Page 1 Reishauer are not liable for printing errors or conformity of illus- trations. Danger Prior to the operation of the machine RZ 150, the CHAPTER For Your Safety must be read and understood by each of the operators.
Page 2 RZ 150 Contents 76XXX...
Page 3: Table Of Contents
RZ 150 Contents Contents Documentation of Machine..................9 Contents of this Manual..................9 Using the Manual ..................... 9 Additional Documentation ................10 Structure of Manual ..................... 11 Structure of Manual ..................11 Description of Procedure ..................12 For Your Safety......................13 Classification of Safety Symbols ................. 13 Introduction.....................
Page 4 RZ 150 Contents Coolant ......................33 Disposal......................34 Reishauer’s Responsibility .................. 35 Measures in Design..................35 Measures During Manufacturing ..............35 Company Intern Measures ................35 What is expected from the Customer ..............36 Environment Compatible Operation ............... 36 Disposal......................36 Emissions ......................
Page 5 RZ 150 Contents Record Measured Values................67 Levelling of Machine.................. 67 Check and Record Levelling ................67 Tolerances / Measured Values............... 67 Maintenance ......................69 Introduction......................69 Training of Maintenance Prsonnel ..............69 Maintenance-Specific Safety Instructions ............69 Spare Parts..................... 69 Lubricants / Oils....................
Page 6 RZ 150 Contents Required Tools ....................94 Work Sequence....................94 Restarting After Exchange of Toothed Belt............ 96 Y- Axis, Exchange Toothed Belt................97 Required Tools ....................97 Work Sequence....................97 Restarting After Exchange of Toothed Belt............ 98 Z- Axis, Exchange Toothed Belt................ 100 Required Tools .....................
Page 7 Description of PLC Alarms ................130 Measurements Geometry...................201 Machine Geometry .................... 201 Axis Geometry ....................201 Axes Designation Machine RZ 150 ..............202 Axes Definition ..................... 203 Axis Movement with Protective Door Open..........203 Required Tools and Aids ................203 Axial and Radial Runout of the C1 / C2 Axes (Workpiece Spindle)....
Page 8 RZ 150 Documentation of Machine Contents of this Manual 76XXX...
Page 9: Documentation Of Machine
Customary regulations of the re- spective country have to be obeyed. CHAPTER Installation describes mounting and installation at the customer’s site under supervision of a Reishauer representative, if not otherwise specified. 76xxx...
Page 10: Additional Documentation
Information for the operation of the machine can be found in the “Machine Opera- tion Manual”. Further information for non-Reishauer products, as balancing system, coolant filtra- tion unit and loading can be found in binder Non-Reishauer products or in separate instruction manuals of the sub-supplier. 76XXX...
Page 11: Structure Of Manual
RZ 150 Documentation of Machine Structure of Manual Structure of Manual Structure of Manual This manual is structured in chapters, sections and subsections. Table 1: Structure of manual Operator manual Example Chapter For your safety Section General safety regulations Subsection...
Page 12: Description Of Procedure
RZ 150 Documentation of Machine Description of Procedure Description of Procedure A single procedure is shown as follows: Target of the action > Perform the action • Result of the action. If need be, a framed information will follow and will be helpful in case of problems:...
Page 13: For Your Safety
This chapter illustrates the safety regulations which must be strictly adhered to in the operation of the RZ 150. It defines the responsibility of the user and it shows the safety notes with reference to various danger classifications in the respective chapters.
Page 14: Characterization Of Other Notes
A comment informs about legal matters and in this point it represents the stand- point of Reishauer as against the customer. In addition to the Maintenance & Service Instructions RZ 150, the generally ac- cepted, lawful or other, provisions governing safety precautions, accident preven- tion and environmental protection in the country in which the machine is operated, are to be observed.
Page 15: General Safety Regulations
Local Provisions and Regulations In addition to the Maintenance & Service Instructions RZ 150, the local, lawful or other, provisions governing safety precautions, accident prevention and environ- mental protection must be observed.
Page 16: Duty Of Notification In Case Of Failures And Damages
Reishauer’s authorized personnel. In such a case it is the customer’s responsibility to contact either Reishauer or the local branch office or agent. Neither Reishauer nor the local branch office or agent are liable for damages re- