, E11 - E18; Base 20, E21 - E28), only if the Profibus module is integrated in the press-in control system and the
Profibus is switched on.

10.11.6 Inputs when Profibus I/O = Off

The table is identical to that described in chapter "10.11.5 Inputs when Profibus I/O = On", with the exception that the inputs of
bases 10 and 20 are allocated to the IO Extension. The Profibus inputs are not assessed.
Decoding of the possible inputs when Profibus I/O = Off
Input 1 11 21 31 41 51 61 71 81 91 101 111 121 131 141 151 161

- - - - - - - - - - - - - - - - -
Connection 4 18 28 38 48 58 68 78 88 98 108 118 128 138 148 158 168
X52 59 X
60
IO-Extension
Base 10 X
Base 20 X
Base 30 X
Base 40 X
Base 50 X
Base 60 X
Base 70 X
Base 80 X
Base 90 X
Base 100 X
Base 110 X
Base 120 X
Base 130 X
Base 140 X
Base 150 X
Base 160 X
Profibus L L
10.11.7 Outputs
The following table shows the possible communication interfaces X52, IO Extension and Profibus in the left column. The columns
to the right show the allocation of the output numbers to the respective connection, for example, the inputs 1 to 4 are allocated to
the X52 interface integrated in the press-in control system.
When using an IO Extension each module receives a basic address. Because 16 modules max. can be connected the basic
addresses 10 to 160 are possible. The output number of an IO Extension is derived from the basic address and the output of the
I/O module. The table shows the outputs of an IO Extension of the type 8/8 (8 outputs). An IO Extension of type 4/4 only has 4
outputs, so that the respective 4 rear outputs of a column are obsolete. This means if the device with the base 80 is an IO
Extension of type 4/4, only the outputs A81 – A84 can be used.
The outputs of base 10 and 20 are available at the IO Extension as well as on the Profibus in parallel.
Decoding of the possible outputs
Output 1 11 21 31 41 51 61 71 81 91 101 111 121 131 141 151 161

- - - - - - - - - - - - - - - - -
Connection 4 18 28 38 48 58 68 78 88 98 108 118 128 138 148 158 168
X5259 X
IO-Extension60
Base 10 X
Base 20 X
Base 30 X
Base 40 X
Base 50 X
Base 60 X
Base 70 X
Base 80 X
Base 90 X
Base 100 X
Base 110 X
Base 120 X
Base 130 X
Base 140 X
Base 150 X
Base 160 X
Profibus 61 X X
59
X52 Interface = operating equipment interface on the MultiPro FL
60
Optional module IO Extension
61
Outputs on the Profibus only when the Profibus module is integrated in the control system and the Profibus is switched on.

Operation
11 Operation
11.1 Safety
a) Improper operation
Risk of injury due to improper operation!

Improper operation can lead to serious injuries or property damage.
For this reason:
• Perform all operating steps in accordance with the instructions of this operating manual as well as the operating instructions of
the system components.
• Before commencing work, ensure that all safety devices are installed and working properly.
• Never disable safety devices during operation.
• Keep a clean and orderly working environment! Components and tools loosely stacked or spread about constitute accident
hazards.
b) Defect
Property damages by using a defective press-in control system!

A defective press-in control system can lead to inadequate jointing processes and damages.
For this reason:
• In the event of malfunctions, error indications (error messages) as well as apparent deficiencies the press-in control system
must be shut down immediately and the responsible supervisor / DSM Service notified.
c) Unintentional startup

Unintentional starting of the press-in control system may cause injuries.
For this reason:
• Switch off the press-in control system when working on the jointing system and secure against reactivation.
> Chapter 2.8 Safety-relevant information, Page 17

Operation
11.2 Operating controls

Function keys62
- Context-sensitive
Numeric keypad menu navigation
with the keys
- To enter values <F1> – <F6>
- Jump to a line number - Reset function

with the keypad Simultaneously
pressing the F keys
The following must be
<F2> and <F5>
observed in regard to entries
(example "Selection line 5"): cause a reset.
- use the key <5> when selecting

a single digit line number
- use the keys <0> and <5> when

selecting a double-digit line number
- use the keys <0>, <0> and <5>

when selecting a triple-digit line
number
ESC key
- Return key <ESC>,

pressing this key
exits the active menu
Screenshot function without saving.
When keeping this

- When pressing the key <-> the
key depressed the
current screen is stored as user is returned to
BMP file on the CF card. the production
> Chapter 11.13, Page 189 screen.
Arrow keys RET key
- To select the individual - Return key <RET>

menu items / program lines To confirm an entry during
parameterisation and
- Jump function to the last line:
programming.
Highlight first line then <> arrow up.
- Jump function to the first line:
Highlight last line then <> arrow down.
- Toggling the production screens
62
Kontext
11.3 Display functions
 The press-in control system is equipped with an LED status display and an LCD display.
LCD display (production screen)

5.7“ (320 x 240 Pixel), illuminated
LED status display

Limit value monitoring of force and stroke
62
Because of the context-sensitive menu navigation additional functions can be performed using the F-keys. They are indicated on the respective
screen or described in the corresponding chapter of this documentation.

Operation
11.3.1 LED status display (limit value monitoring)

The LED status display is selected in conjunction with the program instruction "Display measurements 63" as well as after closing
the sequence program.
Force
< Force too small
= Force within the entered limits
> Force too large
Length (stroke)
< Stroke too small
= Stroke within the entered limits
> Stroke too large
11.3.2 LCD display (production screen)
Program administration
Designation
RDY PGF IO NIO HA GSE PC v - - PB C: A: Program: 3
PG 001: Press-in pins
Info area
PG 002: Caulk shaft
PG 003: Drive-out
PG 004: Press-in bearings
PG 005: Normal position travel
Work area
Notes line
Please press function key. … Function key fields
New Edit Copy Del. Com. Test
Screen division
Designation This area shows the station name to the user in "Production operation" as well as the name of the
current screen through selection with the function keys.
Info area The information line shows the condition of the status inputs, the possible connections, the integrated
drives as well as the program start.
> Chapter 11.3.2.1 Info area, Page 129
Work area This is the main display area (11.5 x 5.8 cm); the production screen (measured values display,
graphics display) as well as the selected function screen are shown here.
> Chapter 11.3.2.2 Work area, Page 130
Notes line The user is supported through help texts and notices.
Function key fields Depending on the selected screen, functions are assigned to the fields and allocated to the function keys.
63
The instruction refers to the last joint step.
Example: Line1 of the program sequence includes joint step 1, line 2 includes joint step 2, in line 3 the measurements of the last joint step
(= step 2) are placed on the clipboard and the measurements are displayed in line 4. A signal input is expected in line 5 and line 6 includes joint
step 3. The programme is closed in line 7.
The status display indicates the result of joint step 2 and joint step 3.

Operation
11.3.2.1 Info area
RDY PGF IO NIO HA GSE PC - IP C DFU x PB C: A: Programm: 3
Status outputs Connections Drive Start
a) Status outputs info area
Active Inactive Off Message
RDY RDY RDY Ready, operational
PGF PGF PGF Program completed, end of PG, reset at start
IO IO IO Jointing process okay
NIO NIO NIO Jointing process not okay
HA HA HA Hold force
GSE GSE GSE Normal position reached
No output assigned
Output defined, output not set
Output set
b) Connections info area
Message Message
PC ─ No connection with PC DFU "I" Flashing, no comparison of time
PC v Connected with PC DFU I Radio clock active
PC a Logged into MultiControl4 ─ No DSM radio clock module present
PC p MultiControl4 parameterised
IP x Not connected with TCP/IP PB Profibus on, connection established
IP c Establishing connection PB Profibus on, but no connection
IP C Connected with TCP/IP PB PB on, but no module found 64
─ TCP/IP off / no TCP/IP module 65 ─ Profibus (PB) off
c) Drive info area

The press-in control system MultiPro FL is equipped with an internal memory "Drive C:" and a mobile long-term memory "Drive
A:" (CF card). The drive info area provides information on the status of the memory units.
Int. memory
CF card
Message
C: A: Memory unit was initialised and is functional
C: A: Access to memory unit
A: CF card can be removed
"C:" "A:" Flashing, memory unit has an invalid format
Memory unit does not exist
64
The Profibus is integrated into the control system MultiPro as standard. Check whether the module is plugged in or defective.
65
Functions only with integrated TCP/IP module. The interface is integrated into the device as standard feature; the function of the connection is
ensured by purchasing the option module.

Operation
d) Start info area
Message
Program: ─ ─ ─ Direct start, no program started
Program: 1 Program started, e.g. program 1
Program: x x x Start locked, no program can be started
Preselection: 1 Program selection (indirect start) set
Err KAL data Error calibrating data  notify DSM service
Err BirthDat Error date of birth data  notify DSM service
Err Press Error press-in unit
Err Device para. Error device parameter  data record damaged, verify parameters
Err Programs Error programs  check programs
Err Press para Error joining parameters  data record damaged, verify parameters
Err System bus para Error system bus parameter  data record damaged, verify parameters
Err Userlist Error user list
Err Access jour. Error access journal
Err Power pack Error power pack
Err Load cell dat Error load cell data  notify DSM service
11.3.2.2 Work area
a) Work area: „Production screen program is executed“

Program running Press-in bearing (PG003)

Status
Program comment /
Program number
Travel
F / [kN] = 20.15 Current instruction

to be processed
S / [mm] = 160.73
Wait for start …

Operation
b) Work area: „Production screen measuring value display“
By default the production screen is set to display the measuring results. You can use the arrow keys <> / <> to toggle to the
graphic mode "Force / Stroke" and "Force / Time"
Joining process OK (okay)
Result of the joining procedure

(Joint step)
RDY PGF OK NOK HA GSE PC - - - PB C: A: Program: 3
Comment / program no.

OK
Press in bearing (PG003)
Joint step with line number and
result
Fastening stage 2 OK
(TPG = 5388 ms) Program runtime
F / [kN] = 20.15
S / [mm] = 160.73 Measuring value display
Wait for start ...
Joining process NOK (not okay)

(Joint step)
Comment / program no.

NOK
Press in bearing (PG003)
Joint step with line number and result
Fastening stage 2 NOK

Force < Stop reason
F / [kN] = 15.78
S / [mm] = 142.25 Measuring value display
Wait for start ...

NOK
Retract (PG004)
Joint step with listing of line number
= 0, i.e. step was not carried out
Step 0 NOK
SG: Start aborted Stop reason

Operation
c) Work area: "Production screen Graphic display"
Jointing station 0001

Joint step number
(Line number)
OK window
Direction
>> Drive-out; << Drive-in
Grid lines
Threshold force, show FS

Wait for start ...
On the screen menu "Settings control unit" you can configure the settings for the graphic mode.
Menu navigation
Production screen  <Setting>  <Settings/Test>  <Settings>  <Control unit>
Graphic settings
RDY PGF OK NOK HA GSE PC - - - PB C: A: Program: xxx
PG-Start (Manual, Preselection, E1) Select parameter with the arrow

Graphic
Graphic settings
settings
Line Off keys <> / <>.
Graphic output
SBUS-Start Off On
Activate / Deactivate with <RET>.
Grid lines On
Status outputs
IO window On Exit with <ESC>.
Graphic settings
DShow
isplaytreshold force
threshold FS MS
torque Off
On
LCD contrast
Graphic recording from FS Off
LCD Graphic over time Off Off
DateShow
/ Timeswitch-off point Off
Show envelope
Language Off 0
AbortPress
modeUp / Down key to select, then RET . 0
Press Up / Down key to select, then RET .
Function Setting Description
Off Standard production screen "Measured value display"

Graphic output
On Graphic recording (graphic mode) as default display on the screen
Off No grid lines

Grid lines
On Show grid lines
Off OK window deactivated

OK Window
On Display of OK window (Min/Max range of force / stroke measurement)
Threshold force FS Off Do not display FS

display On Display FS
Off Graphics recording with start of joint step

Graphic recording from FS
On Start graphic recording from threshold force FS
Off Force / stroke diagram, requires graphic output "On"

Graphic over time
On Force / time diagram as default display on the screen
Off Switch-off point is not displayed

Show switch-off point
On Switch-off point is displayed
Off Envelope is not displayed

Display envelope
On Envelope is displayed

Operation
Graphic mode: Force / Stroke
Joining station 0001 Current program

Pro
Currently processed instruction,

Stop reason
Joining curve
Graphic display
F: Force
S: Stroke
Wait for start ... F: Final force in kN

S: Final stroke in mm
Graphic mode: Force / Time


OK: Okay
Graphic display
F: Force in kN
t: Joining time in ms
Wait for start ...
Graphic mode: NOK joining process force / stroke

Result of the jointing procedure
NOK: Not okay
Stop reason
Wait for start ...

Operation
Graphic mode: NOK joining process force / stroke with envelope
Füge-Station 0001
RDY PGF IO NIO HA GSE PC - - - PB C: A: Programm: 1
Stop reason
Envelope (upper band)
Envelope (lower band)
Warten auf Start …
Einstellung Systeminfo CF entfernen
d) Work area: „Function screen“
Using the various function screens lets you configure, program and test the press-in system directly on the device. Furthermore,
you can retrieve important information about your MultiPro FL as well as analyse the measured data directly on the screen.
Example: Press-in unit settings
Press-in unit settings

Select the parameter with the arrow keys
<> / <>.
Auto-parametrisation On
Unit of force kN
Change the setting with the <RET> key,
Calibration value 10.00 kN enter numeric values with the numeric
Maximum feed 200 mm/s keypad and confirm with <RET>.
Direction reversal On
Feed ramp On Leave the menu with <ESC>.
Correction factor Force 1.000
Correction factor Path 1.000
Maximum ramp time 50 ms Hint:
Normal position (Pos) 11 mm
Keeping the <ESC> key depressed
returns you to the production screen.
Press RET key to change ...
Example: Program sequence protocol
Program sequence protocol

SeqNo Program instruction: 10 t [ms]
0 Initialization 38
1 1 Output A011 = On 4
2 2 Wait till t = 1000 ms 1002
3 3 Output A011 = Off 5
4 4 Graphic start TAB = 1 ms 2
5 5 Travel to F = 20.00 kN 3477
6 6 Measurements to intermediate memory 2
7 7 Measurements in long-term memory 3
8 8 Measurements in statistic memory 2 5
9 9 Display Measurements 2
10 10 Graphic stop 2 The notes line provided
11 11 Jump if Res = NOK > 013 2 information about the possible
12 12 Normal position travel 834
13 13 End 10 actions.
Total 5388
Up / Down keys for scrolling ...

Operation
11.3.2.3 Menu navigation and menu overview

Coming from the production screen you navigate to the required function screen via the function keys by means of the context-
sensitive menu navigation. The following illustrations demonstrate this using the example "Press-in unit settings".
a) Menu guidance
Wait for start ...
Press <F1> or <F2>
Please press function key.
Programs User administration Device service
Press <F5> or <F6>
Test Service Settings
Press <F5> or <F6>
Press-in unit Communication Control unit
Press <F1> or <F2>

Operation
b) Menu overview
Start screen
approx. 5 sec
Production
screen
Protected area.
Query only with active access
control.
> Chapter 11.5.16 Access control,
Page 147
Settings System info Remove CF
Main menu System information CF card remove
Program administration User Press-in unit Measurements

Programs management Data of the Main menu
press-in unit
New Test New Change Delete Statistics Measured PG

Create Test selected Statistics values protocol
new program program program X Production Program
data sequence
protocol
Edit Com. Settings/Test

Edit selected Change
program comment
Main menu
Copy Del.
Copy Delete
selected selected
program program Service
Service menu
Service break fuse
Storage management
Factory settings
Reset service counter
Service DCM – Extension
Service DSM
Settings
Main menu
Test Press-in unit Communication Control unit

Main menu Settings Main menu Settings
press-in unit control unit
Press-in unit System bus Control unit PC / Printer System bus Other
Load cell data Test system bus Test control unit Settings for Settings TCP/IP Profibus
PC and printer system bus
Load cell Motor System System TCP/IP Profibus

Test Test bus bus
TCP/IP Profibus
load cell motor parameter devices
parameter parameter
Test Test
system bus system bus
parameter devices

Operation
11.4 Operating functions
a) Configuration
The operation of the press-in system requires configuring the collected press-in unit as well as the communication interfaces. For
this purpose the press-in control system is adapted with the parameters to be set, depending on the connected periphery as well
as the user requirements. The parameters are entered by the user himself. This does not apply to the parameters that are read by
the connected press-in unit when auto-parameterisation 66 is activated.
The press-in control system is configured directly on the unit. Alternatively, the settings can be made via the
MultiControl4 software supplied.
The configuration can be changed at any time provided no start signal is applied.
> Chapter 11.5 Operation: Configuration control unit, Page 138

> Chapter 11.7 Operation: Configuration communication interfaces, Page 150
b) Sequence programming
To be able to carry out a joining process the exact sequence must be entered in a program with the help of instructions. Several
programs can be stored. The number of programs to be started depends on the availability of inputs or the settings for the
programs start. The respective program number is assigned to the corresponding start input/start signal.
The press-in control system is programmed directly on the unit. Alternatively, program entry can be made via the
MultiControl4 software supplied.
The program sequence as well as the joining parameters can be changed at any time provided no start signal is
applied.
c) Display system information, measured data

On the press-in control system the function keys allow retrieving system information, data about the connected press-in unit, the
stored measured data 67 as well as the measured execution times of the joining sequence directly on the device.
> Chapter 11.10 Operation: Accessing system information, Page 185
> Chapter 11.11 Operation: Display tool data memory, Page 186
> Chapter 11.12 Operation: Display measurements, Page 187
d) Screenshot function
The operating concept of the press-in control system MultiPro FL allows generating a screenshot of the current display by
pressing a key.
> Chapter 11.13 Operation: Creating a screenshot, Page 189
The procedure of configuration, parameterisation and programming by using the MultiControl4 software describes the
operating instructions of the press-in control system MultiClassic FL.
The PDF file of the operating instructions you will find on the CD-ROM "MULTI CD".
The MultiControl4 software offers the possibility (amongst others) to print the relevant data or to save the data in a
PDF format file. To do this, there are <Print> buttons in almost each screen view.
66
Configuration of the press-in unit
67
Measurements of the long-term memory and statistics data

Operation
11.5 Operation: Configuration control unit
Menu navigation
The following screen opens after pressing the key <Control unit>.
Settings control unit

PG-Start (Manual, Preselection, E1)

Linearisation table Off
Function screen
SBUS-Start Off
Status outputs
Configuration of the
Graphic settings control unit
LCD contrast
Date / Time
Language 0
Abort mode 0
External release 0
Press Up / Down key to select, then RET .
11.5.1 PG Start
After selecting the menu item PG Start (=Program start) and pressing the <RET>key the screen "Settings for program start" is
opened.“
Settings for program start

Qty. Prog. START input Prog. preselection
4 I1 – I4 None
8 I11 – I10 None
7 I1 I2 – I4 Use the arrow keys <> / <>
15 I11 I12 – I15 to select and confirm
31 I11 I12 – I16 with the <RET> key.
63 I11 I12 – I17
127 I11 I12 – I18
32 I1 ToolControl
128 I1 PG Schalter
128 I1 PosiControl
128 I1 Manually
The screen displays the maximum number of the programs to be started, the associated start input as well as, in case of program
preselection, the required inputs for binary coding or the optional module used.
Select the suitable program start for your application scenario.
Please note that only one program start can be selected.

Example: When activating the "128PG-Mode ToolControl" a program cannot be started with the inputs I1 – I4 or with
the help of an IO Extension.
When activating the parameter "SBUS Start", the mask of the "PG Start" settings screen changes. No programs can be started
directly. The start input is permanently defined and starts the preselected program via system bus.
> Chapter 10.11.1 System inputs, Page 122
The individual options for the program start are explained on the following pages.

Operation
4 Programs Direct start
Up to 4 programs can be started. The allocation of the programs to the start signal is made directly without coding, this means
input I1 starts program 1, I2 starts program 2, etc.
When using all inputs (I1 – I4) for the program start (PG1 – PG4), no other inputs for additional tasks are available at the "X52
INTERFACE". The input/output level can be extended with the optional IO Extension.
Input Program
I1 PG 1
Direct
I2 PG 2
I3 PG 3
I4 PG 4
7 Programs Program preselection, start with input I1
Up to 7 programs can be started. The program to be started is preselected binary-coded with the inputs I2 to I4- Input I1 starts the
preselected program.
When using this setting no other inputs for additional tasks are available at the "X52 INTERFACE". The input/output level can be
extended with the optional IO Extension.
Inputs
Program
I4 I3 I2
0 0 0 -
0 0 1 PG 1
Start input = I1
0 1 0 PG 2
0 1 1 PG 3
1 0 0 PG 4
1 0 1 PG 5
1 1 0 PG 6
1 1 1 PG 7
8 Programs Direct start via IO Extension (optional module)
Up to 8 programs can be started. The allocation of the programs to the start signal is made directly without coding using an IO
Extension with the basic address 10, this means input I11 starts program 1, I12 starts program 2, etc.
The inputs (I1 – I4) of "X52 INTERFACE" are freely available.
Input Program
I11 PG 1
I12 PG 2
I13 PG 3
Direct
I14 PG 4
I15 PG 5
I16 PG 6
I17 PG 7
I18 PG 8
15 Programs
31 Programs
Program preselection via IO Extension (optional module), start with input I11
63 Programs
127 Programs
Depending on the setting up to 15, 31, 63 or 127 programmes can be started. The program to be started is preselected binary-
coded with the defined inputs:
- 15 Programs, preselection with I12 – I15
Input I11 starts the preselected program. The inputs are made available through an IO Extension with the basic address 10. The
inputs (I1 – I4) of "X52 INTERFACE" are freely available.

Operation
The table for the setting 15 programs / 31 programs / 63 programs / 127 programs are available on the following pages.
15 Programs
Inputs
Program
I15 I14 I13 I12
0 0 0 0 -
0 0 0 1 PG 1
0 0 1 0 PG 2
0 0 1 1 PG 3
0 1 0 0 PG 4
0 1 0 1 PG 5
Start input = E11

0 1 1 0 PG 6
0 1 1 1 PG 7
1 0 0 0 PG 8
1 0 0 1 PG 9
1 0 1 0 PG 10
1 0 1 1 PG 11
1 1 0 0 PG 12
1 1 0 1 PG 13
1 1 1 0 PG 14
1 1 1 1 PG 15
31 Programs
Inputs
Program
I16 I15 I14 I13 I12
0 0 0 0 0 -
0 0 0 0 1 PG 1
0 0 0 1 0 PG 2
0 0 0 1 1 PG 3
0 0 1 0 0 PG 4
0 0 1 0 1 PG 5
0 0 1 1 0 PG 6
0 0 1 1 1 PG 7
0 1 0 0 0 PG 8
0 1 0 0 1 PG 9
0 1 0 1 0 PG 10
0 1 0 1 1 PG 11
0 1 1 0 0 PG 12
0 1 1 0 1 PG 13
Start input = E11
0 1 1 1 0 PG 14
0 1 1 1 1 PG 15
1 0 0 0 0 PG 16
1 0 0 0 1 PG 17
1 0 0 1 0 PG 18
1 0 0 1 1 PG 19
1 0 1 0 0 PG 20
1 0 1 0 1 PG 21
1 0 1 1 0 PG 22
1 0 1 1 1 PG 23
1 1 0 0 0 PG 24
1 1 0 0 1 PG 25
1 1 0 1 0 PG 26
1 1 0 1 1 PG 27
1 1 1 0 0 PG 28
1 1 1 0 1 PG 29
1 1 1 1 0 PG 30
1 1 1 1 1 PG 31

Operation
63 Programs
Inputs
Program
I17 I16 I15 I14 I13 I12
0 0 0 0 0 0 -
0 0 0 0 0 1 PG 1
0 0 0 0 1 0 PG 2
1 0 0 0 0 0 PG 32
1 0 0 0 0 1 PG 33
1 0 0 0 1 0 PG 34
1 0 0 0 1 1 PG 35
1 0 0 1 0 0 PG 36
1 0 0 1 0 1 PG 37
1 0 0 1 1 0 PG 38
1 0 0 1 1 1 PG 39
1 0 1 0 0 0 PG 40
1 0 1 0 0 1 PG 41
1 0 1 0 1 0 PG 42
1 0 1 0 1 1 PG 43
1 0 1 1 0 0 PG 44
1 0 1 1 0 1 PG 45
Start input = E11

1 0 1 1 1 0 PG 46
1 0 1 1 1 1 PG 47
1 1 0 0 0 0 PG 48
1 1 0 0 0 1 PG 49
1 1 0 0 1 0 PG 50
1 1 0 0 1 1 PG 51
1 1 0 1 0 0 PG 52
1 1 0 1 0 1 PG 53
1 1 0 1 1 0 PG 54
1 1 0 1 1 1 PG 55
1 1 1 0 0 0 PG 56
1 1 1 0 0 1 PG 57
1 1 1 0 1 0 PG 58
1 1 1 0 1 1 PG 59
1 1 1 1 0 0 PG 60
1 1 1 1 0 1 PG 61
1 1 1 1 1 0 PG 62
1 1 1 1 1 1 PG 63
127 Programs
Inputs
Programs
I18 I17 I16 I15 I14 I13 I12
0 0 0 0 0 0 0 -
0 0 0 0 0 0 1 PG 1
0 0 0 0 0 1 0 PG 2
1 0 0 0 0 0 0 PG 64
1 0 0 0 0 0 1 PG 65
1 0 0 0 0 1 0 PG 66
1 0 0 0 0 1 1 PG 67
Start input = E11
1 0 0 0 1 0 0 PG 68
1 0 0 0 1 0 1 PG 69
1 0 0 0 1 1 0 PG 70
1 0 0 0 1 1 1 PG 71
1 0 0 1 0 0 0 PG 72
1 0 0 1 0 0 1 PG 73
1 0 0 1 0 1 0 PG 74

Operation
Continuation 127 Programs
I18 I17 I16 I15 I14 I13 I12 Program

1 0 0 1 0 1 1 PG 75
1 0 0 1 1 0 0 PG 76
1 0 0 1 1 0 1 PG 77
1 0 0 1 1 1 0 PG 78
1 0 0 1 1 1 1 PG 79
1 0 1 0 0 0 0 PG 80
1 0 1 0 0 0 1 PG 81
1 0 1 0 0 1 0 PG 82
1 0 1 0 0 1 1 PG 83
1 0 1 0 1 0 0 PG 84
1 0 1 0 1 0 1 PG 85
1 0 1 0 1 1 0 PG 86
1 0 1 0 1 1 1 PG 87
1 0 1 1 0 0 0 PG 88
1 0 1 1 0 0 1 PG 89
1 0 1 1 0 1 0 PG 90
1 0 1 1 0 1 1 PG 91
1 0 1 1 1 0 0 PG 92
1 0 1 1 1 0 1 PG 93
1 0 1 1 1 1 0 PG 94
1 0 1 1 1 1 1 PG 95
1 1 0 0 0 0 0 PG 96
1 1 0 0 0 0 1 PG 97
1 1 0 0 0 1 0 PG 98
1 1 0 0 0 1 1 PG 99
Start input = E11

1 1 0 0 1 0 0 PG 100
1 1 0 0 1 0 1 PG 101
1 1 0 0 1 1 0 PG 102
1 1 0 0 1 1 1 PG 103
1 1 0 1 0 0 0 PG 104
1 1 0 1 0 0 1 PG 105
1 1 0 1 0 1 0 PG 106
1 1 0 1 0 1 1 PG 107
1 1 0 1 1 0 0 PG 108
1 1 0 1 1 0 1 PG 109
1 1 0 1 1 1 0 PG 110
1 1 0 1 1 1 1 PG 111
1 1 1 0 0 0 0 PG 112
1 1 1 0 0 0 1 PG 113
1 1 1 0 0 1 0 PG 114
1 1 1 0 0 1 1 PG 115
1 1 1 0 1 0 0 PG 116
1 1 1 0 1 0 1 PG 117
1 1 1 0 1 1 0 PG 118
1 1 1 0 1 1 1 PG 119
1 1 1 1 0 0 0 PG 120
1 1 1 1 0 0 1 PG 121
1 1 1 1 0 1 0 PG 122
1 1 1 1 0 1 1 PG 123
1 1 1 1 1 0 0 PG 124
1 1 1 1 1 0 1 PG 125
1 1 1 1 1 1 0 PG 126
1 1 1 1 1 1 1 PG 127

Operation
32 Programs
Program preselection via ToolControl, start with input I1
ToolControl
Up to 32 programs can be started. The program to be started is preselected with ToolControl. Input I1 starts the preselected
program. The inputs I2 – I4 of "X52 INTERFACE" are freely available.
128 Programs
Program preselection via PG switch, start with input I1
PG Schalter
Up to 128 programs can be started. The program to be started is preselected with the program switch (Status Indication Selector
ONE / TWO). Input I1 starts the preselected program. The inputs I2 – I4 of "X52 INTERFACE" are freely available.
128 Programs
Program preselection via PosiControl, start with input I1
PosiControl
Up to 128 programs can be started. The program to be started is preselected with the control PosiControl (P Control). Input I1
starts the preselected program. The inputs I2 – E4 of "X52 INTERFACE" are freely available.
128 Programs Manual program preselection via MultiPro,

Manual Start with input I1
Up to 128 programs can be started. The program to be started is preselected directly on the press-in control system MultiPro.
MultiPro is operational.
Enter the PG No.

PG no. = 3 █
to be started via the keypad.
Confirm the input with the <RET> key.
The input can be deleted with function

Please enter program no. …
key <F6>.

Function principle "Manual program preselection“
MultiPro FL is operational and displays the status message "Wait for start "; a previously created joining program can be
preselected by entering the corresponding program number with the numeric keypad of the press-in control system MultiPro FL.
The selected program is used from the next start until a new selection is made. After switching off the device or when restarting it
the program set last is preselected. Input I1 starts the preselected program. The inputs I1 – I4 of "X52 INTERFACE" are freely
available.
128 Programs
Program preselection and start via LineControl
LineControl
Up to 128 programs can be started. The program to be started is preselected and started with the LineControl software.

Operation
11.5.2 Linearisation table

Linearisation can be enabled or disabled with this setting. If linearisation is active, you may enter up to 5 values in the
linearisation table to compensate for the bending up of the components.
Linearisation table
RDY PGF IO NIO HA GSE PC- - - PB C: A: Program: xxx
Pos F [kN] S [mm] Use the arrow keys <> / <>

01 0.000 0.000
to select and confirm
02 0.000 0.000 with the <RET> key.
03 0.000 0.000
04 0.000 0.000
05 0.000 0.000
Enter the linearisation values by highlighting the corresponding line (position) and confirming your selection with <RET>. First
enter the force value and then the path value using the numeric keypad. Confirm the respective value entered with the <RET>
key.
The complete table is deleted with the <Delete> function key, following a verification prompt.
Linearisation is described in the following chapter:

> Chapter 5.5 Linearisation, bending-up compensation, Page 38
11.5.3 SBUS-Start
The parameter "SBUS-Start" activates the function "Programme start via System bus". For example, when using a program
selector switch of the type "Status Indication Selector ONE S (Start) / Selector TWO S (Start)". You can only use SBUS Start
when the program to be started is preselected.
Settings for program start

Qty. Prog. START input Prog. preselection
- - -
- - -
7 SBUS Start I2 – I4 Use the arrow keys <> / <>
15 SBUS Start I12 – I15 to select and confirm
31 SBUS Start I12 – I16
with the <RET> key.
32 SBUS Start ToolControl
128 SBUS Start PG Switch
128 SBUS Start PosiControl
128 SBUS Start Manually
Input E1 / E11 is freely available when starting via system bus.

> Chapter 15.2.4 Execution: Status Indication Selector ONE S / TWO S, Page 228

Operation
11.5.4 Status outputs

You can define the status outputs in this menu item. Any output available in the press-in control system can be used as status
output. The following window opens after pressing the key <RET>:
Statusausgänge
Output for Output no.
The status outputs are
assigned by default as shown.
Ready 1
Jointing procedure was OK 2
Jointing procedure was NOK 3
Program ready 0
Hold active 0
Int. pos. reached 4
FS Trigger 0
Operational If the system is operational a 24 V signal 68 is put out at the defined output.
Joining process was OK If a joining process is assessed to be OK (okay), a 24 V signal is applied to the defined output68
until another joining process is started or a system restart takes place.
Joining process was NOK If a joining process is assessed to be NOK (not okay), a 24 V signal is applied to the defined
output68 until another joining process is started or a system restart takes place.
Program done After the program is completed a 24 V signal68 is put out at the defined output.
Hold active When using in Hold mode, a 24 V signal68 is put out for the duration of the hold time entered.
Int. pos. reached When the plunger reaches the initial position with observation of the limits (± 0.5 mm NP) a 24 V
signal68 is put out at the defined output.
FS Trigger When exceeding the threshold force FS, a 24V signal68 is put out at the defined output.
> Joining parameter: Threshold force, Page 159
Entering a zero activates the corresponding system output and allows it to be used as "free output" in a sequence program.
> Chapter 10.11.3 System outputs, Page 123
11.5.5 Graphic settings

Settings for the graphic display: Graphic grid, graphic output, OK window, graphic over time, display threshold force FS, graphic
recording from FS, display envelope.
The configuration of the graphic mode is described in the following chapter:

> Chapter 11.3.2.2 Work area, Page 130
11.5.6 LCD contrast

After pressing the <RET> key, the contrast of the LCD display can be reduced (<F3> or <F4>) and increased (<F5> or <F6>).
Set contrast with F keys …
Done - +
11.5.7 LCD continuous light

OFF The active duration of the display lighting of the control system depends on the time specified in "LCD black time" (can
be set only via MultiControl4 software; Edit device configuration).
Entering a "0" in "LCD black time" switches the lighting off..
ON The lighting of the display is permanently on.
68
24 V / 100 mA, DC, potential-free

Operation
11.5.8 Date and Time

After pressing the <RET> key, the date as well as the time are displayed. Both settings can be edited with the function keys.
Set date/time with F keys ...
Date Time
When pressing the appropriate function key a cursor appears in the selected display. The values are entered with the numeric
keypad. Each input (date: day/month/year, time: hour/minute/second) is confirmed with <RET>. Exit setting with <ESC>.
Date and Time
Enter date: 15 . 09 . 12
Time: 21 : 06 : 25
11.5.9 Language
After pressing the <RET> key, you can select between German "Key <0>" and a foreign language "Key <1>".
Language 0 Press the <RET> key, enter the

Abort mode 0 number and confirm with <RET>.
External release 0
0 = German, 1 = Foreign language
 The input can be deleted with function

key <F6>.
The following screen appears when selecting the foreign language.
SBUS Start Off

Status outputs
Graphic settings The device language was changed.
LCD contrast The device is now restarted.
Date and Time
Language 1
Abort mode 0
External release 0
OK Cancellation
Confirm with <Ok> (<F1> / <F2> / <F3>) and the press-in control system is restarted with the selected foreign language.
11.5.10 Abort mode

In this menu item, the response of the sequential program when removing the start signal is set. Press the <RET> key and the
following configuration window is opened.
Abort mode
The response of the program to removing the START signal is

set via the abort mode.
Mode = 0 Program is closed with NOK

Mode = 1 Current instruction is terminated, control waits
for RESTART.
Attention, with RESTART the instructions e mpty
travel, travel, wait and normal position travel are
repeated.
Mode = 0
Enter number of abort mode

Operation
11.5.11 External release

In this menu item the input for the external release is set.
0: Deactivated
1 – 168 : In addition to the start signal a 24 V signal must constantly be applied to the defined input (Low-Active),
a start of the press-in unit is otherwise not possible or the running program is terminated.
The input "External release" is also required when using the optional module "MSI" in connection with an
emergency-off switchgear.
> Chapter 5.2 Protective device / Protection concept, Page 36
11.5.12 Station number

When operating several press-in control systems the option of assigning a station number to each control unit is available. The
station number (0....9999) can be entered by pressing the <RET> the and is confront by pressing the <RET> once more.
The station number facilitates the overview especially when linking several systems. The station number is transferred during the
communication with the PC software and is shown on each printout.
11.5.13 Statistics about X-values

The setting defines the number of measurements included in the statistics calculation. This means, when using the instruction
"Measurements in statistics memory 1/2" the max. number of measurements defined here is written to the respective statistics
memory. Once the defined quality has been reached no further values are written to the statistics memory.
Input range: 0 – 32000
11.5.14 Red print

The parameter "red print" allows printing the results of NOK joining processes as well as error messages in red. This function is
activated with the setting "On". A prerequisite for using the red print is that the connected printer supports this function.
11.5.15 Input NOK interlock

In this menu item the input for the NOK interlock is set. The NOK interlock is used for release after an NOK joining process. If no
24 V signal is applied to the defined input the program sequence cannot be restarted.
Red print Off

Input NOK interlock 0 Press the <RET> key, enter the
Access control 0 number and confirm with <RET>.
Enter input number (0 = deactivated)
 The input can be deleted with function

key <F6>.
0: Deactivated
1 - 168: Activated, NOK interlock via an available input of the I/O level.
99: Activated, NOK interlock via key switch of the optional module Status Indication Key Switch,
Status Indication Selector ONE KS or Selector TWO KS.
> Chapter 15.2 System bus device Status Indication (optional module), Page 228
11.5.16 Access control

Access control can be activated with this parameter (=On), that is, to be able to make adjustments on the press-in control system
the user must login with his personnel number and his access number. The user can perform settings on the MultiPro FL
according to the defined access rights.
Personnel – No: 1
Access – No: ******
Please enter access no. …

Operation
11.5.17 Statussignal
This device parameter controls the LED 69 at the press-in unit of the QMP series.
End of program Displays the joining status at the press-in unit when the end of program is reached.
Stage-related Displays the joining status at the press-in unit after every joining stage, e.g. when
you use the instruction „wait till position is reached“.
Measurements to intermediate Depending on the instruction "measurements to intermediate memory“, the joining
memory status at the press-in unit is set.
11.5.18 External test mode

OFF Default setting, no external test mode possible.
ON The function „IO simulation“ is switched on. With the help of the MultiControl4 software the available inputs and outputs
of the complete I/O-section can be watched and controlled for simulation.
> Chapter 12.3 Test mode / simulation of the inputs and outputs at the press-in control system, Page 204
11.6 Operation: User administration
Menu navigation
Production screen  <Settings>  <User administration>
The following screen opens after pressing the key <User administartion>.
User administration
RDY PGF OK NOK HA PC - - - PB C: A: Program: 3
Seq. No. Rights Personnel no.
1 all 000001
-- ----------------------- --- Function screen
-- ----------------------- --- User administration
-- ----------------------- ---
-- ----------------------- ---
-- ----------------------- ---
-- ----------------------- ---
-- ----------------------- ---
Select user with Up / Down key…
New Change Delete
If the access control is active the login data defined in the user administration is requested. The user administration is used to
manage the access data of the persons that shall be given access to the system.
The user is identified by a 6-digit personnel number. In addition to this number an access number can be assigned to each user.
The created user is also granted specific rights. The possible rights are: none, view only, all. A new user can be created, edited or
deleted with the function keys.
New
The following window appears after pressing the function key <New>.
Enter the personnel number (max. 6 digits)

User No. 02
with the numeric keypad and confirm your
entry with <RET>.
Personnel number: 123
Access number: 001

Can assign an optional access number (max.
Authorisation: 6 digits) and confirm your input with <RET>.
The current entry can be deleted again with function key <F6 ()> and the entry can be closed with the <ESC> key. Finally,
determine the access rights for the user by using the corresponding function key.
none view only all
69
Lighting unit integrated in the press-in unit of the QMP series; displaying the joining status RUN / OK / NOK.

Operation
Change
Use the corresponding function key to change a parameter.
Changing user settings

Seq. No. Rights Personnel No
1 alle 000001
User No. 03 Close the change with the
-- ----------------------- ---
function key <Done>.
- - Personnel number:
- - - - - - -123
---------------- ---
-- ----------------------- --- <ESC> for Abort.
- - Access number:
- - - - - - -001
---------------- ---
-- ----------------------- ---
- - Authorisation: - - - - - - -all- - - - - - - - - - - - - - - - ---
-- ----------------------- ---
F-keys to change user data …
Done Per. No Acc: No Rights
Delete
Select the user with the arrow keys <> / <> and press the function key <Delete>.
Delete user
Seq. No. Rights Personnel No

1 all 000001
2 all 001509
-- ----------------------- ---
-- ----------------------- ---
-- ----------------------- ---
-- ----------------------- ---
-- ----------------------- ---
-- ----------------------- ---
Do you really want to delete user 001509?
Yes No
To confirm the verification prompt with the function key <Yes>. <No> returns you to the main selection of user administration.
The last 9 users are logged via the access journal. The journal is displayed only after entering the protected area.

Operation
11.7 Operation: Configuration communication interfaces
Menu navigation
Production screen  <Settings>  <Settings/Test>  <Settings>  <Communication>
The following screen opens after pressing the function key <Communication>.
Communication settings
Function screen
Configuration of the
Please press function key… communication interfaces.
PC / Printer System bus Other

> Chapter 10.8.3 Settings at system bus, Page 97
After pressing the function key "Other" the selection screen for the configuration of the TCP/IP interface and the Profibus interface
opens Select the respective interface with the function keys.
Please press function key …
TCP / IP Profibus
Please note that the TCP/IP module is not integrated in the press-in control system MultiPro FL by default.
> Chapter 10.9.2 Settings at Profibus (press-in control system), Page 99

11.8 Operation: Configuration press-in unit
Menu navigation
Production screen  <Settings>  <Settings/Test>  <Settings>  <Press>
The following screen opens after pressing the function key <Press>.
Press-in unit settings

Auto-parameterisation On
Unit of force kN Function screen
Calibration value 20.00 kN
Maximum feed 200 mm/s
Configuration of
the press-in unit
Direction reversal On
Feed ramp On
Correction factor Force 1.000
Correction factor Path 1.000
Maximum ramp time 0 ms
Normal position (Pos) 11 mm
Press RET key to change ...

Operation
11.8.1 Auto-parameterisation
To rule out a possible error source during parameterisation, this setting is used to read the parameters Unit of force, Calibration
value, Maximum feed, Rotational direction reversal, End position drive-in and End position drive-out directly from the press-in unit.
These parameters cannot be edited when auto-parameterisation is enabled.
By contrast, the parameters Feed ramp, Correction factor for force, Correction factor for path, Max. starting time, Normal position
(Pos), Normal position (Vmax) and Service cycle can be configured independently from the auto-parameterisation setting.
On (default): The parameters of the press-in unit are read when the system starts.
Off: Parameter as entered. When auto-parameterisation is disabled, the warning "Attention, Auto-
parameterisation is off!" appears when ramping up the press-in control system (press-in unit
initialisation).
Auto-parameterisation should normally not be switched off (factory setting = On). Entering values not matching the connected press-in
unit may lead to wrong measuring results and destroy the press-in unit.
11.8.2 Unit of force (=Auto-parameter)

When auto-parameterisation is enabled, the unit (N or kN) stored in the digital force transducer is displayed.
With manual input it must be remembered that the unit of force must match the calibration value of the press-in unit. This means
when entering the unit "N" and a calibration value of, e.g. 10 kN (type plate press-in unit) the calibration value of the unit must be
adjusted, in this example 10 000 N.
11.8.3 Calibration value (=Auto-parameter)

The calibration value specifies the max. force of the connected press-in unit in N or kN. The calibration value is shown on the type
plate of the press-in unit. Note the parameter "Unit of force" with manual input. The parameter is read when auto-parameterisation
is switched on.
11.8.4 Max. feed (=Auto-parameter)

This parameter specifies the maximum plunger velocity of the connected press-in unit in mm/s. The maximum ramp velocity is
entered on the type plate of the press-in unit. The parameter is read when auto-parameterisation is switched on.
11.8.5 Direction reversal (=Auto-parameter)

Off (default): Direction (drive-in / drive-out) of the press-in unit as specified in the sequence programme (joining
parameter).
On: Direction inverted.
The parameter is read when auto-parameterisation is switched on.
11.8.6 Feed ramp

Off: Rapid increase from "v" to specified feed.
On (default): Slow increase from "v" to specified feed (t approx. 300 ms).
Off: Rapid increase On: Gradual increase
11.8.7 Correction factor force

The force factor can be entered according to the specification on the type plate of the press-in unit. With all standard press-in
units of the QMP and SMP Series the factor 1,000 is set at the factory. Verify this setting against that on the type plate of the
press-in unit.
The correction factor can be changed for customer applications upon consultation with DSM.
Please note that the parameter "Correction factor force" has a direct impact on the recording of measurements!

Operation
11.8.8 Correction factor stroke

The stroke factor can be entered according to the specification on the type plate of the press-in unit. With all standard press-in
units of the QMP and SMP Series the factor 1,000 is set at the factory. Verify this setting against that on the type plate of the
press-in unit.
The correction factor can be changed for customer applications upon consultation with DSM.
Please note that the parameter "Correction factor path" has a direct impact on the recording of measurements!
11.8.9 Maximum ramp time

Enter the maximum permissible duration for the ramp-up of the press-in unit after the start in this parameter. The plunger must
begin to move within this time. The entry is made in ms.
0 (default): Function deactivated
1 - 9999: Max. duration [ms].
11.8.10 Starting position

The starting position (initial position) can be defined with this parameter. The area within the positions EE and EA 70 is available
for this purpose. The starting position is travelled to after switch-on, after a start termination, at the initial start or upon the
instruction "Go initial position".
> Chapter 6.6 Go initial position, Page 64
11.8.11 Starting position (Vmax)

With the parameter "Starting position Vmax" the max. feed for the normal position travel is defined. When accessing the normal
position, depending on the distance of the starting position of the plunger until reaching the normal position, the velocity is
controlled.
Input range: 20% of "Max. feed" to "Max. feed" in mm/s.
11.8.12 Starting position (only comp.)

The parameter determines when the procedure "Go initial position" runs.
Off (standard): The initial position is approached during the first program start after switching on; with the instruction "Go
Initial Pos" as well as in the event of any modification of the parameters as well as in the event of measures
that the plunger was not moved by a program.
On: The initial position is approached exclusively during the first program start after switching on as well as via the
instruction "Go Initial Pos".
11.8.13 Service cycle

The parameter "Service cycle" can be used to determine when service shall be performed.
Input range: 0 ... 9 999 999

The function is deactivated when entering a zero.
The defined value entered in the parameter "Service cycle" determines when service shall be performed. A service flag is set
when the load counter rises above his value.
> Chapter 13.2.4 Restart service counter, Page 208
70
Limits of the working range EE = limit switch driven-in, EA = limit switch driven-out. The positions EE and EA are listed on the type plate of the
press-in unit as well as the menu System info / Press-in unit.

Operation
11.9 Operation: Sequence programming
 All tasks of sequence programming can be handled in the menu of program management.
Menu navigation
Production screen  <Settings>  <Programs>
The following screen opens after pressing the function key <Programs>.
PG 001: Setup programme
PG 002: Caulk shaft
PG 003: Press-in pins Function screen
PG 004: Press in bearing Main menu of program
U-PG 129: Drive-out management
New Edit Copy Del. Com. Test
The functions listed below and described further down can be accessed with the function keys.
<New> Create new program

<Edit> Edit selected program
<Copy> Copy selected program
<Del.> Delete selected program
<Com.> Change comment of selected program
<Test> Test sequence of selected program
If no program sequence has been entered at the factory only the function key <New> can be selected.

Operation
11.9.1 Create new program

Before beginning with creating a programme the exact jointing process must first be clear.
Menu navigation
Production screen  <Settings>  <Programs>  <New>
Create new program

Program No.: 10
(PG No. > 128, then subroutine!)
Comment:
Please enter program no. ...
128 programs are available, which can be divided by the user into direct-start programs and into subroutines.
Subroutines (macros) provide the user with the option of programming frequently recurring process sequences.
The subroutine can be integrated into any program and called from there (instruction "UP Start"). A subroutine cannot be started
directly.
Program no. Determine the program number for the new program and confirm with <RET>.
PG 1 – 128 Programs Direct Start
PG 129 – 255 Subgroup Subroutines Start by program
If this program number has already been signed this is detected and indicated as follows.
Prog. is available. Overwrite?
Yes No
Verify before entering the program number which inputs can be used.
> Chapter 11.9.3 Enter / edit program, Page 155
Comment Finally, a programme name (comment) can be entered which, for example, describes the function of the
programme. Confirm with <RET> after the entry. Next, the programming environment opens where the
joining sequence is entered.
The programme name can also be entered / edited later.
> Chapter 11.9.2 Enter / edit comment (program name), Page 155

Operation
11.9.2 Enter / edit comment (program name)

The function "Comment" is opened when creating a new program and when selecting the function key <Com>.
Menu navigation
Production screen  <Settings>  <Programs>  <Com>
Create new program

RDY PGF OK NOK HA GSE PC v - - PB C: A: Program: xxx
Program No.: 10
(PG No. > 128, then subroutine!)
Comment:
Turn-out at d
ABCDEFGHIJKLMNOPQRSTUVWXYZ
Up/Lo   Del. Blank
The characters are entered with the arrow keys <> / <> on the keypad of the press-in control system. Press the arrow key
until you have reached the character you want to enter. This is shown by a frame acting as cursor. A number and also a dot is
entered directly via the keypad.
Do not use hyphen = Screenshot function

> Chapter 11.13 Operation: Creating a screenshot, Page 189
You can carry out the following functions with the function keys:
<> / <> Move input cursor <Del.> Delete character
<Up/Lo> Upper/lower case <Blank> Enter a space
Enter a special character by pressing a <9> on the numeric keypad and then press the key <>. You can now enter a special
character with the arrow key <>.
Character string after entering the number <9>: : ; < = > ? @
11.9.3 Enter / edit program

When creating a new program the function screen "Edit program (sequence programming)" opens automatically after entering the
comment.
To edit an existing program select it with the arrow keys <> / <> in the main menu of the program administration and then
confirm the function key <Edit>. The edit mode is opened.
Menu navigation
Production screen  <Settings>  <Programs>  <New>
Edit program 10
RDY PGF OK NOK HA PC - - - PB C: A: Program: xxx
001 End
Additional function through F keys …
Done Edit Ins. Del.
When creating a new program only the instruction "End" is already inserted. When creating a subroutine (PG > 128) the
command "UP End".
The end instruction determines the end of the program. Each sequence must be ended with this instruction.

Operation
You can insert a program instruction into the sequence with the function key <Ins.>. When pressing the function key <Ins.> all
available instructions are displayed.
Programm 1 editieren
RDY PGF IO NIO HA GSE PC v - - PB C: A: Programm: xxx The description of the instructions can be
01 Normal position travel found from page 157
02 Travel
03 Empty travel
04 Measured values
05 Jump
06 Output
07 End
08 Wait
09 Graphic
Notes line
10 UP Start
Measurements of the last joining process ...
An instruction is selected with the arrow keys <> / <> or by entering the instruction number. Fee notes line thereby provides
information on the basic function of the respective instruction. Shall the selected instruction be added to the program sequence
the selection must be confirmed with the <RET> key.
The integration of an instruction into the program sequence is done in a context-sensitive manner, this means, after the
confirmation the corresponding parameterisation window automatically opens to define the function of the instruction.
Edit program 1
RDY PGF IO NIO HA GSE PC v - - PB C: A: Program: xxx

02 Ausdrehen Measurement processing
03 Measurement values
Messwerte to intermediate memory Parameterisation window after
Measurements to long-term memory selecting an instruction
04 Springe
Measurements to long-term memory (OK)
05 Measurements
Ausgang to long-term memory (NOK)
Measurements to statistics memory 1
06 Ende
Measurements to statistics memory 2
07 Warte
Measurements Display
08 Measurements
Grafik Print (all)
Measurements Print (NOK)
09 UP-Start
Press UP and DOWN key to select
10 UP-Start
Depending on the instruction a selection must be made in the parameterisation window using the arrow keys <> / <> or the
value entered with the <numeric keys>. Confirm with <RET>. The instructions "End" and "Blank line" are an exception and are
directly integrated into the program sequence. Furthermore, it must be remembered that the instruction "UP End" is exclusively
used in subroutines.
Additional function through F-keys ...
Done Edit Ins. Del.
The setting (parameterisation window) of an instruction can be changed with the function key <Edit. The function key <Del>
deletes the highlighted instruction from the program sequence. The function key <Done> saves the program and ends the edit
mode. You can also leave the programming environment with <ESC>; a prompt then appear whether the program shall be saved
(F-key <Yes>) or not (F-key <No>).
When closing the program it is checked for plausibility and any error detected is displayed immediately.
Attention Errors were found

in line 002 with program verification
Parameterisation error!
ESC = back, RET = next …

Operation
11.9.4 Program instructions

The instructions are integrated into the program sequence in the order of the tasks to be carried out.
No. Instruction Function Page
01 Normal position travel Joining process "Normal position travel" 157
02 Travel Joining process "Stroke" / "Force" / "Initiator" 157
03 Empty travel Joining process "Empty travel" 158
04 Measurements Processing the production data 169
05 Jump Program jump to line X if condition for jump function is met 170
06 Output Set / reset output 171
07 End Defines the program end 171
08 Wait Program sequence continues when defined event has occurred 172
09 Graphic Measurement recording for the graphic display 174
10 UP Start Starting a subroutine 174
11 UP End Defines the program end of a subroutine 175
12 Variable Set variable (16 variables, value range 0 … 255) 175
13 Blank line Wildcard 176
14 Transmit Data transfer to PC, CF card or Profibus 176
15 Offset adjustment This instruction perform an automatic zero-point adjustment of the measuring amplifier 176
11.9.4.1 Go Initial Pos

>> Instruction No. 01
With this instruction the procedure "Go initial position" is integrated into the programme sequence. The plunger is moved up to the
defined position "Starting position" using the velocity set "Starting position Vmax".
With the process "Go initial position" no OK/NOK monitoring takes place.

> Chapter 11.8.10 Starting position, Page 152
> Chapter 11.8.11 Starting position (Vmax), Page 152
> Chapter 11.8.12 Starting position (only comp.), Page 152
11.9.4.2 Travel
Use the program instructions "Travel" to determine the joining process to be used (main switch-off criteria) via the selection window.
Travel
Use the arrow keys <> / <> to select and
Travel on stroke confirm with <RET>.
Travel on force
Travel on initiator
> Chapter 6.5 Joining process, Page 45

> Chapter 6.5.1 Travel on stroke, Page 46
> Chapter 6.5.2 Travel on force, Page 48
> Chapter 6.5.3 Travel on initiator, Page 51
> Chapter 6.5.9 Envelope function, Page 61
> Joining parameters, from Page 158

Operation
11.9.4.3 Empty travel

Using the programme instruction "Empty travel" the plunger is moved to a predefined position (switch-off stroke).
> Chapter 6.5 Joining process, Page 45
> Chapter 6.5.4 Empty travel on stroke, Page 54
> Joining parameters, from Page 158
11.9.4.4 Joining parameters (Instruction Travel / Empty travel)

After selecting the joining process (instruction "Travel" / "Empty travel") and confirmation with <RET>, the input screen opens to
configure the joining process. The parameters to be entered hereby depend on the selected switch-off criterion (joining process).
All parameters are described on the following pages.
Switch-off stroke
Abbreviation Sstop
Unit mm
Input range If path measurement absolute: EE to EA If path measurement relative: 0 to EA - EE
Dependency Smin ≤ Smax
TS TF TI ETS
Parameter for joining process
x x
The "Switch-off stroke" is the main switch-off criterion with the joining process "Travel to stroke (TS) / Empty travel on stroke
(ETS)". The "Switch-off stroke" is the position at which the press-in unit is cut off.
EE = End position driven-in, EA = End position driven-out

The values can be taken from the type plate or read in the menu "Data of press-in unit"
( <System info>  <Press-in unit>).
Switch-off force
Abbreviation Fstop
Unit N or kN
Input range 0 N / kN to Fmax (press-in unit)
Dependency Depends on the calibration value of the press-in unit
TS TF TI ETS
x
The "Switch-off force" is the main switch-off criterion with the joining process "Travel to force (TF)". The "Switch-off force" is the
force at which the press-in unit is cut off.
Switch-off input
Abbreviation INstop
Unit -
Input range 1 to 255 (only freely available input)
Dependency The switch off inputs is not used as system input
TS TF TI ETS
x
The "Switch-off input" is the main switch-off criterion with the joining process "Travel to initiator (TI)". The "Switch-off input"
entered is the input at which the press-in unit is cut off. A 24 V (DC) signal must be applied to the selected input for switch off.
Ideally, use the direct inputs on the press-in control system (X52 Interface, IO-Extension).
When using a Profibus input, a delayed switch-off may occur due to runtime delays of the Profibus and/or delays
through the cycle time of the PLC.

Operation
Direction of travel
Input drive-in, drive-out, automatic
TS TF TI ETS
x x x x
The "Direction of travel" specifies the lifting direction in which the joining process shall be applied. With automatic travel the
direction to travel to reach the target position always depends on the starting position.
Please note also the overrun time in this context since with travelling from different starting positions undesired tolerances may
develop in regard to the target position.
The direction of travel "Automatic" can only be used for absolute stroke measurement.
Stroke measurement relative

Input range On (=Relative measurement), Off (=Absolute measurement)
TS TF TI ETS
x x x x
The parameter "Stroke measurement relative" determines the method for stroke measurement.
Absolute stroke measurement is activated when the parameter is disabled, i.e. travel takes place according to the absolute stroke
measurement system.
Travel takes place according to the relative stroke measurement if relative stroke measurement is enabled. This means, the
threshold force Fs determines the start position and sets it to zero; measuring is done coming from the start position.
Absolute measurement is possible only when working without threshold force (FS = 0).
Threshold force
Abbreviation Fs
Unit N or kN
Input range 0 N / kN to 120 % of the calibration value of the press-in unit
Dependency Fs ≤ Fmax
Fs ≤ Fblk
The parameter "relative stroke measurement" must be enabled.
TS TF TI ETS
x x x
The "Threshold force" is the force from which relative stroke measurement starts. The value to be set depends on the application
and must be determined empirically.
The values can be taken from the type plate or read in the menu "press-in unit settings"
( <Setting>  <Device service>  <Settings>  <Press-in unit>).

Operation
Stroke min
Abbreviation Smin
Unit mm
Input range If stroke measurement "absolute": EE to EA
If stroke measurement "relative": 0 to EA - EE
Dependency Depending on the parameter "relative angle measurement" Smin≤ Smax
TS TF TI ETS
x x x x
The "minimum stroke" is the stroke at which the joint step is still assessed to be OK (lower limit OK band stroke).
Absolute: The position after the switch-off for the OK assessment≥ must be of the value entered.
Relative: The stroke travelled for the OK assessment must be ≥ of the value entered.

Stroke max
Abbreviation Smax
Unit mm
Input range If stroke measurement "absolute": EE to EA
If stroke measurement "relative": 0 to EA - EE
Dependency Depending on the parameter "relative angle measurement" Smin≤ Smax
TS TF TI ETS
x x x x
The "maximum stroke" is the stroke at which the joint step is still assessed to be OK (upper limit OK band stroke).
Absolute: The position after the switch-off for the OK assessment ≤ must be of the value entered.
Relative: The stroke travelled for the OK assessment must be ≤ of the value entered.

Review stroke
Abbreviation Sdelta
Unit mm
Input range 0 to max. stroke
Dependency Setting "0" = Review stroke is disabled
When using a review stroke, a "block dimension max"
and a "block force max" must be defined.
TS TF TI ETS
x x x
The assessment of the joining process is done at the position resulting after subtracting the defined review stroke.

Operation
Block dimension max

Abbreviation Sblk
Unit mm
Input range End position driven-in (EE) to end position driven-out (EA)
Setting "0" = block dimension max. disabled
Dependency If review stroke > 0, a block dimension max must be entered.
TS TF TI ETS
x x x
The dimension block max. is used for monitoring and to protect the work piece during the joining process. If the defined block
dimension is exceeded, an NOK message is displayed and the joining process is terminated immediately.
NOK termination if stroke > parameter "Block dimension max" (drive-out)
NOK termination if stroke < parameter "Block dimension max" (drive-in)
Force min
Abbreviation Fmin
Unit N or kN
Dependency Fmin ≤ Fmax
When using the block force max. parameter the following applies: Fmin ≤ Fblk
TS TF TI ETS
x x x
The "minimum force" is the force at which the joint step is still assessed to be OK (lower limit OK band force). The force for the
OK assessment must be ≥ of the value entered.
The values can be taken from the type plate or read in the menu "Press-in unit settings"
( <Setting>  <Device service>  <Settings>  <press-in unit>).
Force max
Abbreviation Fmax
Unit N or kN
Dependency Fmax ≥ Fmin
When using the block force max. parameter the following applies: Fmax ≤ Fblk
When using the joining process "Travel to force (FK)" and disabled
review stroke, the following applies: Fmax ≥ Fstopp
TS TF TI ETS
x x x
The "maximum force" is the force at which the joint step is still assessed to be OK (upper limit OK band force). The force for the
OK assessment must be ≤ of the value entered.

Operation
Max. block force

Abbreviation Fblk
Unit N or kN
Dependency When using the review stroke a max. block force must be entered; the following applies:
Fblk ≥ 0
TS TF TI ETS
x x x x
The max. block force is used for monitoring and to protect the work piece during the joining process. If the defined block force is
exceeded, an NOK message is displayed and the joining process is terminated immediately.
Force progression in OK window

Input On, Off
TS TF TI ETS
x x x
Enabling the parameter causes monitoring of the force-stroke progression according to the following criteria:
• Entry of the force / stroke progression into the OK window must take place from the left.
• The force / stroke progression must remain within the OK window during the further process until the switch-off point has been
reached.
Joining time
Abbreviation TP
Unit ms
Input range 0 ms to 60000 ms
TS TF TI ETS
x x x x
The setting "Joining time" specifies how long the joint step may last at the most. If the press-in unit does not reach the specified
main switch-off criterion within the "Joining time", the joint step is rated NOK.
Hold time
Abbreviation TH
Unit ms
Input range 0 ms to 3000 ms; Setting "0" = Hold time is deactivated
TS TF TI ETS
x x x x
The "Hold time" specifies how long the force ("Hold force") shall be held after reaching the main switch-off criterion.
This parameter can be used only after activation.


Operation
Overrun time
Abbreviation TN
Unit ms
TS TF TI ETS
x x x x
Due to the inertia of the mass of the press-in unit it does not come to a stop immediately after switch-off but runs over. The
overrun time allows determining how long after switching off the press-in unit the force and stroke shall be measured.
> Chapter 6.4 After reaching the switch-off criterion, Page 43
Ramp time
Abbreviation TR
Unit ms
TS TF TI ETS
x x x x
The "Ramp time" specifies how much time the press-in unit has to reach the value specified in the parameter "Plunger velocity".
Plunger velocity
Abbreviation V
Unit mm/s
Input range 0 mm/s up to max. feed of the press-in unit.
Dependency Parameter "Max. feed" (press-in unit configuration).
TS TF TI ETS
x x x x
The parameter "Plunger velocity" is used to specify a velocity for the press-in unit. The press-in unit tries to reach this velocity
within the ramp time.
The max. plunger velocity (feed) can be taken from the type plate or read in the menu "Press-in unit settings"
( <Setting>  <Device service>  <Settings>  <Press-in unit>).
It is recommended for the min. feed not to choose it smaller than 5% of the max. feed.
You should consider the following points to determine the suitable feed.
• The slower the plunger velocity the more exact the switch-off, i.e. the smaller the overrun.
• Please note that for physical reasons, the plunger needs a braking distance; it is captured with the overrun time.
Envelope number
Input range 1 - 10: Envelopes stored globally in the device
0: Envelop monitoring deactivated
TS TF TI ETS
x x x
The "Envelope" function gives you the option of checking the joining progression based on a master curve (envelope) in addition
to the conventional monitoring (OK band). For envelope monitoring 10 envelopes can be stored globally per device and used in
all processes. Of course, the envelope resulting from the master curve must match the respective application. Note that the
defined envelope refers always only to one step in the program sequence. This means that in a sequence programme with
several steps a suitable envelope must be assigned to the process (step) to be monitored.
Enter the number of envelope you have created in this parameter.

Operation
Envelope switching
Input Yes = switching, No = not switching
TS TF TI ETS
x x x
Define with the parameter "Envelope switching" how to travel when the envelope has been fallen below / exceeded.
Switching: The press-in unit is switched off when leaving the envelope (stopping reason).
Non-switching: The point when leaving the envelope is stored and the joining process assessed as NOK (=error). The force-
stroke value at which the envelope was left is displayed.
Possible error display: HK > Top, HK < Bottom.
Motor current max

Abbreviation Imax
Unit %
Input range 0 % (no current) to 100% (max. current)
TS TF TI ETS
x x x x
The parameter "Motor current max" is used to specify a max. current for the press-in unit in percent. If the press-in unit (drive
motor) requires more current then specified in the joining step, the basic module shuts off the press-in unit. Damages to the
press-in unit can thus be prevented.
Determining the value

First a low value, e.g. 10 %, is entered and a joining process is then performed. If the joining process is still
terminated because the motor current is too high, the current level needs to be increased incrementally until the
joining process was rated OK.

Operation

Input On / Off
TS TF TI ETS
x x x x
This parameter switches on or off the function "measurands add-on memory".
Off: Function is deactivated.

On: Writes the results of the joining process in the add-on memory.
In a multi-stage joining process the user defines the processes, whose measuring results shall be written into the add-on memory.
The results of max. 5 processes can be stored in the add-on memory of a program (joining process). For the OK/NOK evaluation
it is necessary, to write at least the measured values of one process in the joining process in the add-on memory (instruction
"Measurands in add-on memory"). The MultiPro FL sends the production data from the add-on memory and from the temporary
storage to the selected interface with the instruction "Transfer ...".
Example
Program sequence with function add-on memory Program sequence with the standard functionality
01 Travel on S = x mm (measurands add-on memory = on) 01 Travel on S = x mm (measurands add-on memory = off)
02 Jump if result NOK --> 08 02 Measurements to intermediate memory
03 Travel on S = x mm (measurands add-on memory = on) 03 Transmit measurements to PB
04 Jump if result NOK --> 08 04 Jump if result NOK --> 17
05 Travel on F = x N (measurands add-on memory = on) 05 Travel on S = x mm (measurands add-on memory = off)
06 Jump if result NOK --> 08 06 Measurements to intermediate memory
07 Travel on F = x N (measurands add-on memory = on) 07 Transmit measurements to PB
08 Measurements to intermediate memory 08 Jump if result NOK --> 17
09 Jump if result OK --> 11 09 Travel on F = x N (measurands add-on memory = off)
10 Empty travel on S = x mm (measurands add-on memory = on) 10 Measurements to intermediate memory
11 Transmit measurements to PB 11 Transmit measurements to PB
12 End 12 Jump if result NOK --> 17
13 Travel on F = x N (measurands add-on memory = off)
15 Transmit measurements to PB
16 Jump if result OK --> 18
17 Empty travel on S = x mm (measurands add-on memory = off) 71
18 End
This parameter can be used only after activation.
71
In this program sequence, the measured values of the "Empty travel to stroke" cannot be stored temporarily and transferred, otherwise the overall
statement of the program is falsified (OK/NOK evaluation).

Operation
Delay
Abbreviation mm/s²
Unit 100 mm/s² to 2000 mm/s²; Setting „0“ = delay deactivated
Dependency The greater the delay the smaller the travel time. However, if applicable,
"Sstop" is travelled past (reached inaccurately).
The smaller the delay the greater the travel time. The switch-off stroke "Sstop" is
reached more precisely. The optimal value for the delay must be determined empirically.
TS TF TI ETS
x
The "Delay" parameter specifies the value of how much the plunger is slowed down from the brake point "SBrake" till reaching the
target position "SStop".
> Chapter 6.5.4 Empty travel on stroke, Page 54
Determining the "Delay" value"
First perform an empty travel with the desired velocity =V0 plunger velocity. The delay is thereby initially disabled. Furthermore, an
overrun time of approx. 500 ms must be entered to be able to determine the braking distance.
The maximum possible delay is calculated as follows:
V0²
aVmax =
2 · SB
aVmax = Delay
V0 = Plunger velocity
SB = Braking distance (V0 till standstill)
Example: SB = 20 mm, V0 = 200 mm/s
(200 mm/s)²
aVmax =
2 · 20 mm
aVmax = 1000 mm/s²

Operation
Evaluation force
Input EF 1 (in tracking time); EF 2 (in whole process); EF 3 (at stop)
TS TF TI ETS
x x x
This parameter determines the force value, which is used to evaluate the joining stage.
EF 1 (standard): Uses the peak force during the tracking time for evaluation of the force within the OK / NOK assessment
of the joining stage.
EF 2: Uses the peak force during the whole process of the joining stage for evaluation of the force within the
OK / NOK assessment of the joining stage.
EF 3: Uses the force value at the switch-off of the press-in unit for evaluation of the force within the OK / NOK
assessment of the joining stage.
When the function "Review stroke" is used the setting of the parameter "Evaluation force" is irrelevant.
The result of force measurement at the calculated waypoint (review stroke) is used for the OK / NOK assessment of the
joining stage.

Operation
Evaluation length
Input EL 1 (in tracking time); EL 2 (in whole process); EL 3 (by stop); EL 4 (by force)
TS TF TI ETS
x x x
This parameter determines the length value, which is used to evaluate the joining stage.
EL 1 (standard): Uses the length value at the end of the tracking time for evaluation of the length within the OK / NOK
assessment of the joining stage.
EL 2: Uses the peak value of length during the whole process of the joining stage for evaluation of the length
within the OK / NOK assessment of the joining stage. This means: in driving direction "move out" =
highest length; in driving direction "move in" = smallest length.
EL 3: Uses the length value at the switch-off of the press-in unit for evaluation of the length (stroke) within the
OK / NOK assessment of the joining stage.
EL 4: Uses the length value at result "force" (depending of parameter "Evaluation force") for evaluation of the
length within the OK / NOK assessment of the joining stage.
When the function "Review stroke" is used the setting of the parameter "Evaluation length" is irrelevant.
The result of length measurement at the calculated waypoint (review stroke) is used for the OK / NOK assessment of the
joining stage.

Operation
11.9.4.5 Measurements
Use the instruction "Measurements" to determine the option to be used via a selection window.
Measurement processing
Measurements to intermediate memory

Measurements to long-term memory Use the arrow keys <> / <> to select
Measurements to long-term memory (OK) and confirm with <RET>.
Measurements to long-term memory (NOK)
Measurements to statistic memory 1
Measurements to statistic memory 2
Measurements display
Measurements print (all)
Measurements print (NOK)
The instruction "Measurements" specifies how the production data shall be processed further.
The first step for the further processing of the production data must always consist of the instruction "Measurements
to intermediate memory".
All other instructions 72 processing production data always refer to the data of the intermediate memory.
- Long-term memory: all production data first stored in the intermediate memory is written to the cyclic memory
- Long-term memory (OK): only the OK results are written to the cyclic memory
- Long-term memory (NOK)" only the NOK results are written to the cyclic memory
- Statistics memory 1 / 2: writes the data of the intermediate memory to the statistics memory 1 or 2
- Display: shows the current data of the intermediate memory on the display of the press-in control system
- Print (all): all production data are put out at the X7 printer interface of the press-in control system
- Print (NOK): only the NOK results are put out at the X7 printer interface of the press-in control system
a) Production data
The data generated during production is called production data. The production data always refers to a joining process and is
available after the process has been completed.
Saving the production data:

The production data record is stored in the intermediate memory until it is overwritten by saving again. The production data
stored in the intermediate memory can be transmitted to the PC, the CF card or via the Profibus using the instruction 'Transmit'.
In the long-term memory production data records are permanently stored in form of a cyclic memory. Internal ring buffer for 500
measurements.
In the statistics memory the data required for statistic analysis is stored permanently. 2 statistics memories are available for
each sequence program.
Approximate structure of the data record:

Date, Time, Program number, Number of the joint step (=line number), Joining process, Measured max. force of joint step, Measured stroke of joint
step, Result of the joint step (in case of NOK with error bit).
b) Graphic recording - Graphic data

If graphic recording is requested, the measurements (force and stroke) are saved at a sampling interval (TAB) to be entered by
the user. Recording begins with the instruction "Start graphic". The measurements are recorded continuously over max. 10 joint
steps; i.e. the measurements are continuously stored in the graphics measurement memory with each new joint step. 10,000
measurements can be stored.

Last measurement, programme number, number of joint step (=line number), joining process, measures max. force of joint step, measured stroke of
joint step, threshold force from which stroke measurement is started (with relative stroke measurement), min. force for analysis, max. force for
analysis, min. stroke for analysis, max. stroke for analysis, result (error bit if NOK).
72
Exception: To use the instruction Jump OK / NOK, Station OK / NOK the data does not need to be stored first in the intermediate memory.

Operation
c) Statistic recording of the production data

The production data is statistically recorded and analysed. The production data can be added to the statistics memory (1 or 2)
with the instruction "Measurements".

Date of the last production data record, time of the last production data record, program number, number of joint step, number of measurements,
number of OK measurements, total of switch-off forces, total of squared deviation from mean value, min. value of the switch-off force, max. value of
the switch-off force, number of measurements <MIN, number of measurements >MAX, target value of joint step F-MIN, target value of joint steps F-
MAX, absolute and relative frequency distribution of the switch-off force in 12 classes, total of strokes, total of squared deviation from mean value,
min. value stroke, max. value stroke, number of measurements <MIN, number of measurements >MAX, target values of joint step S-MIN, target
values of joint step S-MAX, absolute and relative frequency distribution of strokes in 12 classes.
11.9.4.6 Jump
>> Instruction-No. 05
The basic function of the instruction "Jump" is a program jump to line X. Determine via the selection window - which opens when
entering the instruction - which condition the jump function must meet.
Jump …
Jump if jointing procedure was OK

Jump if jointing procedure was NOK Use the arrow keys <> / <> to select
Jump if input X = 0 and confirm with <RET>.
Jump if input X = 1
Jump if variable …
Jump always
Jump if station was OK
Jump if station was NOK
Jump if joining process was OK

First enter how often to jump when the result is OK. Next, the program sequence is shown in a selection window. Select the jump
target with the arrow keys.
Jump …

002 Empty travel till S = 110.00 mm (>>) Use the arrow keys <> / <> to select
003 Travel till F = 2.50 kN (>>)
and confirm with <RET>.
005 Measurements to long-term memory
006 Measurements to statistics memory
008 Graphic stop
009 => Jump <=
010 End
Jump if joining process was NOK

First enter how often to jump when the result is NOK. Next, the program sequence is shown in a selection window. Select the
jump target with the arrow keys.
Jump if input X = 0
First enter the number of the input which shall be monitored for this jump instruction. Then select the program line to which to
jump if no signal (=0) is applied at the defined input.
Jump if input X = 1
First enter the number of the input which shall be monitored for this jump instruction. Then select the program line to which to
jump if a signal (=1) is applied at the defined input.
> Chapter 12.3 Test mode / simulation of the inputs and outputs at the press-in control system, Seite 204

Operation
Jump if variable (jump if variable is smaller, equal or greater than the reference value)
First enter the number of the variable (1-16) which shall be used for this jump instruction.
After this select the condition "< (smaller), = (equal), > (greater)" that shall be used for the comparison with the comparative value
(0-255) subsequently to be entered.
Finally, determine the program line to which to jump if the defined variable is smaller, equal or greater than the comparative value.
> Chapter 11.9.4.13 Variable, Seite 175 (Anweisung)
Jump always
Enter how often the jump shall be performed. Next, the program sequence is shown in a selection window. Select the jump target
with the arrow keys.
Jump if station was OK

First enter the system bus ID of the station to be monitored. Then define how often to jump when the result at the defined station
is OK. Finally, the program sequence is shown in a selection window. Select the jump target with the arrow keys.
Jump if station was NOK

First enter the system bus ID of the station to be monitored. Then define how often to jump when the result at the defined station
is NOK.
Finally, the program sequence is shown in a selection window. Select the jump target with the arrow keys.
11.9.4.7 Output
The instruction "Output" is used to set a free output (1... 255) (output = on) and to reset it (output = off).
Switch output on or off

Enter the output number at the keypad
of the press-in control system.
Output no. (1 … 255) = 5
Enter output no …
Please verify whether the output you select it is available!
Switch output on or out

The selected output is switched on or off
with the function keys.
Output O 005 = 5On
Close the input with the RET key …
> Chapter 12.3 Test mode / simulation of the inputs and outputs at the press-in control system, Seite 204
11.9.4.8 End
The "End" instruction determines the end of the program. Each program must be ended with this instruction. "End" is always
followed by an OK/NOK analysis.
Several end instructions can also be entered within a program sequence, for example, use the instruction "Jump if joining process
was NOK" to jump to a program line outside the actual joining sequence (after "End"), enter the instruction "Empty travel" there
and close once more with "End".
The instruction "End" is already inserted into the sequence when creating a new program.

Operation
11.9.4.9 Wait
With the program instruction "Wait" the press-in control system only continues with the program sequence when the defined event
has occurred. The following options are available.
Wait for an event …
Wait till input = 0

Wait till input = 1 Use the arrow keys <> / <> to select
Wait till time has elapsed and confirm with <RET>..
Wait till nut removed
Wait till position is reached (DCM)
Wait till position is reached (Posi)
Wait for station
Wait till restart
Wait till data release
Wait till input = 0

The program sequence is continued when at the set input (0 ... 255) no signal is applied.
Wait till input = 1

The program sequence is continued when at the set input (0 ... 255) a signal is applied.
Please check before the entry whether the input is available.
Wait till time has elapsed

The program sequence is continued when the set duration (0 ... 60000 ms) has elapsed.
Wait till nut removed

The program sequence is continued when the set nut (No. 1 ... 32) has been removed from the ToolControl. Using this setting
requires that a ToolControl (DSM tool change box) is connected with the press-in control system via the system bus.
Wait till position is reached (DCM)

The program sequence is continued when the set position (0.0 ... 999.9 mm) operated with the DCM Extension (ID 73 DCM 44 ...
47), DSM hole puncture adjustment, DSM Horizontal / Vertical axis, has been reached.
Using this setting requires the connection of a DCM Extension to the press-in control system via systembus. Furthermore, one of
the two mechanical components DSM hole puncture adjustment or DSM horizontal/vertical axis is required, which is connected
with the DCM Extension.
Wait till position is reached (Posi)

The program sequence 74 is continued when the position (1 ... 200) set at the position control electronics PosiControl (ID 75 40 ...
43) is reached.
Wait till position is reached

Entry with number keys;
confirm with <RET>.
ID PosiControl (40 … 43) = 40
Position no. (1 … 200) = 50
Please enter position no.
73
The ID of the DCM Extension is entered in the field "Base" on the cover foil.
74
After "Wait" the program should be continued with the instruction "Turn in/Turn out".
75
The ID of the PosiControl is entered in the constants menu "SETC" on page 2 (selection with arrow ) in the parameter "Systembus" (confirm with
"RET") of the position control electronics.

Operation
Finally, choose a condition for the start of the press-in unit or for continuing in the program sequence after the position was
reached.
Select continuation condition Use the arrow keys <> / <> to select
Always
PG start 01
Input 01
Press Up / Down key to select  RET key
Always
The press-in unit starts or switching to the next program line occurs after the position was reached.
PG start
No function in connection with joining technology.
Input
Select an available input in the selection screen. The press-in unit starts or switching to the next program line occurs after the
position was reached and a 24 V signal is applied to the selected input.
Using the setting "Wait till position reached" requires the connection of a PosiControl to the press-in control system
via system bus. Furthermore, a sensor unit for position monitoring, connected with the position control electronics, is
required.
Wait for station

The program sequence is continued when the press-in control system set via the system bus ID (0 ... 15), is ready. The function
is only ensured if the instruction "Wait for station" is integrated in the programme sequence of all participating press-in control
systems. The press-in control systems must be connected with each other via the system bus.
Example, connection of 3 press-in control systems:
Station 0001 (ID= 5) Station 0002 (ID= 6) Station 0003 (ID= 7)

001 Graphic start TAB = 2 ms 001 Graphic start TAB = 2 ms 001 Graphic start TAB = 2 ms
002 Travel to S = 60.0 mm (>>) 002 Travel to S = 60.0 mm (>>) 002 Travel to S = 60.0 mm (>>)
003 Measurements to intermediate memory 003 Measurements to intermediate memory 003 Measurements to intermediate memory
004 Measurements display 004 Measurements display 004 Measurements display
005 Wait for station = 6 005 Wait for station = 5 005 Wait for station = 5
006 Wait for station = 7 006 Wait for station = 7 006 Wait for station = 6
007 Travel to F = 4 kN (>>) 007 Travel to F = 4 kN (>>) 007 Travel to F = 4 kN (>>)
008 ... 008 ... 008 ...
Wait for restart

The program sequence is continued when the start signal is applied again.
This means, the sequence is processed up to the instruction "Wait for restart", then the message "Wait for restart (Start=0)"
appears on the display of the press-in control system. The start signal can only be removed from this time.
Please note that if the start signal is removed too early a start termination takes place (stop reason "SG: Start
aborted").
The program sequence is continued with the next instruction when the start signal is applied again.
Wait for parameter

The programme sequence is continued if the parameters were sent by the PLC via Profibus. The instruction "Wait for parameter"
must immediately precede the instruction "Travel" in the program sequence. The parameters sent are entered in the joining
process and deleted again after the step is completed.
> Chapter 10.9.6 Parameterisation via Profibus (option), Page 120
The function of the instruction "Wait for parameter" is only ensured in connection with the Profibus module and the
extension "Parameterisation via Profibus".

Operation
11.9.4.10 Graphic
The instruction "Graphic" can be used to record measurements for the graphic output. The following options are available for this
purpose, which controls the graphic recording in conjunction with the instructions "Graphic".
A joint step can only be shown on the display if it has first been recorded with the instruction "Graphic start" and "Graphic stop".
Graphic recording is also relevant for the instruction "Transmit graphic data to ...".
Measurement recording for graphic

Press the arrow keys <> / <> to select
Graphic start
Graphic stop
Graphic continue
Press UP and DOWN key to select ...
Graphic start
Graphic recording is started. To determine the resolution of the graphic a scan time interval (tab) must be entered for graphic
recording in ms (1 ... 1000 ms) after selecting the instruction "Graphic start".
Measurement recording for graphic
Please enter the scan time interval for

graphic recording …
tab (1 … 1000 ms) = 2
Enter scan time interval …
Graphic stop
Graphic recording is stopped or interrupted. The instruction "Graphics stop" always closes graphic recording.
Example

002 Travel to S = 20.50 mm (>>)
005 Graphic stop
006 Transmit graphic data to PC
007 End
Graphic continue
Graphic recording previous interrupted with "Graphic stop" is continued.
11.9.4.11 UP start
Subroutines can be started with the instruction UP Start. In these subroutines you can store frequently recurring function
sequences. Remember that the direct start of a subroutine is not possible. The subroutines can be started only from other
programs (PG and U-PG). The numbers 129 – 255 are reserved for the subroutines (U-PG) and the numbers 1 – 127 for the
directly starting programs (PG).
Programming after subroutines also takes place in program administration.
The following status is available for the instruction integrated into the program sequence:
UP-??? The subroutine "No." has not yet been entered.

UP Start UP = No. The subroutine "No." was entered but no comment was entered yet
(description of the U-PG).
Comment UP = No. The subroutine "No." was entered and a comment was provided for
it (the description is displayed in the sequence).

Operation
11.9.4.12 UP End
The instruction "UP End" replaces the "End" instruction in a subroutine. The "UP End" instruction determines the end of the
program. Each subroutine must be closed with "UP End". When creating a new subroutine, the instruction "UP End" is already
included in the sequence.
When copying a program (PG) into a subroutine (U-PG), the "End instruction" is automatically replaced with "UP end".
11.9.4.13 Variable
With the program instruction "Variable" up to 16 variables with a value range from 0 to 255 can be managed.
Set the value of a variable …
V=X
V=V+X
V=V-X
V=X Enter variable no. (1...16) and then define the value (0...255) of the variable.
V=V+X Enter variable no. (1...16) and then enter the value (0...255) by which the variable is increased.
V 01 = V01 + 10
Enter number (0 … 255) …
V=V-X Enter variable no. (1...16) and then enter the value (0...255) by which the variable is reduced.
V 01 = V01 - 15
Enter number (0 … 255) …
Program example for using the instruction "Variable":
001 Variable V01 = 2

002 Travel to F = 4.50 kN (>>)
005 Jump if Result = OK  010
006 Empty travel till S = 20.00 mm (>>)
007 Variable V01 = V01 -1
008 Jump if V01 < 001
009 Jump always 2x  002
010 End
> Chapter 11.9.4.6 Jump, Variable, Page 171 (Instruction)

Operation
11.9.4.14 Blank line

The program instruction "Blank line" places a wildcard into the program sequence. This instruction has no function.
11.9.4.15 Transmit
A data transfer can be performed with the instruction "Transmit". The following options are available.
Transmitting of production data
Transmit Measurements to PC
Transmit Measurements to CF
Transmit Measurements to PB
Transmit Graphic data to PC
Transmit Graphic data to CF
Press UP and DOWN key to select …
Transmit measurements to PC
With this instruction the production data placed last in the intermediate memory is transmitted to the PC.
> Chapter 11.9.4.5 Measurements, Page 169 (Instruction)
Transmit graphic data to PC

With instruction the graphic data recorded with graphic start / graphic stop is transmitted to the PC. No separate transmission of
the measurements must take place.
> Chapter 11.9.4.10 Graphic, Page 174 (Instruction)
Transmit measurements to CF
With this instruction the production data placed last in the intermediate memory is transmitted to the mobile long-term memory
(CF card).
> Chapter 4.3 Interfaces and CompactFlash slot on the control modul, Page 26
Transmit graphic data to CF

With instruction the graphic data recorded with graphic start / graphic stop is transmitted to the CF card. No separate transmission
of the measurements must take place.
> Chapter 15.3 Software tool: CFG Data Converter, Page 230
Transmit measurements to PB
With this instruction the production data placed last in the intermediate memory is transmitted to the PB.
11.9.4.16 Offset adjustment

The instruction "Offset adjustment" perform an automatic zero-point adjustment of the measuring amplifier. The result of this
adjustment is the actual force offset value of the measuring amplifier. This will be compared with the calculated value "Offset
target" (max. high and low limit) deposited in the control module. "Offset target" depends in percent to the calibration value.
The actual measured offset value shall not exceed or drop below the "Offset target"; otherwise, an error message is issued.
After the adjustment the system returns to the normal measuring operation mode automatically.

Operation
11.9.5 Programming example

The following example serves as guide for programming the press-in control system MultiPro FL.
In this programme example the shutdown force is known. It is recommended to first create a setup programme with the joining
process "Travel on force" according to the known specifications.
The parameterisation of the joining process should thereby be performed with generously open limits. The graphic data is
recorded for future optimisation of the programme sequence and then transferred to the PC.
Line Instruction Description

001 Graphic start TAB = 2 ms - Start of the graphic recording, recording interval 2 ms
002 Travel to F = 5.00 kN (>>) - Drive-out until switch-off force reached
Switch-off force = 5.00 kN - Force that ends the joining process
Force min = 4.00 kN - The force for the OK assessment must be ≥
Force max = 6.00 kN - The force for the OK assessment must be ≤
Block force max = 7.00 kN - NOK cancellation, if force > block force max.
Threshold force = 0.0 kN - Absolute stroke measurement, therefore no threshold force required
Plunger velocity = 15 mm/s - Max. speed
Joining parameter - Travel to force -
Stroke measurement relative = Off - Absolute stroke measurement

Direction of travel = drive-out - Stroke direction of the joining process
Stroke min = 10.00 mm - Position after switch-off for the OK assessment must be ≥
Stroke max = 200.00 mm - Position after switch-off for the OK assessment must be ≤
Block dimension max = 200.00 mm - NOK cancellation, if stroke > block dimension max.
Review stroke = 0.00 mm - Review path disabled
Envelope number = 00. = Off - Envelope monitoring disabled
Envelope switching = Off - Envelope monitoring disabled
Joining time = 20000 ms - Max. permissible time for this joint step
Overrun time = 100 ms - Time how long measuring continues after switch-off
Ramp time = 50 ms - Duration to reaching the stamp velocity
Hold time = 0 - Hold time disabled
Current = 100% - Percentage determination of the max. current for the QMP
Force progression in OK window = Off - Force progression in OK window disabled
003 Measurements to intermediate memory - Save measured values for further processing
004 Measurements to long-term memory - Store saved measured values in internal ring memory
005 Display measurements - Show saved measured values on the display
006 Graphic stop - Stop the graphics recording
007 Transmit graphics to PC - Transmit the recorded graphics data to the PC
008 Normal position travel - Travel to normal position (not absolutely necessary)
009 End - Programme end
> Chapter 11.9.3 Enter / edit program, Page 155

> Chapter 11.9.4 Program instructions, Page 157
> Chapter 11.9.4.4 Joining parameters (Instruction Travel / Empty travel), Page 158
The graphics of the joint step is recorded with the setup program. The assessment is done with the help of the MultiControl4
software.

Operation
11.9.5.1 Optimisation of the program sequence
a) Define joining stages
Define and program (edit) the individual joining stages using the recorded graphics.
b) Optimised program sequence (standard program)
Line Instruction Description

001 Empty travel to S = 30.00 mm (>>) - Rapid stroke, rapid drive-out until switch-off stroke is reached
Switch-off stroke = 30.00 mm - Position that ends the joining process
Joining parameters

Ramp time = 50 ms - Duration to reaching the plunger velocity
Current = 80 % - Percentage determination of the max. current for the press-in unit
Delay = 500 mm/s² - Value how much the plunger is slowed down
003 Display measurements - Show saved measured values on the display
004 Jump if Res = NOK  016 - Programme jump at NOK result after line 016
005 Graphic start TAB = 5 ms - Start of the graphic recording, recording interval 5 ms
006 Travel to F = 1.20 kN (>>) - Place on workpiece, drive-out until switch-off force is reached
Joining parameters

Review stroke = 0.00 mm - Review stroke disabled

Operation
Continuation Optimised program sequence
008 Measurements Display - Show saved measured values on the display
009 Jump if Res = NOK  016 - Programme jump at NOK result after line 016
010 Travel to F = 5.00 kN (>>) - Press-in, drive-out until switch-off force is reached
Path measurement relative = Off - Absolute stroke measurement
Joining parameters
Review stroke = 0.00 mm - Review stroke disabled
Current = 100% - Percentage determination of the max. current for the press-in unit
Measurements to long-term
012 - Store saved measured values in internal ring memory
memory
013 Measurements to statistics memory 1 - Store saved measured values in statistics memory 1
014 Measurements Display - Show saved measured values on the display
015 Graphic stop - Stop the graphics recording
016 Empty travel to S = 25.00 mm (<<) - Driving-out the plunger without OK/NOK assessment
Switch-off stroke = 25.00 mm - Position that ends the joining process
Joining parameters

Direction of travel = drive-in - Stroke direction of the joining process
Delay = 500 mm/s² - Value how much the plunger is slowed down
017 Normal position travel - Travel to normal position (not absolutely necessary)
018 Transfer measurements PB - Transfer saved measurements via Profibus
019 End - Program end
The illustration on the next page shows the programming example (standard program) schematically.

Operation
c) Schema of the optimised program sequence
Press-in unit
0 mm Zero point
BE: Break fuse switch "driven-in"
10 mm EE: End range retracted
20 mm Normal position
30 mm Rapid stroke (1. Stage)
45 mm Place on workpiece (2. Stage)
90 mm Press-in (3. Stage)
Stroke
[mm]

Operation
11.9.6 Copy program
Menu navigation
Production screen  <Settings>  <Programs>  <Copy>
Select the program (source) to be copied with the arrow keys <> / <> in the main menu of program administration and press
the function key <copy>.
Programmverwaltung
RDY PGF IO NIO HA GSE PC- - - PB C: A: Programm: 3
PG 001: Setup program
PG 002: Anzug Stahlfelge
PG 003: Lösen Progr. 4 in memory!
PG 004: Bremssattel M10 Input window
PG 005: Enter M8
Bremssattel new program no.
…
Copy program
U-PG 129: Ausdrehen bei NIO
Program no: 0
Bitte Programm-Nr. eingeben …
Next, enter the program number for the new program and confirm with <RET>. The copy process is started and the new program
is added to the program list. If a program with the same number already exists, a verification prompt asks whether the program
shall be overwritten.
Verify before selecting the programme number which inputs can be used.
Please note that also with the "Copy" function the program numbers > 128 are assigned to the subroutines.
Subroutines cannot be started directly!
Press <ESC> to end the "Copy program" function prematurely. The input window closes.
You can delete an incorrectly entered program number again with the function key <F6 ().
11.9.7 Delete program
Menu navigation
Production screen  <Settings>  <Programs>  <Del.>
Select the program to be deleted in the main menu of program administration with the arrow keys <> / <> and press the
function key <Del.>.
RDY PGF IO NIO HA GSE PC v - - PB C: A: Programm: xxx
PG 001: Setup programme
PG 002: Caulk shaft
PG 003: Press-in pins
PG 004: Drive-out
U-PG 006: Drive-out Yes
The program is
deleted.
No
Back to program
administration.
Do you really want to delete program 004?
Yes No

Operation
11.9.8 Test program
Menu navigation
Production screen  <Settings>  <Programs>  <Test>
The menu item "Test program" of program administration allows you verifying the program sequence entered in detail. This can
be done in jogging mode, i.e. observing each individual instruction, or in the "Run mode". The run mode has the advantage that
the program sequence can be tested already before a connection is made to a higher level control system. You can also use the
function "Test program" for error analysis. Call the program test after an error message appears to obtain an accurate overview.
This overview may include the error flags set if several errors occur.
Select the program to be tested in the program administration with the arrow keys <> / <> and press the function key <Test>.
The following information appears on the display:
Test program
Attention, the motor may start to run in the

following mode
when pressing a key!
Make sure nobody is in the danger area!
Any key to continue ...
Option Start Step I Run Hold
Make sure that the danger area is adequately secured. In test operation the "Start" does not occur externally but directly with the
function key <Start>. In case of disregard a possibly harmful situation may occur for the health of persons and/or property damages.
The function screen "Test program" opens after pressing any key (Page183).

Operation
Function screen: Test program
Test program
RDY PGF OK NOK HA GSE PC v - - PB C: A: Err BRUSI
F = 0003.13 kN PG: OK 1
NOK S = 160.12 mm SG: Break fuse
PDA: F = 0003.13 kN (0000.00 / 0000.00) S = 160.12 mm (0000.00 / 0000.00) 2

PDZ: F = 0003.13 kN (0000.00 / 0000.00) S = 160.12 mm (0000.00 / 0000.00)
On: 011 002 003 007 F< F> FM FB EE BR TP SA AN NIO 3

8
Off: 001 002 003 008 S< S> SM SB EA EF IM EL ES ST
9 VAR: V001=0 V002=0 V003=0 V004=0
PG=1 waits for START 4
001 Output A018 = On
5
003 Output A018 = Off
004 Graphic start Tab = 1 ms
Wait for start ... 6
Option Start Step I Run Hold 7
1: Minimised presentation of the production screen (result)
2: PDA, Process Data Actual (F = Force, S = Path)

PDZ, Process Data Buffer storage (F = Force, S = Path)
3: Error flags, the error flags set are shown inverted.

F< Force too small S< Stroke too small
F> Force too large S> Stroke too large
FM Stop reason FMax SM Stop reason SMax
FB Error, travel on block SB Error, travel on block
EE Error, limit switch driven-in EA Error, limit switch driven-out
BR Error, break fuse EF Error, OK window monitoring
TP Joining time (pressing time) exceeded IM I Max reached (max. current)
SA Start aborted EL Error basic module
AN No start of press-in unit ES Irregular stop
NOK Not okay, NOK flag ST Error system test
4: Status line
5: Program sequence, the current program line is highlighted in black.
6: Notes line
7: Function key assignment "Test program"

<Option> Inputs /Outputs, set variables
<Start> Program starts (notes line "Program running ..."); no instruction was carried out yet. Now press the F-
key <Step I> or <Run>. After processing the instruction "End", the function <Stop> is displayed in the
function button field. After pressing the F-key <Stop>, the program sequence is closed.
<Step I> After triggering the Start with the function key with the same name, you can run the highlighted
instruction in the program sequence (7) with the F-key <Step I>. After this the next instruction in the
sequence is automatically highlighted. To continue processing the sequence in jogging mode, you must
confirm each selected instruction with the <Step I> key until the last instruction "End" was run. Now
close the program sequence with the F-key <Stop>
<Run> After triggering Start using the function key with the same name, you can start the program sequences
with the F-key <Run>. After processing the "End" instruction, close the program sequence with the F-
key <Stop>.
<Hold> The program sequence started with <Run> can be stopped with the <Hold> F-key.
8 / 9: Max. 4 inputs (=IN), max. 4 outputs (=OFF) and max. 4 variables can be displayed on the screen for observation. If a
high-level is applied to the input / output, is shown inverted.
The value of the respective variable is displayed. The selection of the inputs, outputs and variables to be observed is
made with the function key <Option>.

Operation
The table shows the inputs, outputs and variables which are currently observed; you can set them as follows with the function
keys.
Settings for the program test

Inputs Outputs Variable
I1=011 O1=001 V1=001

I2=002 O2=002 V2=002
I3=003 O3=003 V3=003
I4=007 O4=008 V4=004
Input for `next` = 000
Press F keys to change …
Input Output Var. Input w
<Input> Define inputs for observation.
<Output> Define outputs for observation.
<Var.> Define variables for observation.
<Output w> Define input for "next"; allows executing the next instruction in jogging mode via an external pushbutton.
Exit the menu item "Test program" with the <ESC> key.

Operation
11.10 Operation: Accessing system information
Menu navigation
Production screen  <System info>
The menu item displays the device information about the press-in control system MultiPro FL.
System information
S t a n d a r d so f t wa r e 2 G (3200)
S t a t i o n n am e : D S M J oi n i n g st a t i o n
Programs : 5 / 255
Program lines : 65 / 3000
N u m b e r of se q u e n c e s : 314
N u m b e r of se q u e n c e s O K : 310
N u m b e r of se q u e n c e s N O K : 4 Function screen
Press and Hold : Off
P a r a m et e r i sa t i o n P B : Off
C y c l i c a l v al u e s P B : Off System information
S o f t wa r e v e r si o n C P U : 3200 Pro-E V1.18
D a t e of bi r t h : 21/04/2010
S o f t wa r e u p d a t e d a t e : xx.xx .xxxx
Hardware type CPU : CPU 4.5.4
S e r i a l n um b e r d ev i c e : 06V000127
S e r i a l n um b e r C P U : 05V000539
Press-in unit Printing Measurements
a) Station name
Name of station, input possible only with PC software
b) Programs
Number of the programmes entered as well as number of the max. programmes available.
c) Program lines
Number of the instruction lines (of all programmes) already programmed as well as number of the max. instruction lines available.
d) Number of sequences
Total number of joining operations (cannot be reset)
e) Number of sequences OK
OK counter, number of the joining procedures assessed as "Okay". The OK counter can be reset to zero directly on the device or
with the PC software.
> Chapter 13.2.2.4 Delete OK/NOK counter, Page 207
f) Number of sequences NOK

NOK counter, number of the joining procedures assessed as "Not okay". The NOK counter can be reset to zero directly on the
device or with the PC software.
> Chapter 13.2.2.4 Delete OK/NOK counter, Page 207
g) Software version CPU

3200 Pro-E V1.18 (example), number and version of the integrated firmware
h) Device serial number

Serial number of the control module (MultiPro).
i) CPU serial number

Serial number of the printed circuit board (CPU).

Operation
11.11 Operation: Display tool data memory
Menu navigation
Production screen  <System info>  <Press-in unit>
The press-in units of the QMP and SMP series are equipped with a digital parameter memory. The press-in unit is identified when
connected to the control system and the tool data stored is read. If auto-parameterisation (=default) is activated, the unit of force,
calibration value, max. feed, rotational direction reversal as well as the end position "Driven-in" and "Driven-out" are entered
automatically in the configuration of the press-in unit. These parameters can be edited when auto-parameterisation is deactivated
but they cannot be overwritten in the parameter memory of the press-in unit. The settings parameter Correction Factor Force and
Correction Factor Stroke are preset at factory (default value = 1.000). In case of changes, the modified value is also stored in the
parameter memory of the press-in unit. Regardless of the "Auto-parameterisation" setting, the following information is transmitted
to the press-in control system or synchronised and the current status is displayed in the menu "System info / Press-in unit data".
Data of the press-in unit

RDY PGF OK NOK HA GSE PC v - - PB C: A: Program: 1
Re ce i ver t yp e : KMDi 2 5
Ca li b ra ti o n val ue : 2 5 . 0 0 kN
L a st Cali b r a ti on : 0 6 / 0 4 / 2 01 0
Se r i al nu mb e r KMD' s : 0 4 S8 9 8 1 Function screen
Se r i al no . p re ss -i n u ni t : 3 0 R0 0 R6
L o ck L T - Mo d e 1 : 0 System information /
UR- T yp e : UR6 0 0 _ 1
En d p o sit io n i n . : Data of the press-in unit
En d p o sit io n o u t . : 2 1 1 , 0 0 mm
O f f se t ze ro p oi n t SO :
T o t al co u nt e r :
I n t e r val co un t e r :
L o a d co u nt e r :
O ve rl o a d cou n t e r :
O ve rl o a d da t e / ti me :
Se r vi ce fla g : 0
ESC key for back ...

a) Total counter
The total counter provides information about the number of joining procedures carried out with the connected press-in unit. The
total counter increases with each joint step and is stored in the digital parameter memory (ECK) of the press-in unit. The total
counter reading cannot be deleted.
b) Interval counter
Just as the total counter the interval counter increases with each joint step and is stored in the digital parameter memory (ECK) of
the press-in unit. Contrary to the total counter, the interval counter can be reset to zero by the service personnel. This has the
following advantage: for example, to check a subsequently installed component in regard to the number of joining procedures or
to record the joining procedures since the last calibration.
c) Load counter
The load counter is calculated after each joint step in the control system MultiPro FL and the reading, depending on the load
percentage (approx. every 100 cycles), is increased. All counters are stored in the digital parameter memory of the press-in unit
only after the load counter is counted up by one increment. The load counter is used to check when the press-in unit should be
overhauled or replaced as a precaution. The load counter can be reset to zero by the service personnel.
d) Overload counter
The overload counter is increased when the measurement rises above 120% of the calibration value. In the event of an overload,
the counter is stored immediately in the parameter memory of the press-in unit as well as in the memory of the receiver. The
overload counter cannot be deleted.
e) Overload date / time

In case of overload the current data and time (timestamp) are saved.
f) Service flag
A defined value can be entered in the configuration window of the press-in unit in the "Service cycle" parameter; this value
determines when maintenance should be performed. A service flag is set when the load counter rises above his value.
Status: Service flag = 0 no service Service flag = 1 service required
The status of the service flags is transmitted to all interfaces and is displayed (display, measurements, graphic data, Profibus:
Byte 5 Bit 0).
> Chapter 11.8.13 Service cycle, Page 152

Operation
11.12 Operation: Display measurements
Menu navigation
Production screen  <System info>  <Measurements>
Please press function key …
Statistics Measurements PG protocol
Select the measurements you want to analyse on the display of the press-in control system with the corresponding function keys.
Alternatively, you can also record and analyse the data with the MultiControl4 software.
11.12.1 Statistics
After pressing the function key <Statistics>, you will be prompted to enter the program number of which you want to view the
statistics analysis.
Please note that measuring results are only included in the statistics calculation when the instruction "Measurements
to statistics memory" was included in the program sequence.
> Chapter 11.9.4.5 Measurements (Instruction), Page 169
Statistics Program 5 / 1
RDY PGF OK NOK HA GSE PC v - - PB C: A: Program: 5 Statistics of OK analysis,
Measurements memory 1: 74 OK: 62
machine and process capability, mean
Set point F (kN) S (mm) value, standard deviation
Maximum 22.00 173.00
Minimum 19.00 165.00
Assessment F (kN) S (mm)
Arith. Mean valuet 20.15 168.48
Standard deviation 0.30 1.00
Miean value + 4 SI 21.34 172.48
Mean value - 4 SI 18.97 164.48 The numeric keys <1> and <2> are used
Maximum value 20.39 168.91
Minimum value 10.14 153.31
to toggle between the statistics memories.
Spread 10.25 15.60
Other characteristic values F(-) S(-)
Machine capability (Cmk) 1.29 1.16
Measurements > Max 0 0
Measurements < Min 36 0
Key1 = Memory1, Key2 = Memory2
Delete statistics Graphics display
Select function with F-keys.

A verification prompt appears when deleting the statistics.
Statistics Program 5 / 1
Frequency distribution of the "Torque".

Switching to angle with F-key.
Key1 = Memory1, Key2 = Memory2
Force spread Stroke spread

Operation
11.12.2 Measurements
The analysis screen "Long-term memory" displays the production data recorded with the instruction "Measurement to long-term
memory". Press the arrow keys <> / <> to switch between the individual screen pages.
Long-term memory (Page 1 / 29)

SeqNo Date time PG PNo Type F (kN) S (mm) Res
1 24.01.2013 06:43:16 1 3 FF 18.86 155.27 OK
2 24.01.2013 06:43:13 1 3 FF 18.86 155.14 OK
3 24.01.2013 06:43:10 1 3 FF 18.86 155.16 OK
4 24.01.2013 06:43:07 1 3 FF 18.88 155.34 OK
5 24.01.2013 06:43:04 1 3 FF 18.89 155.14 OK
6 24.01.2013 06:43:01 1 3 FF 18.91 155.14 OK
7 24.01.2013 06:42:58 1 3 FF 18.89 155.14
NOK
8 24.01.2013 06:42:55 1 3 FF 18.95 155.18 OK
9 24.01.2013 06:42:52 1 3 FF 18.96 155.84 OK
10 24.01.2013 06:42:49 1 3 FF 18.96 154.96 OK
11 24.01.2013 06:42:46 1 3 FF 16.36 155.05 OK
12 24.01.2013 06:42:43 1 3 FF 12.22 160.12 OK
13 24.01.2013 06:42:40 1 3 FF 12.15 161.83 OK
14 24.01.2013 06:41:49 1 3 FF 12.15 161.83 OK
15 24.01.2013 06:41:46 1 3 FF 12.15 161.83
NOK
16 24.01.2013 06:41:43 1 3 FF 12.16 161.92 OK
17 24.01.2013 06:41:40 1 3 FF 12.15 161.90 OK
18 24 01 2013 06:41:37 1 3 FF 12 14 161 79 OK
The production data is stored in a ring buffer (non-volatile data memory).
Seq. No. Sequential number

Date / time Date and time of the joining process
PG Program number
PNo. Number of the joining step (=line number of joining process)
Type Type of process
TS Travel on stroke
TF Travel on force
TI Travel on initiator
ETS Empty travel on stroke
F Force measurement in N / kN
S Stroke in mm
Res Assessment of the joining step OK (okay) or NOK (not okay)
11.12.3 PG protocol
The program sequence protocol shows the measured run time for each individual instruction. Furthermore, it shows the total
duration of the complete sequence as well as the joint process carried out last.
Program sequence protocol

SeqNo Program instruction: 10 t [ms]

0 Initialization 38
1 1 Output A011 = On 4
2 2 Wait till t = 1000 ms 1002
3 3 Output A011 = Off 5
4 4 Graphic start TAB = 1 ms 2
5 5 Travel to F = 20.00 kN (>>) 3477
6 6 Measurements to intermediate memory 2
7 7 Measurements in long-term memory 3
With longer program sequences the user
8 8 Measurements in statistic memory 2 5 can switch to the next screen with the
9 9 Display measurements 2
10 10 Graphic stop 2 arrow keys <> / <>.
11 11 Jump if Res = NOK > 13 2
12 12 Normal position travel 834
13 13 End 10
Total 5388
The analysis screen "PG Log" can be used as tool for cycle time optimisation.

Operation
11.13 Operation: Creating a screenshot
 Use the screenshot function to take a screenshot of the current display. Press the <-> key and the screenshot is saved as
BMP file on the CompactFlash card. The file is generated automatically according to ascending number (0 to max. 999).
The screenshots are available in the directory "SCREENSH" of the CompactFlash card as BMP files for further processing.
Display MultiPro FL
- Current display
Pres the <-> key.
Screenshot examples:

Error state detection, system verification
12 Error state detection, system verification
12.1 Error state detection

 The occurrence of an error is detected by the press-in control system and an error number as well as a description of the error
is shown on the display. For the error analysis, you should also observe the status of the integrated basic module.
12.1.1 Description of error

The message or a system error that has occurred is displayed in a so-called error window. The origin of the error as well as its
description are provided in plain text and help identify the error in detail.
Joining station 001

RDY PGF OK NOK HA GSE PC v - - PB C: A: Err Press
Error number
An error has occurred!
Error number: 152 123 002
Hex-coded error bits;

Programme sequence control
Additional display of error on the basic
Error power supply! module
Test LT. (EC=0002)
Press any key!
Program running ...
a) Error number
The error number displayed is composed as follows:

152 123 002
Origin
Description
Type (DSM internal)
The error description can be found on the subsequent pages. The current state is included as Excel file on the CD
enclosed with these operating instructions..
> Chapter 12.1.2 Error display „Origin“, Page 191

> Chapter 12.1.3 Error display “Description”, Page 191
b) Error bits
If an error occurs on the basic module (=power pack), the hex-coded error bits of the basic module are displayed in addition to the
error number.
Bit 0 fault Motor controller error message Bit 8 hss Position encoder fault (Hall sensor state =000 or 111)
Bit 1 is End stage defective Bit 9 par Parameter error
Bit 2 tmot Motor temperature too high Bit 10 pwr Converter fault (isi)
Bit 3 cb Sensor cable defective Bit 11 vd15 Driver voltage fault
Bit 4 uhs No sensor voltage Bit 12 pe Protective earth fault
Bit 5 up15 System voltage +15 V fault Bit 13 res Reserve
Bit 6 umot Motor voltage fault Bit 14 res Reserve
Bit 7 tsys System temperature fault Bit 15 res Reserve

12.1.2 Error display „Origin“
No. Origin (error description) No. Origin (error description)

101 I2C-Bus internal: EEPROM_Write() 143 CAN_SendRemoteFrame()
102 Textfield_Init() 144 I2C-Bus: Read request
103 AddUser() 145 Jump instruction()
104 AccessJournal_NewAccess() 146 Wait instruction()
105 AccessJournal_Show() 147 EMP_Direction_Set_and_wait()
106 I2C-Bus external: EEPROM_Read() 148 RES
107 I2C-Bus internal: EEPROM_Read() 149 Device monitoring
108 I2C-Bus external: EEPROM_Write() 150 QMP_Init()
109 I2C-Bus: IO_8Bit_Write() 151 Test_Press-inUnit()
110 I2C-Bus: IO_8Bit_Read() 152 Programme sequence control
111 I2C-Bus: IO_16Bit_Write() 153 Initialise force measuring amplifier
112 I2C-Bus: IO_16Bit_Read() 154 CAN_INI_REC()
113 I2C-Bus: Temp_Read() 155 Output_Set()
114 I2C-Bus: RTC_Init() 156 DateOfBirth_Load()
115 SetTime() 157 DeviceParameter_Load()
116 GetTime() 158 PressParameter_Load()
117 SetDate() 159 System busParameter_Load()
118 GetDate() 160 User_Load()
119 UserInList() 161 CalibrationData_Load()
120 Program_New() 162 QMP_NormalPositionTravel()
121 Program_ListEntry() 163 QMP_Travel_from_critical_Position()
122 ProgramsInList() 164 FS_Can_Receive_Measurements()
123 DSM_EditStringAt() 165 Set status output HA
124 InstructionsInList() 166 Systemtest_Minor()
125 Edit program() 167 IO Extension
126 LT_Init() 168 ProgramsSave()
127 F_2RegFact_Set() 169 SW98_C37_Send()
128 InputCheck() 170 ISR_Undefined_instruction()
129 Set status output OK 171 Data storage
130 Set status output NOK 172 System bus
131 Set status output READY 173 CF card A:
132 Set status output PG-READY 174 Joint unit settings
133 Set status output GSE 175 PB_TransmitError()
134 Instruction transmit() 176 OK_Handle()
135 Instruction press cancellation() 177 TCP Initialisation
136 List_Init() 178 Sequence control
137 InstructionLine_Add() 179 CF card C:
138 New_ParameterList() 180 Instruction measurements()
139 Program_Load() 181 Envelope monitoring
140 I2C_Set_Highspeed1() 182 DCM-Extension
141 Program_Copy() 183 Program abort motor current > Imax!
142 CAN0_Send() 184 Press overload
12.1.3 Error display “Description”
No. Description (error description)

101 Not sufficient working memory
102 I2C-Device doesn't react
103 Invalid instruction
104 Program end is open
105 Offset measurement amplifier couldn't be coordinated!
106 Data were read faultily . Check parameter!
107 Subroutine isn't available. Check programs!
108 CAL-Value outside limiting values. Check transducer!
109 System voltage U1 outside limiting values! Check device!
110 System voltage U2 outside limiting values. Check device!
112 Unknown error
113 Error was eliminated

Continuation Error display "Description"

115 External operating voltage outside limiting values!
116 Short circuit at an output!
117 Output current too high!
118 An incorrect output was mentioned
119 Voltage from outside
120 Return address isn't available!
121 Unknown press method!
122 I2C-Bus is busy.
123 Error Power Pack! Check it.
124 Message couldn't be sent!
125 No answer to remote request!
126 Plunger in BRUSI BA!
127 Press doesn't send any measurements!
128 Plunger in BRUSI BE!
129 TA couldn't be set!
130 Plunger by end switch!
131 Check value range switch off force!
132 Check value range switch off length (stroke)!
133 Check value range switch off input!
134 Check value range length (stroke) measurement relative!
135 Check value range threshold-force!
136 Threshold force > Force max!
137 Threshold force > Block force max!
138 Check value range min length (stroke)!
139 Min length (stroke) > max length (stroke)!
140 Min length (stroke) > max block length (stroke)!
141 Check value range max length (stroke)!
142 Switch off length (stroke) > max length (stroke)!
143 Max length (stroke) > max block length (stroke)!
144 Check value range review length (stroke)!
145 Check value range max block length (stroke)!
146 Check value range min force!
147 Min force > max force!
148 Min force > max block force!
149 Check value range max force!
150 Switch off force > max force!
151 Max force > max block force!
152 Check value range tightening time!
153 Check value range tracking time!
154 Check value range ramp time!
155 Check value range speed!
156 Check value range motor current!
157 Switch off length (stroke) < min length (stroke)!
158 Bridging of the break safeguarding couldn't be moved back!
159 Bridging of the break safeguarding couldn't be set!
160 Abort by timeout!
161 Abort by current limitation! Attitudes of the press examine!
162 CAL-Signal couldn't be set!
163 Force measuring couldn't be initialized!
164 Lenght measuring couldn't be initialized!
165 KMDi parameters couldn't be loaded!
166 ECK parameters couldn't be loaded!
167 LED couldn't be set!
168 Error when transmitting the graphic data!
169 Error when transmitting the measurements!
170 No profibus connection!
171 Timeout profibus handshake!
172 Parameter structure has changed! Check programs.

Continuation Error display "Description"

173 Status output cannot be used here!
174 Status input cannot be used here!
175 Switch off input = system input!
176 An incorrect input was mentioned
177 No Press found! Check cable set.
178 Press was declined! Call DSM-Service.
179 Press isn't adjusted! Call DSM-Service.
180 Recursiver call in subroutine! Recursion are not supported.
181 Too much subroutine started!
182 Test POSITION-SENSOR failed!
183 Direction couldn't be set!
184 Setting couldn't be set!
185 Check value range max block force!
186 Block length (stroke) must be supplied!
187 Block force must be supplied!
188 Force measuring reports faults!
189 Stamp stock-still
190 Not sufficient memory free! Please remove CF.
191 Systembus isn't ready! Also see test systembus
192 Systembus is overloaded ! (Current is to high)
193 Supply is smaller than 15 V !
194 No release!
195 Unknown format
196 Check parameter Starting Position!
197 Incorrect MAC-Address
198 Program does not exist
199 No external release
200 Longtime memory couldn't be saved!
201 Not integrated into the system!
202 No access possible!
203 File save, possible data loss!
204 File couldn't be open!
205 Number of instructions isn't correct!
206 Statistics couldn't be saved
207 Instruction isn't implemented in this firmware!
208 No DCM extension is available!
209 No answer of DCM extension!
210 PosiControl isn't ready!
211 No PosiControl is available!
212 At relativ movements an automatic direction isn't possible!
213 Error in envelope parameter!
214 Targetposition greater MAX!
215 Targetposition smaler MIN!
216 Motor doesn't run!
217 Unit of force is not set
218 CPU isn't connect!
219 CPU on SBUS isn't READY!
220 Check and if necessary increase parameter Imax or Ramp time
221 Min length (stroke) < max block length (stroke)!
222 Max length (stroke) < max block length (stroke)!
223
224 Parameter over PB are not plausible
225 Function isn't activated
226 Parameter error in press (KMDI)
227 Parameter error in press (ECK)
228 Check value range holding time!
229 Function res. to auxiliary mem. isn't activated
230 Envelope: Graphic must be switched on
231 Force too high

12.2 System verification, error analysis
 You can use the system test to test the press-in control system as well as the connected press-in unit for function and
accuracy. The system test also includes verifying the system bus parameters and the associated system bus devices. The
functionality of the test menu can also be used with error analysis.
Menu navigation
Production screen  <Settings>  <Settings/Test>  <Test>
The menu can only be selected if the MultiPro FL is operational, i.e. the start message is displayed or a system error
occurs. An external start is not possible in the test mode for safety reasons!
Please select a test …
Press-in unit System bus Control unit
Navigate to the individual tests with the function keys.
<Press-in unit> Test load cell, test motor

<System bus> System bus parameter (properties of the system bus), number of system bus devices connected
<Control unit> System voltages, power supply status, test printer, system temperature, test inputs/outputs, test
Profibus
12.2.1 System test: Press-in unit

The following screen opens after pressing the <Press-in unit> function key.
Press-in unit test

Position,
graphic display
Position,
value display
BE EE 28.30 mm EA BA
What do you want to test?
Load cell Motor
BE: Break fuse switch driven-in BA: Break fuse switch driven-out
EE: End range retracted EA: End range extended
The break fuses "BE" and "BA" protect the press-in unit against mechanical damage. The press-in unit shuts off automatically
when the plunger travels into the break fuse. When using customer monitoring of the interface X91 BRUSI (only with QMP), the
output signals (Pin 1 and Pin 6) are interrupted in addition.
The range limits "EE" and "EA", measures from the actual zero point, are entered on the type plate of the press-in unit as well as
in the menu "System info / Press-in unit". The press-in unit shuts off if one of these limits is exceeded, and the MultiPro FL press-
in control system shows the stopping reason "SG" as message "Limit switch retracted" or "Limit switch extended" on the display.
The inverted display of EE , EA , BE or BA indicates the limit that was exceeded.
> Schematic presentation of the working and monitoring areas, Page 195
> Service shearing element, Page 195

Working and monitoring areas
Execution
Press
S [mm]
ae
0 mm
Break fuse switch
BE
Switch-off via software See
EE
(sample value)
Working area
10 mm
Drive out
200 mm
Drive in
(sample value)
Sb
210 mm
(sample value)
EA
Switch-off via software Sea
BA
Break fuse switch
0 mm
S [mm]
aa
Execution
Pull
BE: Break fuse switch driven-in ae: Stop driven-in

EE: End range retracted EA: Stop driven-out
EA: End range driven-out See: Stroke (distance) from EE to BE
BA: Break fuse switch driven-out Sea: Stroke (distance) from EA to BA
Sb: Stroke from BE to BA
 Service break fuse
Menu navigation
Production screen  <Settings>  <Settings/Test>  <Service>
If no error message "Plunger in BRUSI (BA or BE)" is present on the press-in control system, the following message is shown
after pressing the <RET> key.
Break fuse is OK
ESC - key for back …
If following a shut-off the plunger is located in the position "Break fuse switch driven-out (BA)" or "Break fuse switch driven-in
(BE)", a corresponding error message is shown on the display of the control system. The plunger can be moved from the break
fuse by hand with this menu item.
> Chapter 13.2.1 Service Break fuse, Page 206

12.2.1.1 Load cell test

The data of the force transducer (load cell) integrated in the press-in unit is displayed after pressing the "Load cell" function key.
The functionality of the transducer (load cell) can be checked through manual action on the plunger.
Load cell test

Type KMDi 25
Calibration value target 25.00 kN An external start is not
Calibration value actual (1635) 25.06 kN possible in the test mode for
Offset target +- 3.76 kN safety reasons!
Offset actual -0.78 kN
Current force 0.13 kN
Max. force 0.16 kN
Current pos. 28.30 mm
BE EE 28.30 mm EA BA
Reset force
The measured force value is reset with the function key <Reset force>.
Type Designation of the built-in load cell.
Calibration value target The calibration value of the load cell entered in the Settings / Press-in Unit menu or read if
auto-parameterisation is active.
Calibration value actual The actually measured calibration value may deviate max. ± 5 % from the "Target calibration
value". An error message is displayed if exceeded. The calibration value is checked before each
joining process.
Offset target Comparison of the measuring amplifier. Stored, calculated value permanently stored in the
control module MultiPro interdependent on the calibration value.
Displayed as "± Value" in N / kN.
Offset actual Display of the actual force offset value of the measuring amplifier. At system start, an
automatic comparison of the zero point of the measuring amplifier takes place;
the offset value is the result of this comparison.
Current force The force currently acting on the plunger of the press-in unit. The function of the load cell
(transducer) can be verified through a manual force action on the stamp of the press-in unit.
Max. force The maximum force value occurred. It is reset with the function key "Reset force".
Current stroke The stroke travelled last; the current position of the plunger (graphic display).

12.2.1.2 Test motor
Please note that in the following operating mode the drive motor of the press-in unit can start by pressing a key. Make sure that no one
is about in the danger area and take care that the working area of the press-in unit (travel stroke of the plunger) is clear. Disregard may
cause a defect and possibly lead to a harmful situation for the health of persons!
This test allows for the free movement of the plunger in the "drive-out and drive-in direction" with display of the distance travelled.
This can be used, for example, for setup and measuring as well as monitoring the stroke and force measurement. The following
screen is displayed after pressing the function key <Motor>.
Test motor
RDY PGF OK NOK HA GSE PC v - - PB C: A: Program: GSF?
Motor state Off

Direction Drive-out
Target velocity 20 % An external start is not
Target motor current 50 % possible in the test mode for
Actual motor current 1 % safety reasons!
Current force 0.00 kN
Imax Yes
Fault LT No
BE EE 28,30 mm EA BA
I/A I+ I- V+ V- AF/EF
Motor state The drive motor of the press-in unit is switched on with the function key <E/A> (On/Off) and the
status of the motor is set to "On", i.e. the plunger of the press-in unit travels with the selected
settings as long as the key is pressed. The press-in unit stops when releasing the <On/Off>
button and the status of the motor "Off" is displayed.
Direction Travel direction of the plunger. The setting "Drive-out" / "Drive-in" is made with the function key
<AF/EF>.
Target velocity Percentage-based setting of the plunger velocity in 1% increments, starting with the max. rate of
feed of the press-in unit. The value is specified using the function keys <V +> / <V –>.
Target motor current Percentage-based setting of the maximum motor current in 1% increments (100% = max. motor
current). The value is specified with the function keys <I +> / <I –>.
Actual motor current Display of the actual motor current in percent. The press-in control system switches off the
press-in unit if the motor current is exceeded and signals "Imax (max. motor current)".
Current force Indicates the force occurring in N / kN when the plunger is moved.
Imax Current status display of "Imax (max. motor current)".

No = No fault; Yes = Imax. fault
The press-in control system switch-off if the drive motor of the press-in unit must delivery more
power than specified under "Target motor current".
Target velocity Current status display of an error on the basic module.

No = No fault; Yes = fault.

12.2.2 Test system bus
Menu navigation
After pressing the function key <systembus> you have the option in the menu "Test systembus" to test the systembus parameters
as well as the connected systembus devices.
What do you want to test?
System bus parameter System bus devices
12.2.2.1 System bus parameter
Test system bus parameter

Bit rate system bus 500 KBit/s

System bus ID Bh
System bus voltage ok
System bus release yes
System bus overload No
System bus supply internal
System bus error No
System bus status ok
TX_ERROR = 118 TX_MSG’ s = 00012

RX_ERROR = 000 RX_MSG’ s = 00013
MSG_LOST = 00000
Bit rate system bus Transmission rate for system bus interface.
System bus ID The address of the control unit within the system bus.
System bus voltage Monitoring the system bus voltage (24 V).
System bus release Indication whether the 24 V release signal is applied. A sequence program can
only be run when the signal is applied.
System bus overload Overload of the system bus. The system bus is overloaded when the max. current
exceeds 1 A and with external supply, 2 A.
System bus supply Display of 24 V supply for the Profibus. "Internal", supply by press-in control system
MultiPro FL (max. 1 A). "External" ,supply from external through interface X58 SBIN (max. 2 A).
System bus error Display whether an error is present at the system bus.
System bus status Shows the status under consideration of all system bus parameters.
12.2.2.2 System bus devices
Test system bus devices

RDY PGF OK NOK HA GSE PC v - - PB C: A: Program: xxx
Multisystem 0
IO Extension 2
PG switch 0
Multiterm 0
Posi 0
ToolControl 1
Radio clock 0
Minicontrol 0
The screen displays the possible system bus devices which can be connected to the MultiPro FL. The available system bus
devices may differ from firmware to firmware. The respective counter indicates how may units of a particular device are
connected on the system bus.

12.2.3 Test control unit
Menu navigation
The following screen opens after pressing the function key <Control unit>.
Test control unit

System voltages : Display
Power supply : Display status
Printer : Test
System temperature : Display
Inputs/Outputs : Test
Inputs/Outputs : Display status
Profibus : Test
12.2.3.1 Display system voltages

Display of system voltages U1, U2, U3 with specification of respective tolerance range. When falling below or exceeding a system
voltage, the press-in control system MultiPro indicates a system error.
System voltages
U1 ( 4.7 ... 5.3V) = 5.02

U2 ( 14.2 . . . 15.8V) = 15.01
U3 ( -14.2 . . . -15.8V) = -15.26
The menu item is relevant, amongst others, in case of an error.
12.2.3.2 Show power supply status

The menu "Test LT" contains several screen pages with information on the status of the integrated basic module (=power supply).
Press the arrow keys <> / <> to navigate to the individual screen pages.
a) Test LT: Specifications
Test LT: Specifications

Operating mode rpm
Rpm ramp On
Rotational direction Right
Self-start Off
Step value 65486 µs
Press up / down key to scroll.
Operating mode Factory-set operating mode of the basic module. Rotational speed (rpm control, standard), rotational
speed with brake (rpm control with active rpm reduction), current (current regulation), Step (step motor
operation).
Rpm ramp On: Gradual increase from "v" to specified feed (default setting).
Off: Rapid increase from "v" to specified feed.
> Chapter 11.8.6 Feed ramp, Page 151

Rotational direction Actual rotational direction of the motor (right or left).
Self-start Not relevant in press-in control system.

Default setting: Off
Step value Setting the step width (special process).
b) Test LT: General Information
Test LT: General Information

UR Serial no.: 24 Q 0055
UR Type: UR80_3
MSM Serial no.: 44 Q 0130
MSM Type: MSM-1.5
MSM Firmware: 1.50
MSM PLDware: 1.04
UR .... Data on converter used (internal hardware)

MSM ... Date on motor control module (internal hardware)
This menu item is relevant, amongst others, in case of service.
c) Test LT: Error Information
Test LT: Error Information

Error parameter No
Error converter (isi) No
Error driver voltage +15 V No
Error ground wire system No
Test LT: Error Information

Error motor controller No

Error hall sensor state No
Error hall sensor voltage No
Error system voltage +15 V No
Error motor voltage No
Error converter (is) No
Error motor temperature No
Error system temperature No
Error cable break No
To enable an exact diagnosis when the error message "Error power supply" is shown on the display of the press-in control
system MultiPro FL, the screen pages "Test PS: Error information" show the possible errors on the basic module (=servo
controller). This is visualised with the status display No (no error) / Yes (error).

d) Test LT: System Information
Test LT: System Information

Operating state operation

Switch-off via Imax No
Start No
Self-start No
Temperature motor 35 °C
Temperature system 30 °C
Voltage Hall sensor 08.99 V
Voltage system 14.98 V
Motor voltage ----- V
Operating state Status of basic module.

Operation: Basic module waits for internal start removal; error is cancelled, start (internal) still
applied to basic module.
Error: Error pending.
Switch-off Imax The maximum motor current defined in the joining parameters was exceeded, i.e. the
electronics switch-off the power supply to the press-in unit after the drive.
Start Start currently applied at the servo controller (monitoring of the control line).
Yes: Start applied. No: Start not applied.
Self-start Not relevant with press-in control system. No: No self-start (default setting).
Temperature motor Current motor temperature.
Temperature system Current temperature of the press-in control system.
Voltage Hall sensor Supply voltage of the motor position sensor.
Voltage system Current system voltage.
Motor voltage Supply voltage of motor, for basic modules of type series "DS-S", the measured value is
indicated in volt; the measured value is not displayed with the other types (dashes).
When one or several of these values have been exceeded, the press-in control system displays "Error power supply (Err power
supply)".
> Chapter 12.1 Error state detection, Page 190
12.2.3.3 Test printer

Ensure the connection to a serial printer via the X7 interface. Press the function key to start printing the test page.
Printer test
Test page is printed.

Print test page
The following information should appear on the printout:

Printer test MultiPro 3200 Pro-E (=No. of firmware version)

12.2.3.4 Display system temperature

The current system temperature as well as he highest and lowest values measured are shown on the display together with the
time of measuring.
The system temperature

Current temp: 32 °C
Max. temp: 40 °C (25/06/2012 / 15:09)
Min. temp: 21 °C (06/04/2012 / 21:04)
ESC – key for back ...
Delete temp.
The minimum and maximum value can be deleted with the function key.
12.2.3.5 Test inputs / outputs

In this menu item the inputs and outputs for testing can be set and reset. For this purpose the test screen displays all possible
inputs and outputs graphically.
Please take care that no processes that may affect safety are triggered when testing the outputs.
Disregard may cause a defect and possibly lead to a harmful situation for the health of persons!
Test the inputs / outputs

Set output: press numeric key …

Select base + Select base -
The available inputs/outputs are displayed as numbers according to their basic address. An input is shown inverse when voltage
is applied to it.
An output is set by selecting the basic address 76 using the function keys followed by entering the corresponding number key.
A selected output is shown inverse when voltage is applied to it. The output remains set until it is reset with the corresponding
number key. The test menu is exited with <ESC> and all outputs are reset.
76
The 4 inputs/outputs of interface X52 are permanently allocated to the base 000. When using an IO Extension, a basic address is also allocated to
it at the factory. The number of the input/output is comprised of the basic address (1st digit) and the respective number of the input/output (2nd
digit). E.g. base 020, input 3 of the IO Extension = input 23

12.2.3.6 Display status of inputs / outputs

The current status of the inputs and outputs used is shown in the overview.
Status of the inputs/outputs

RDY PGF OK NOK HA GSE PC - - - PB C: A: Preselection:
12.2.3.7 Test Profibus

The menu point shows the status as well as the state of the inputs (=outputs at the PLC) and outputs (=inputs at the PLC). The
error counter can be reset with the function key.
Test Profibus
ErrCounter: 0
Baudrate: 1200
DP-State: 2
WD-State: 2
Input 0 00
Input 1 01
Input 2 02
Output [0]: 00
Output [1]: 0E
Output [2]: 00

Reset ErrCounter

12.3 Test mode / simulation of the inputs and outputs at the press-in control system
 Switch on the parameter „external test mode“ (=ON) to activate the I/O simulation.
> Chapter 11.5.18 External test mode, Page 148
a) Functionality
The available inputs and outputs of the complete I/O-section can be watched and controlled for simulation with the function „IO
simulation“.
Menu navigation
MultiControl4  <Online>  <IO simulation>
For this, the window shows all the possible inputs and outputs. The inputs and outputs which are available in the system are
marked „white“, the there from active inputs and outputs are marked „blue“.
According to their basic address, the inputs and outputs are displayed/shown as digits/numerics.
The 4 inputs and outputs of the interface X52 are dedicated to basis 000. By use of an IO-extension, this will also get a basic
address assigned from DSM. The number of the input/output is put together out of the basic address (1. digit) and of the
respective number of the input/output (2. digit), e.g. basis 40, input 3 of the IO-extension = input 43. By use of the Profibus, the
basic addresses 10 and 20 are assigned to the Profibus.
b) Watch I/O-section
The watch mode is activated by actuation of the button <Watch>. The window „IO simulation“ shows the conditions of the inputs
and outputs by an active joining program.
Please take care, that no safety-related actions/processes will be triggered by the simulation of the inputs/outputs. The non-observance
can result into a defect as well as into a possible dangerous situation for the health of persons!
c) Simulate input signal

After pressing the button <input simulation> can with the help of the pointing device an input signal can be simulated at the
available inputs.
d) Simulate output signal

After pressing the button <output simulation> can with the help of the pointing device an output signal can be simulated at the
available outputs.

Service, fault correction, maintenance, cleaning
13 Service, fault correction, maintenance, cleaning
13.1 Safety
 Service, fault correction, maintenance, cleaning
Have the press-in control system repaired only by qualified skilled personnel using only original spare parts.
This ensures that the functionality and safety of the press-in control system is maintained.
Risk of injury from moving parts!

Rotating and/or parts moved in a linear direction may cause serious injuries.
For this reason:
• Do not reach into moving components or handle moving components during operation.
• Observe the overtravel time! Before working on the plunger/tool of the press-in unit, make sure that no more parts
are moving.
• Wear closely fitting protective work clothes.
Risk of injury from improperly performed tasks for fault correction / maintenance / cleaning!
Improper fault correction / maintenance / cleaning can lead to serious injuries or property damages.
For this reason:
• Provide sufficient installation clearance before beginning with the work.
• Keep a clean and orderly working environment!
Components and tools loosely stacked or spread about constitute accident hazards.
• Carry out only tasks for fault correction / maintenance / cleaning described in these operating instructions. All other tasks must be
coordinated with DSM-Service.
• Once the press-in unit / press-in control system was removed pay attention to the correct assembly, reinstall all mounting elements
and observe the screw tightening torques.

Unintentional starting of the press-in control system / press-in unit while working on fault correction / maintenance / cleaning may cause
injuries.
For this reason:
• Turn off power before beginning the work activities and secure against turning on again.
Risk of burning through hot surfaces!

Contact with hot components may cause burns.
For this reason:
• Make sure that all components have cooled down to the ambient temperature before commencing any work.

13.2 Service menu
Menu navigation
Production screen  <Settings>  <Settings/Test>  <Service>
Service
Service Break fuse
Storage administration
Function screen
Factory settings Service
Reset service counter
Correction value stroke
Service DSM
13.2.1 Service Break fuse

After a protective shut-down, the plunger of the press-in unit must be moved out of the break fuse with the service menu.
Depending on the type of fault, one of the error messages described below is displayed.
The plunger is in the position "Break fuse switch driven-out (BA)" or "Break fuse switch driven in (BE)". The respective error
message is shown on the display of the press-in control system. Acknowledge the error message and select the menu item
"Service Break fuse".
By applying an external start, the plunger is automatically driven out of the break fuse. The plunger can also be moved manually
using the function key <Manual mode>.
Service Break fuse

Plunger located in break fuse!
To move the plunger out of the

break fuse, an external start
must now be applied.
Wait for start …
Manual mode
There are two causes for the display of the following error message:
1: Absence of the 24 V supply at interface X91 of the press-in unit (QMP series only)
2: Position encoder defective
Service Break fuse

Break fuse has tripped!
Attention, this contradicts the

position encoder.
(Check BRUSI feed!)
The plunger can now be moved manually

from the break fuse.
Press the F-key …
Drive-in plunger Drive-out plunger

13.2.2 Storage administration

he following actions can be carried out in the menu item "Storage management".
Storage management
RDY PGF IO NIO HA GSE PC - - - PB C: A: Program: xxx
Delete long-term memory
Delete statistics memory
Delete access protocol
Delete OK/NOK counter
Copy log files to A
Save parameter on compact flash
Load parameter from compact flash
Information about the memory card A:
Information about the memory card C:
Press Up / Down key to select  RET key
13.2.2.1 Delete long-term memory

Pressing the <RET> key is followed by a verification prompt whether the data shall really be deleted. Press the function key <OK>
to delete all recorded measurements from the long-term memory.
13.2.2.2 Delete statistics memory

The following window opens when pressing <RET>.
Program No. = 1
(= 0 deletes memory for all programs)
Enter the number of the program the statistics memory of which shall be deleted. All statistics data is deleted when entering <0>.
Confirm your entry with <RET>. You can exit the input window with the <ESC> key.
13.2.2.3 Delete access protocol

Pressing the <RET> key is followed by a verification prompt whether the journal shall really be deleted. Delete the access journal
with the function key <OK>.
13.2.2.4 Delete OK/NOK counter

Pressing the <RET> key is followed by a verification prompt whether the OK and NOK counter shall really be deleted. The delete
process is confirmed with the function key <OK>. The OK/NOK counter is reset to zero.
13.2.2.5 Copy log files to A:

After pressing <RET>, the control system copies the log files "BOOT1" and "ERROR1" to the CF card.
"BOOT1", amongst others, includes the boot times (system start time with data and time) with information of the CPU version and
the firmware installed.
"Error1" includes the system errors that have occurred (fault number, error description), specifying data and time as well as the
firmware version installed
The saved log files can be opened and analysed in a editor (format selection "all files") or with the MultiControl4 software (menu
<Extras>  <View>).
13.2.2.6 Read out / view log files
Menu navigation
MultiControl4  <Online>  <Error log from device> / <Boot log from device)
After selecting the menu point specify the memory location for the log file. Change the file name as required. By Pressing the
"Save" key the protocol file is read out. A message window will be displayed when the process is completed. If you confirm with
"Yes" you can see the file immediately.
The saved log files can be opened and analysed in a editor (format selection "all files") or with the MultiControl4 software (menu
<Extras>  <View>).

13.2.2.7 Save parameter on compact flash

Pressing the <RET> key is followed by a verification prompt whether the already existing parameter backup shall really be
deleted. Start the storage process with <OK> and all current parameters (settings, programs) are written to the mobile long-
term memory (CF card A: ). The progress bar indicates the progress of the saving process. An information window lets you know
that the parameters were successfully saved.
13.2.2.8 Load parameter from compact flash

Pressing the <RET> key is followed by a verification prompt whether all device parameters and programs shall be overwritten.
After pressing the function key <OK> the system reads the parameters stored on the CF card (A:). The current parameters
(settings, programs) of the press-in control system MultiPro FL are thereby overwritten. The progress bar indicates the progress
of the loading process. The following note appears after loading is complete:
Parameter loaded successfully!

Please press RESET.
Press function keys <F2> and <F5> to perform a reset. The press-in control system MultiPro FL is restarted.
13.2.2.9 Information about the memory card A:

The screen shows the format (file system) as well as the storage information of the CF card located in the CompactFlash slot.
File system FAT 32

Memory used 315 kB
Memory free 126657 kB
Memory capacity 126972 kB
13.2.2.10 Information about the memory card C:

The screen shows the format (file system) as well as the storage information of the internal storage unit.
13.2.3 Factory settings

Pressing the <RET> key is followed by a verification prompt whether the press-in control system shall be reset to the factory
settings. The process is started with the function key <OK>; all memories are as well as the device parameters and all programs
are thereby deleted. The following note appears after the process is complete.
Device was reset.

Please press RESET.
Press function keys <F2> and <F5> to perform a reset. The press-in control system MultiPro FL is restarted with the factory
settings.
13.2.4 Restart service counter

With this menu item 77 the interval and the load counter of the tool data memory can be reset to zero.
To reset the service counter the press-in unit must be connected with the MultiPro since the data of the interval and
the load counter reside in the parameter storage of the press-in unit.
Pressing the <RET> key is followed by a verification prompt whether the service counter of the press-in control system shall be
reset. Both counters are reset to zero with the function key <Yes> (F1 – F3). The process is aborted and followed by a return to
the service menu with the function key <No> (F4 – F6).
77
The function "Reset service counter" is possible from firmware version 3200 V1.15.

13.2.5 Correction value stroke

The menu item "correction value stroke" 78 serves to compensate production-related discrepancies as well as process specific
discrepancies. It means, if a press-in unit will be replaced it is possible that the position of the plunger at position "S0" of the two
machines is different.
The value "S0" describes the distance between the lower edge of the press-in unit up to the zero point of the absolute stroke
measurement system and is therefore a non editable parameter. The value is entered on the type plate of the press-in unit.
It is possible to compensate this difference via the menu item "correction value stroke" so that it is not necessary to edit all the
stroke values in the programs.
After pressing the key <RET> in the service menu the correction value stroke (in millimetres) can be entered.
Input range: - 3 mm ... + 3 mm
When entering a zero the function is disabled.
The correction value entry means a direct intervention into the stroke measurement system. For this reason the hint
"Correction value unequal to zero " will be shown on the display as well as transmitted to the MultiControl4 (PC),
Profibus and Error-Log.
78
The function "correction value stroke" is contained in the firmware from version 3200 V 1.33 and is available after activation.

13.2.6 Service DCM-Extension

In this service menu the DC motor connected via a DCM Extension 79 can be moved "by hand".

RDY PGF OK NOK HA GSE PC v - - PB C: A: Program: xxx Determine ID:
ID = 5
Basic address
44
45
46
Target ID via number key (4 ... 7) 47
Travel direction 1 Travel direction 2 ID
First select the ID of the DCM Extension with the numeric keypad. Now you can move the motor in the respective direction with
the function keys.
13.2.7 Service DSM

Protected area, this menu is exclusively for the Service. Access is permitted only to DSM service staff as well as authorized
persons.
79
Module for the selection of an external DC motor, e.g. DSM hole puncture adjustment, horizontal/vertical axis.

13.3 Maintenance and Cleaning
a) Safety

Unintentional starting of the press-in control system / press-in unit while performing cleaning tasks may cause injuries.
For this reason:
• Turn off power before beginning the work activities and secure against turning on again.
b) Maintenance
The hardware of the press-in control system MultiPro FL is maintenance-free.

In the event of defects or conversion on the press-in control system, ship it to our service department upon consultation.
c) Cleaning
Keep the press-in control system clean to facilitate working well and reliably.
Do not use any aggressive solvents or gaseous cleaning agents for to clean the press-in control system.
> Chapter 13.1 Safety, Page 205

> Chapter 13.5 Service address, Page 212
> Chapter 13.6 Return shipment to DSM, Page 212

13.4 Disassembly of the control module
When working on the press-in control system the electrical power supply must be absolutely switched off and
secured against reactivation. Disregard means risk of life from electrical shock.
> Chapter 2 Safety, Page 14
 Disconnect the cables before removing the control module. Next, loosen the setscrews at the left and right edge (1) with a
hexagon screwdriver (size 1.5).
Hold the control module at the upper and lower side of the front panel and pull it out (2). Pay attention that the control module is
connected with the basic module with a ribbon cable and a ground wire (3). Unplug the ribbon cable at the basic module (4); to do
so press the plug together at both sides at the same time and pull out by moving it to and fro (4).
Finally, disconnect the ground wire by pulling at the cable lug (5).
1
Pull 2
4x setscrews M3
5
Pull
4 Pull
Press together
Make sure to remove the CF card and store it securely if the control module is replaced.
> Chapter 4.3 Interfaces and CompactFlash slot on the control module, Page 26
13.5 Service address
 Please contact our service for faults that cannot be remedied.

> Chapter 1.6 Service address / contact, Page 13
13.6 Return shipment to DSM
 Please enclose the completed DSM service form 80 in case of a return with the shipment. The return shipment to DSM
Messtechnik GmbH is made at the expense and risk of the customer, including notifications of defects and warranty obligations.
DSM Messtechnik GmbH assumes the costs for return shipments to the customer in case of warranty claims.
Please note that when returning a press-in control system MultiPro FL, DSM does not assume any liability for transport damages
due to wrong or incorrect packaging. The costs for necessary repairs are borne by the customer / sender.
> Chapter 7.3 Repacking / Temporary storage, Page 71
80
The service form is on the CD-ROM "MULTI CD", which is included in the operating instructions. Of course we also can send you this form by
e-mail. For this, send an e-mail to info@dsm-messtechnik.de.

13.7 Firmware update
 It is very comfortable to input a new firmware (e.g. special firmware, firmware upgrade) by an update file into the press-in
control system MultiPro FL. Depending on the hardware version of the control module the update process is either made with the
CF card (CPU 4.54) or with the PC program "UpdateCenter" (CPU 4.50).
Please make sure to save the parameters (settings, programs) before making the update. Use the latest MultiControl4 software /
LineManager software.
13.7.1 Firmware update CPU 4.54: Updating with CF card
Step 1
Install and setup the latest version of the software (MultiControl4 / LineManager) and connect them with the control system.
Step 2
Read out the data of the control system by using the PC software. Select the menu <Order>  <Order from Multi> in the PC
software. Please observe, store the data in an new order!
Step 3
Following store the data (= order/job) by the menu <Order/Job>  <Store> in ZIP format onto a memory medium.
Step 4
Check the compatibility before starting the update process. Does the firmware file ("Pro", "Cla" or "Bas" in the file name) match
with the unit (MultiPro, MultiClassic or MultiBasic)?
Step 5
Save the firmware file in the format "C4" (Example: 1200 ProDS-E V1_0_9_CPU4_5_4.c4) to a FAT32-formatted CF card in the
root directory. The C4 file cannot be read from a sub-directory.
Step 6
Switch off the press-in control system.
Step 7
Insert the CF card with the C4 firmware file into the CompactFlash slot.
Step 8
Switch on the press-in control system again. The following message window opens:
Current firmware version

Firmware found on CF card!
Firmware version of the update Version : 1200 ProDS-E V1.20
File : 1200PR˜1. C 4
Hardware version of the control module HW -T ype : C P U 4. 5. 4
SW -T yp e : SCHPRO
Software type
<F2> = Programming
<F4> = Abort
Perform update
Cancel update
Abort: To abort the update press the <F4> key, switch off the press-in control system and remove the CF card with the C4 file.
Restart the system.
Programming: To perform the update select the menu item "Programming" with the <F2> key. The following verification prompt
appears after pressing the F key:
Attention, the current

firmware will be replaced!
Start update Verification prompt:

<F3> = Programming
Service <F4> = only texts
<F5> = Abort
Cancel update

Step 9
Press the <F3> key "Programming" to start the update. The following screen is displayed:
Programming started …
Attention: Do not switch-off the device

during programming!
RED FLASHING: Programming faulty.

=> Notify DSM-Service.
Limit monitoring on the GREEN FLASHING: Programming completed.

Remove CF card and
press-in control system
restart the device.
After approx. 10 sec. the LEDs of the limit monitoring function begin to indicate the programming progress (from yellow via green
to red).
Never switch off the device during programming; this will destroy the firmware.
> Chapter 13.7.3 Boot loader CPU 4.54, Page 218
Programming (firmware update) is completed after approx. 30 sec. and the middle, green LEDs flash.
Step 10
Now switch off the device and remove the CF card with the C4 file. If the C4 file resides on the data CF file, it is imperative to
delete the C4 file before reinserting the card.
Step 11
Start the system with the new firmware.
Step 12
If error messages come up during the control system is booting up, accept/confirm these. This e.g. can happen if the program
structure changes.
Step 13
Read in the before stored data (Zip file) again with the PC software via menu <Order/Job> and the function <Back-Read>.
Step 14
Subsequently transfer the order data to the control system (PC software <Order>  <Order to Multi>).

13.7.2 Firmware update CPU 4.50: Updating with PC software UpdateCenter
Step 1
Install the program "UpdateCenter". Then install and setup the latest version of the MultiControl4 software / LineManager
software. Connect them with the control system.
Step 2
Read out the data of the control system by using the PC software. Select the menu <Order>  <Order from Multi> in the PC
software. Please observe, store the data in an new order!
Step 3
Following store the data (= order/job) by the menu <Order/Job>  <Store> in ZIP format onto a memory medium.
Step 4
Check the compatibility before starting the update process. Does the firmware file ("Pro", "Cla" or "Bas" in the file name) match
with the unit (MultiPro, MultiClassic or MultiBasic)?
Step 5
Switch on the press-in control system and ramp it up; acknowledge possible error messages. The press-in control system shows
the production screen.
Step 6
Start the UpdateCenter program.
Step 7
After the start the program guides you through all setting and action options.
Close <ESC>
E-mail <F8>
DSM homepage <F7>
Settings <F6>
Checklist <F3>
Version information <F2>
Online help <F1>
The "internal links" provide information about certain functions of the UpdateCenter.
a) Selection of device type

You can select between the device types of the DS/QMP/SMP series (Gold Line) and the BL/EMP series (Silver Line).
If with a device of the DS/QMP/SMP series the option boot loader is selected, an external program is started instead of
a data transmission.
> Chapter 13.7.3 Boot loader CPU 4.54, Page 218
 Press <Next> after making the selection to proceed to the next screen view.

b) Settings of the interface

The interface is set by specifying the COM no. and giving the baudrate. For a firmware update with the control systems of the
DS/QMP/SMP series a baudrate of 57600 Bit/s must be absolutely selected. The baudrate must have the same size in the
UpdateCenter as in the press-in control system.
Select COM interface and size of the baudrate. The data can be determined automatically if the number of the COM interface or
the size of the baudrate is not known. For this purpose click on the button <Determine settings>. The results found are noted in
the list below. The procedure takes approx. 20 seconds.
 Click on <Next> after making the settings to proceed to the next screen view.
c) Executables actions
Select the action <Firmware from PC to the unit> and enter the source path.
By clicking on the filed the window "Data

input" opens where you can enter the
path directly.
Opens the window to select the data

source.
List field data source.
To be able to supply control systems of the hardware type CPU 4.50 and smaller with firmware, they must be put in the
so-called boot mode. More information is available by clicking on the "internal links".
 Press <Next> after selecting the action to proceed to the next screen view.

d) Transmission
The data transmission starts with the button <Start>. Confirm the warning with <Yes> if the settings displayed match your
specifications.
A data transmission report is generated during the data transfer. The transfer process can be reviewed after the transmission
based on this report. This is especially important if the data transfer was analysed as failed.
 Click on <Next> after the data transfer was complete to view the report.
Step 8
Programming on the press-in control system is started after the data transmission (approx. 3 min.). After approx. 10 sec. the
LEDs of the limit monitoring function begin to indicate the programming progress (from yellow via green to red).
Never switch off the device during programming; this will destroy the firmware
Programming (firmware update) is completed after approx. 30 sec. and the system is started automatically with the new firmware.
Step 9
If error messages come up during the control system is booting up, accept/confirm these. This e.g. can happen if the program
structure changes.
Step 10
Read in the before stored data (Zip file) again with the PC software via menu <Order/Job> and the function <Back-Read>.
Step 11
Subsequently transfer the order data to the control system (PC software <Order>  <Order to Multi>).

13.7.3 Boot loader CPU 4.54

Step 1
Start the UpdateCenter program. If the program is not yet available then perform the setup program to install the UpdateCenter
on the PC.
Step 2
Select the device type <Gold Line> as well as the option <Boot loader> and click on <Next>.
Step 3
The interface is set by specifying the COM no. and giving the baudrate (57500 Bit/s). The baudrate must have the same size in
the UpdateCenter as in the press-in control system. The data can be read automatically if the number of the COM interface or the
size of the baudrate is not known. For this purpose click on the button <Determine settings>. Click on <Next> after making the
settings to proceed to the next screen view.
Step 4
The screen view "Actions" is locked. Click on <Next> to switch to the "Transmission" window. Select the device version and the
hardware type 81 for the data transmission via external flasher and press <Start>.
The following message is displayed:
81
The hardware type is entered on the type plate.

Step 5
The following steps are required to put MultiPro into the boot mode:
• Switch off the press-in control system.
• Press the two reset keys and keep them depressed.
• Switch on the press-in control system.
• Release the pressed reset keys again.
• All LEDs of the limit monitoring function are lit; the press-in control system is in the boot mode.
Step 6
Confirm the OK button to close the information window. The M16C Flasher is accessed.
 To exit, click on the "Close" symbol.
Click on <Start> to begin with the transfer of the boot loader. The data transmission is shown in a separate window with a
progress bar. The window closes automatically after the transmission is completed. Close the M16C Flasher. The UpdateCenter
is located in the screen view "Transmission" and displays the message: Wait with other actions until the external flasher has
completely transferred the boot loader!
Click on <Next> and the data transmission report is displayed. You can close the UpdateCenter program.
Follow the instructions listed under:

> Chapter 13.7.1 Firmware update CPU 4.54: Updating with CF card, Page 213 / Step 5

13.8 Activation of chargeable options
Menu navigation
MultiControl4  <Tools>  <Service>  Tab: <Activation>
The functions listed are integrated in the press-in control system and can be activated by purchasing an activation code.
Enter the activation code

into the respective data field
and click on the button next to it.

13.9 Remote maintenance
 With the function „remote maintenance“ you have the possibility to get access to a DSM control system via TCP/IP. After the
configuration and the link connection you have the complete function volume of the software MultiControl4 for the external DSM
control system available.
a) Configuration remote maintenance
Menu navigation
MultiControl4  <Edit>  <Device configuration>  Tab: < User and communication settings >  TCP/IP
First of all carry out the basic settings (IP-address, subnet mask, gateway) for the TCP/IP connection. If there's already a
connection to the software “MultiControl4” via TCP/IP existing, these values already have been entered. To use the remote
maintenance you have to switch on the parameter “remote maintenance” (ON) and have to specify an access code for the remote
maintenance in the parameter “Fw. Access”. Furthermore you have to assign a port in the register <Socket2> of the TCP/IP-
settings in the parameter “Own Port”, because the control system has the function of a server. The settings “Target Port” and
“Target IP” are not needed. The IP-address, the port-setting of socket 2 and the access code are needed for access to the remote
maintenance.
b) Installation of remote maintenance

So that you are able to get access to an external DSM control system, you first of all have to install the connection.
Menu navigation

Activate the option panel “remote maintenance client”. Enter the port-settings into the panel „MultiPort“ and the IP-address of the
DSM control system, to which you want to have access, in the panel „Multi-IP“. Finally press the button <Take-Over>.
The menu bar “remote maintenance” is shown in the main window of the software MultiControl4.
However, there is no connection to the external control system yet. This you can see at the status report at the
position on the left side (bottom) on the screen.
c) Access to remote maintenance (connection)
Press the button <Connect> in the menu bar “remote maintenance” to get a connection with the external DSM control system.
Before the access to the remote maintenance is possible, the access code for the remote maintenance has to be entered.
Enter access code and confirm

with button <OK>.
After the login at the external control system you have the complete function volume of the software MultiControl4 for this unit
available.
From the time the connection has been established, the settings 82 on the external control system on site can no
longer be changed.
The external DSM control system indicates on the production screen that a remote maintenance connections is active.
d) Closing remote maintenance
Press the button <Stop> in the menu bar “remote maintenance” to stop the connection and with this also the access to the remote
maintenance.
82
Configuration, jointing parameters, sequential program

Dismantling and disposal
14 Dismantling and disposal
After the end of the service life has been reached, the press-in control system must be dismantled and disposed of in an
environmentally compatible manner.
14.1 Safety
Perform the final decommissioning and dismantling of the press-in control system while observing the safety information of these
operating instructions.
> Chapter 2 Safety, Page 14
Dismantling may only be done by especially trained technical personnel. At least 2 persons are required for the dismantling work
14.2 Dismantling sequence
 To separate the press-in control system MultiPro FL, switch off the control system and disconnect all cables. Finally dismantle
the press-in control system.
> Chapter 10.3 Electrical installation, Page 80
> Chapter 10.2 Assembly, Page 78
14.3 Disposal
Environmental damages from improper disposal!

According to the electrical act, electrical devices must be collected separately. The improper disposal of used electrical devices puts
people and the environment at risk.
For this reason:
• Have electrical devices disposed of only by approved speciality companies / collecting stations.
 Disassemble the press-in control system with consideration of the applicable labour protection and environmental protection
regulations. Obey the locally applicable regulations as well as the generally valid disposal guidelines, such as the electrical and
electronics act (German ElectroG).
If no return or disposal agreement was entered into,

the disassembled components must be submitted to recycling:
• Scrap metals.
• Submit plastic elements to recycling.
• Dispose of all other components sorted according to material properties.
The local municipalities or special disposal companies provide information on environmentally proper disposal.

Supporting documents
15 Supporting documents
15.1 System bus device IO-Extension (optional module)
 The IO Extension is used to expand the standard inputs and outputs of the DSM control systems. The device is selected via the
DSM systembus interface with 24 V.
The inputs and outputs can be used for any control tasks in the sequence programming of the control system. Special commands
are available for the setting and resetting of outputs as well as for querying inputs. Up to 16 extension modules (max. 128 inputs /
128 outputs) can be managed at a control unit. The connection with the inputs and outputs of the IO Extension 4/4S and 8/8S is
made via a plug-in terminal strip included with the delivery. The devices 4/4C and 8/8C require cable plugs provided by the
customer for connection. The information about manufacturer and type of the connectors are described in the overview.
15.1.1 Extension modules overview
4/4S 4/4C 8/8S 8/8C
IO-Extension 4/4S IO-Extension 4/4C IO-Extension 8/8S IO-Extension 8/8S
Inputs / outputs 4I / 4O 4I / 4O 8I / 8O 8I / 8O
83 84
I/O connection Terminal blocks Round connectors Terminal blocks Round connectors
• Selection via system bus

• Status indication via LED’s
• Reset key
15.1.2 Presentation IO-Extension
System bus output
Vout
Supply voltage Vsys
output driver Supply voltage
IO-Extension
Enable
System bus release Error
Terminal blocks
I/O level
Round connectors Reset key
I/O level Resetting is done
with an integrated
reset key.
Status indication
(per input / output)
Basic address
83
Terminal strip manufacturer PTR; 11-pole, designation AKZ1700/11-3.81 (4/4S); 19-pole, designation AKZ1550/19-3.81 (8/8S)
84
Binder flange box 3-pole, Series 718, order number 09-3412-8003; cable plug not included in scope of delivery
(Customer connecting cable)

15.1.3 Electrical specification
a) Connection data
Input signal 24 V (16 V – 32 V); 24 V / 100 mA per output; current consumption of IO Extension approx. 0.15 A
When using the internal 24 V voltage supply (bridge Vin / Vout) it must be noted that the total current at the output may not exceed
max. 1 A (100 mA per output).
An external voltage source (max. 24 V / 2.5 A) can be connected to the supply inputs Vin / GND for larger currents. Furthermore, it
is possible to feed 24 V at the interface SBIN (X58).
> Chapter 10.8.2 Supply voltage 24V, Page 96
The IO Extension is automatically detected by the control system via the systembus.
> Chapter 12.2.2 Test system bus, Page 198
When using one or several extensions it must be remembered that a systembus output (SBOUT) that is not used receives a terminating
resistor.
b) Connections IO-Extension
SBIN
Plug (pins) 5-pin M12 round connector at the IO-Extension: System bus interface input
Assignment
PIN I/O Description
1 In 0V feed
2 In 24V feed
3 I/O C-L
4 I/O C-H
5 In Release
SBOUT
Socket 5-pin M12 round connector at the IO-Extension: System bus interface output
Assignment
PIN I/O Description
1 Out 0V supply
2 Out 24V supply
3 I/O C-L
4 I/O C-H
5 In Release
Round connector
Socket 3-pin M8 round connector at the IO-Extension 4/4C, 8/8C: I/O extension, one round connector per input / output, for use
for the program start, for status inputs / status outputs or freely available in the program sequence
Assignment input Assignment output

PIN Description PIN Description
1 +24 V 1 OUT
3 GND 3 24V
4 IN

Memory location: F:\Daten\01) Dokumentation\02) Fügetechnik\MultiPro FL\0_ENGLISCH\MultiProFL_OperatingInstructions_TD-3191011_V1_3.docx
Terminal blocks
Terminal blocks at the IO-Extension: I/O extension, one round connector per input/output, for use for the program start, for status
inputs / status outputs for freely available in the program sequence
Terminal strip 11-pole (IO-Extension 4/4S) Terminal strip 19-pole (IO-Extension 8/8S)
15.1.4 Adressing in press-in control system

In the parameterisation and programming environment of the press-in control system inputs are identified with E and outputs with
A. The number of an input / output of an IO Extension is comprised of the basic address (1st digit) and the respective number of
the input / output (2nd digit).
Example: Number of the marked input 'E 13' .
15.1.5 Dimensions
Ø4,5 (2x) 144 ±2
4/4S, 4/4C, 8/8S

52
62
132
30
clearance
50
Plug
22

Ø4,5 (2x) 224
8/8C
52
62
30
clearance
50
Plug
22
> Chapter 10.2 Assembly, page 78
15.1.6 Switching principle IO Extension

Program selection with IO Extension.
> Chapter 11.5.1 PG Start ; 15 PG-Modus, Page 138

15.2 System bus device Status Indication (optional module)
 Status display, program switch, key switch and start switch are display and operating elements for the "Status Indication"
device. Depending on the design, the elements are integrated in the "Status Indication".
The connection to the press-in control system is made via the DSM systembus. Two connections, SBIN (input) and SBOUT
(output), are available to the Status Indication for this purpose. This makes it possible to loop the systembus through from device
to device 85. It must be remembered to apply a terminating resistor (Art.No. DSM-200721) to the systembus at the last connected
device on the SBOUT output.
Connecting several identical devices of the Status Indication to a systembus is not intended. Although with different systembus
IDs the press-in control system recognises several identical devices but it cannot distinguish from which device it receives the
respective information. For example, when incorporating several program switches, the program set last is always preselected.
When using several start switches the press-in control system could be started from several locations, however, in actuality this is
primarily not desired.
System bus input SBIN
System bus output SBOUT
Status indication (READY, OK, NOK)
Selector TWO (2 program selector switches)

Rotary switch 10 – 90 (tens)
Rotary switch 1 – 9 (single)
Start switch
15.2.1 Execution: Status Indication

The three coloured status LEDs indicate the states of the three status outputs (READY, OK, NOK) of the press-in control system.
This allows for monitoring of the system both from a larger distance and also directly at the workstation.
15.2.2 Execution: Status Indication Key Switch

This allows for monitoring of the system both from a larger distance and also directly at the workstation. When a fault occurs, the
start release is blocked until the fault was acknowledged by operating the key switch.
15.2.3 Execution: Status Indication Selector ONE / TWO

This allows for monitoring of the system both from a larger distance and also directly at the workstation. The program preselection
is made via a decade rotary switch (Selector ONE, 1-9 programs) or also by using two decade rotary switches (Selector TWO, 1-
99 programs). The program selected at the Status Indication is used from the next start until a new selection is made.
15.2.4 Execution: Status Indication Selector ONE S / TWO S

The program preselection is made via a decade rotary switch (Selector ONE, 1-9 programs) or also by using two decade rotary
switches (Selector TWO, 1-99 programs). The program selected at the Status Indication is used from the next start until a new
selection is made.
The start takes place via the start switch (S) integrated in the Status Indication.
85
"Looping through" refers to all devices (e.g. IO Extension, P Control ...) connected via systembus with the press-in control system.

15.2.5 Execution: Status Indication Selector ONE KS / TWO KS

The program preselection is made via a decade rotary switch (Selector ONE, 1-9 programs) or also by using two decade rotary
switches (Selector TWO, 1-99 programs). The program selected at the Status Indication is used from the next start until a new
selection is made.
When a fault occurs, the start release is blocked until the fault was acknowledged by operating the key switch (KS).
15.2.6 Required settings on the MultiPro FL
a) Program switch "Selector ONE" / "Selector TWO"

If the program preselection is made by the program switch of the Status Indication, you must configure this in the following menu:
Menu navigation

 Parameter: <PG start>  128 PG Mode PG switch
b) "Key Switch" / "Selector ONE KS" / "Selector TWO KS"

If a NOK interlock is realised with a Status Indication Key Switch or a Status Indication Selector ONE KS / TWO KS, you must
configure this in the following menu:
Menu navigation
Production screen  <Settings>  < Settings/Test >  <Settings>  <Control unit>

 Parameter: <Input NOK interlock>
> Chapter 11.5.15 Input NOK interlock, Page 147
c) Start switch "Selector ONE S" / "Selector TWO S"

If in addition to the program preselection an external start is realised with a Status Indication (Selector ONE S / TWO S) via
systembus, you must configure this in the following menu:
Menu navigation
Production screen  <Settings>  < Settings/Test >  <Settings>  <Control unit>

 Parameter: <SBUS Start>

15.3 Software tool: CFG Data Converter
 In a program sequence with the instruction "Transmit graphics data to CF", graphics data recorded with the instruction
"Graphic" can be stored on the CF card.
With the tool CFGDataConverter 86 you can convert the graphics file thus stored into a text format that can be read with Excel.
With the TXT file all columns are tab-separated and can therefore be imported by most of the spreadsheet programs.
> Chapter 11.9.4.15 Transmit, Page 176 (Instruction)
Step 1
Put the CDFehler! Textmarke nicht definiert. in the drive of your PC and start the setup program CFGDataConverter.exe in the
directory CFGDataConverter and follow the installation wizard.
Step 2
Start the CFGDataConverter program. Insert the CF card with the graphics data into a card reader connected with your PC.
Close the program.
In the directory Serial No.\ Result\Graphics

of the CF card the graphic files are stored in
subfolders.
Save as:
Select the destination directory and assign
or retain the file name.
Starts the conversion.

The Txt file has been created when the
progress bar shows 100%.
Progress bar
The file name is composed as follows: 010_0514.012 (example)
PG Sequential no.
Month (mm) Day (dd)
86
The CD, which contains the program "CFGDataConverter", amongst others, is included with these operating instructions.

Authorised DSM partners
16 Authorised DSM partners
 Austria  Italy
MTP Montagetechnik RDB soluzione industriali ergonomiche
Mühlbachstraße 29a Via Pacchiotti, 123
5201 Seekirchen 10146 Torino
Telephone +43 6212 7988 - 0 Telephone +39 0 114 120 771
Telefax +43 6212 7988 - 14 Telefax +39 0 114 120 779
mtp@mtp.at rdb@avvitare.it
www.mtp.at www.avvitare.it
 Brazil  Poland
QS Machines Ltda. OK Strojservis Polska Sp. z o.o.
Mr. Carlos Pestana Jr. ul. Technologiczna 2 A
Rua Dakar, 86 45-839 Opole
04730-040-Santo Amaro Telephone +48 690 368 321
Sao Paulo - Brazil info@ok-strojservis.pl
Telephone +55 (11) 5681 8759 www.ok-strojservis.pl
Mobile +55 (11) 7817 2280
 China  Romania
Shanghai B.I.W Mech Electrical Co., Ltd S.C. ARDASIA SRL
First Shanghai Plaza 6 - Room 501 Str. Aurora, nr. 4
Shanghai Zhangjiang Hi-Tech Park 410547 Oradea
Bisheng Road 299 Telephone +40 359 810 633
201204 Shanghai info@ardasia.ro
Telephone +86 21 502 77 248 Ext. 808 www.ardasia.ro
Telefax +86 21 502 77 247
Pan.frank@biw.net.cn
www.biw.net.cn
 Czech Republic / Slovakia  Spain

LK Machines, s.r.o. GIRA Automation, S.L.
Jičínská 226/17 Parque Empresarial Las Rozas
130 00 Praha 3 C / A. Pérez Esquivel, 3 – Oficina 27
Telephone +42 0 728 255 969 28232 Las Rozas (Madrid)
obchod@lk-machines.cz Telephone +34 91 636 63 49
www.lk-machines.cz Telefax +34 91 636 63 50
comercial@giraautomation.com
www.dsm-messtechnik.de
 France  Turkey (Middle East)

Outils Pneumatiques GLOBE Gemasis Makina Ltd. Şti.
143 avenue du Général de Gaulle B.P. 102 Esensehir Mah. Natoyolu Cad. Atilim Sok. No:41
92252 La Garenne-Colombes Cedex Ümraniye 34776 İstanbul - Türkiye
Telephone +33 1 41 19 33 33 Telephone +90 216 456 0147
Telefax +33 1 41 19 33 19 Telefax +90 216 456 0148
contact@opglobe.com info@gemasis.com
www.opglobe.com www.gemasis.com
 Hungary  United Kingdom

Mint East Europe Kft. AFTSL Aluminium Frames and
Kőér u. 16 Tooling Solutions Ltd Ltd
1103 Budapest Unit 7, Stafford Park 17
Telephone +36 30 910 0398 Telford Shropshire
Telefax +36 1 431 8937 TF3 3DN
kovacs@mint.hu Telephone +44 1952 550 037
www.mint.hu Telefax +44 1952 551 183
sales@aftsl.co.uk
www.aftsl.co.uk

Index
17 Index
A Dimensions 22, 73;

Abort mode 146; Dir. (parameter) 45,54,166;
Absolute stroke measurement 37,58; Direction of travel (parameter) 45,151,159;
Access control 21, 34, 76,99,99,112,136,147,207; Disassembly 223;
Accessories 7, 224,228,230; Display 25,127-136;
Activation (activation code) 220; Disposal 223;
Allocation 85,86,87,88,89,91,92; Drive-in 159,197;
Ambient conditions 17,74; Drive-out 159,197;
Assembly 75,78-79;
Automatic travel 159; E
Auto-parameterisation 34,151; Emergency-off switchgear 33;
Empty travel on stroke 54-56,158;
B End (instruction) 157, 171;
Basic module 23, 24,29-33,80,82-84,199,212; Entry in OK window (parameter) 45,59,162;
Basic module connection 80,82,83,84; Envelope 61-Fehler! Textmarke nicht definiert.,132,163;
Basic module DS-H 31,83; Error analysis 194-203;
Basic module DS-L 30,82; Error description 190,207;
Basic module DS-V 32,84; Error display 128,190;
Bending-up compensation 38-40,144; Error transmission 99,101,117,118,119;
Bit rate 94,97; Example 77,175,177;
Black time 145; Extended configuration 99, 102-115;
Blank line (instruction) 176; External release 16,33,70,147;
Block dimensions (parameter) 45,57,161;
Block force (parameter) 45,57,162; F
Boot loader 217; Factory setting 208;
Brakes 166; Fault 190;
Buffer memory 169; Fblk (parameter) 45,57,162;
Feed 45,151,163;
C Firmware update 213;
Cable 81-93; Firmware version 34,185,213;
Cable clearance 79; Fmax (parameter) 45,161;
Calibration value 151; Fmin (parameter) 45,161;
CF card, Compact Flash 26,129,176,189,207,213; Force (parameter) 45,151,158,159,161;
CFG data converter 230; Force measurement 40;
C-HS cable 81,83-84,88; Force progression in OK window 45, 59,162;
Cleaning 211; Force resolution 40;
Command selection 157 (157-176); Front view 25;
Commissioning 75-77; Fs (parameter) 45,145,159;
Communication 94,97,122,150; Fstop (parameter) 45,158;
Computer interface 26; Function description 34-36;
Configuration 76, 94, 97,99,121,137,138-152; Function keys (F-keys) 25;
Connecting cable 86-89,95;
Connections 81-84,90,128; G
Contact 13, 231; Go Int. pos. (instruction) 64,145,152,157;
Contacts 13, 231; Graphic 132-133,145-187;
Continuous light 145; Graphic data 174,176,230;
Control module 24,25,80,90,212; GSD file 98;
Control module connection 80,90;
Control module removal 212;
H
Correction value stroke 205;
Counter 152,186,207,208; Hold force 60,162;
Current (parameter) 164; Hold, hold time (parameter) 45,60,145,162;
HUKno, envelope number (parameter) 163;
HUKsw, envelope switching (parameter) 164;
D
Data converter 230;
I
Data sheet 21-23;
Date 146; I/O Extension 224-227;
DCM Extension ; I/O level 27,122,145,224;
Declaration of incorporation 8; Imax (parameter) 45,164;
Delay (parameter) , 54,; Info area 128,129-130;
Delete statistics ; Info device 136, 185;
Delay (parameter) 45,54,166; Initial commissioning 75-77;
Design of the control system 24; Input voltage range 30-32;
Designation 14,18; Inputs 27, 99,122,124,125,138-144,145-147,158,170,172,
Device information 185,194-203; 202,203,224;
Dimensions 21,73,78,226; Installation 75,80-81,82-84,90;

Index
INstop (parameter) 158; Plunger velocity 45,151,152,163;

Instruction lines 21; Power 30-32;
Instructions 169-176; Power supply 23,24,29-33,82-85,96,225;
Interfaces 21, 26-33; Press-in unit 23,82,83,84,150;
Interval counter 186; Press time (parameter) 42,162;
IO Extension 79, 224-227; Printer cable 90,92,94;
IOF (parameter) 45,59,162; Printer interface 26;
Printer settings 94;
J Product designation 12;
Production data 21,157,169,176;
Joint unit 23,82,83,84,150;
Production screen 25,128-136;
Joining parameter 45,47,50,53,56,158-162;
Profibus 27,90,98-120,124,125;
Joining processes 21,45,47,50,53,56,158-162;
Program 67,138,153,177;
Joining sequence 67-70,177-180;
Program end 171,175;
Joining time 42,162;
Program instructions 169-176;
Jump (instruction) 157,170 -171;
Program list 153;
Program preselection 35, 69,138,143;
K Program runtime 188;
Key switch 7,147,228,229; Program start 34,36,122,138,144;
Program switch 7, 228,229;
L Program, copy 181;
LCD Display 25,127-136,145,189; Program, delete 181;
Limit monitoring 42,128; Programming commands 157-176;
Line number 131; Programming example 77,175,177;
Linearisation 38-40,144; Programs, back-up 208;
Load counter 186; Protective device 16;
Logistic data 73; Protocol (log) 188,207;
Long-term memory 26,169,176,207;
R
M Ramp time (parameter) 45,151,163;
Mains connection 23, 30-32,85; Ramp time 152;
Manual program preselection 35, 143; Range limits 37,180,195;
Measured values 21,42,128,130,169,174,176,187,188; Rated output 30-32;
Measurements 42; Ready 34,42,101,123,128,145,194,199;
Menu overview 136; Relative stroke measurement (parameter) 37,45,58,159;
Motor cable 81-84,86-88; Release input 16,33,147;
Motor current 164; Remote maintenance -;
Mounting 75,78; Reset 25;
MSI 33, 81-84; Result 187;
MultiControl4 Software 7,34,76,155; Return shipment 71, 212;
Review stroke 45,57,160;
Rotational direction (direction of travel) 151,159,197;
N
Rpm ramp 151;
NOK counter 185,207;
NOK interlock 147, 229;
S
Normal position reached 123,145;
Normal position travel 64,145,152,157; Safety 14-20,36,72,73,75,78,126,205,223;
Notes line 128; Safety identifier 18;
Number of programs 21; Safety shut-off 33;
Save / load parameters 214;
Sblk (parameter) 45,57,161;
O
Scope of delivery 7;
Offset zero point 37; Screen division 128;
Offset adjustment (instruction) 172; Screenshot function 137,189;
OK counter 185,207; Sdelta (parameter) 45,57,160;
OK window 59,162; Sequence programming 77,137,153;
Operating conditions 74; Serial number 20,199;
Operating controls 25,127; Service 13;
Operating equipment interface 26, 27,33,90,138; Service counter 186,208;
Operating functions 137; Service cycle 152;
Operation 126 -189; Service flag 186;
Options for MultiClassic 7; Set contrast 145;
Output (instruction) 157,171; Set language 146,;
Outputs 123,125,145,202,203; Settings 76,94,97,98,121,136,138-152;
Overload counter 186; Setup program 77,177;
Overrun time (parameter) 43-44,45,163; Shearing element BRUSI 37,195,206;
Signal time progression 67-70;
P Smax (parameter) 45,160;
Packaging 71-72; Smin (parameter) 45,160;
Parameter 45,47,50,53,56,158-162; Sstop (parameter) 45,158;
Parameterisation / programming 77,137 ,138,150,153,177; Start 34,36,122,138,144;
Parameterisation via Profibus 120,173; Start aborted 69;
PC connecting cable 81,90-91; Start switch 7, 228,229;
PC settings 94; Statistics 147,169,170,187;

Index
Status Indication 144, 228-229; Total number of joining processes 185;

Status messages 25,127,128; TP (parameter) 45,162;
Status outputs 145; TR (parameter) 45,163;
Step number 130; Transfer (instructions) 157,176;
Stroke (parameter) 45,152,158,160; Transport 71;
Stroke measurement 37,58; Transport damage 71;
Storage management 207; Travel (instruction) 157;
Store, safekeep 71-72; Travel stroke 21,37,46,195,197;
Subroutine 21,154,155,157,174,181; Travel stroke resolutions 21,37;
Supply 23, 29-32,74,82-85,96,225; Travel to force 43,44,45,48-50;
Switch-off criterion 43,45,157; Travel to initiator 45,51-53;
Switch-off force (parameter) 45,48,158; Travel to stroke 45,46-47;
Switch-off input (parameter) 45,51,158; Troubleshooting 190-203;
Switch-off stroke (parameter) 45,46,158; Type overview 23;
System bus 28,90,93,95-97,144; Type plate 20;
System bus cable 93;
System errors 68,190; U
System information 137,185;
UP End (instruction) 157,175;
System inputs 122,146,147;
UP Start (instruction) 157,174;
System outputs 123,145;
Update 213;
System verification 194-203;
User administration 148;
T
V
TCP/IP 27,121,122;
V (parameter) 45,151,163;
Technical data 21-23;
Variable (instruction) 157,171,175;
Temperature 74,201,202;
Velocity 151,152,163;
Terminating resistance 95-96;
Versions 12,23,29,86,87,88,89,95;
Test menu 194-203;
Test outputs 202,203;
Test, drive-in 197; W
Test, drive-out 197; Wait (instruction) 157,172-173;
Test load cell 196; Warnings 14;
TH (parameter) 45,162; Weight 21,71,73;
Thermal properties 85,86,87,88,89,91,92; Work area 128,130-134;
Threshold force (parameter) 45,132,145,159;
Time 146; Z
Time-stamp (overload) 186; Zero modem cable 81,90,91;
TN (parameter) 43-44,45,163;
Torsion procedures 43;
Total counter 186;

Version 1.3 | © 2018 DSM Messtechnik GmbH
DSM Messtechnik GmbH

Dieselstraße 16
73431 Aalen
Germany
Phone +49 (0) 7361 5717 0

Telefax +49 (0) 7361 5717 33
info@dsm-messtechnik.de
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R e g is tr a
001
Register Court Aalen, No. B 431-A
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Place of Business: Aalen
/0
ti o
Managing Director: Raimund Wilhelm nu 10

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VAT-No. DE144633038 r: Q C - Q M
Article number
*ATD-3191011*

MultiProFL OperatingInstructions TD-3191011 V1 3 Lite

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MultiProFL OperatingInstructions TD-3191011 V1 3 Lite

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OPERATING INSTRUCTIONS

Incl. assembly instructions according to EC Machinery Directive 2006/42/EC, Annex VI

Press-in control system

DSM Messtechnik GmbH

PDF version of the operating instructions

1 Important basic information .................................................................................................................................................................. 7

3 Technical data ...................................................................................................................................................................................... 21

4 Design of the press-in control system ............................................................................................................................................... 24

6 Process control description ................................................................................................................................................................ 42

© DSM Messtechnik GmbH 2018. All rights reserved!

6.5.6 Function diagram "Relative stroke measurement" .................................................................................................................................... 58

7 Delivery, in-plant transport, storage................................................................................................................................................... 71

8 Setup requirements ............................................................................................................................................................................. 73

9 Initial operation .................................................................................................................................................................................... 75

10 Assembly and installation................................................................................................................................................................... 78

© DSM Messtechnik GmbH 2018. All rights reserved!

10.11.3 System outputs .........................................................................................................................................................................................123

12 Error state detection, system verification ........................................................................................................................................ 190

© DSM Messtechnik GmbH 2018. All rights reserved!

12.1.3 Error display “Description” ....................................................................................................................................................................... 191

13 Service, fault correction, maintenance, cleaning ............................................................................................................................ 205

14 Dismantling and disposal ................................................................................................................................................................. 223

15 Supporting documents ..................................................................................................................................................................... 224

16 Authorised DSM partners.................................................................................................................................................................. 231

17 Index ................................................................................................................................................................................................... 232

© DSM Messtechnik GmbH 2018. All rights reserved!

1 Important basic information

1.1 Scope of delivery

 Basic configuration Press-in control system MultiPro FL

• Control module MultiPro

 Accessories and Options

• Ethernet module (TCP/IP)

© DSM Messtechnik GmbH 2018. All rights reserved!

1.2 Declaration of incorporation

Product designation: Control system (Press-in control system)

Type designation: MultiPro FL DS-S /-L /-H /-V

Machine type: Incomplete machine

Year of manufacture: 2018

Applied harmonized EN standards, particularly:

Applied national standards, laws and technical specifications, particularly:

Authorised representative for the compilation of the technical relevant documents:

Authorized representative for issuing of declaration of incorporation:

© DSM Messtechnik GmbH 2018. All rights reserved!

1.3 Legal information

 Press-in system documentation

Documentation Standard Option

Operating instructions press-in control system MultiPro FL x

Functional description special firmware x

Safety data sheet lubricant Klüberplex BE 31-102 x

Operating instructions socket box ToolControl x

© DSM Messtechnik GmbH 2018. All rights reserved!

Status A B B C D E F 1.0 1.1 1.2

Status Date Firmware version Last modified

A 30/06/2010 3200 Pro-E V 1.06

Basic modules performance data integrated, various changes and adaptations

C 12/06/2014 3200 Pro-E V 1.25 (3200.05) Access control via PB

D 16/12/2014 3200 Pro-E V 1.28 (3200.05) Redesign

D 10/03/2015 Description of the procedure for updating firmware optimised

E 08/06/2016 3200 Pro-E V 1.31 (3200.06) Profibus, Extended configuration 3

E 02/09/2016 Declaration of incorporation updated

except "Move empty"

© DSM Messtechnik GmbH 2018. All rights reserved!

 Identification - Article number

 Conventions regarding the presentation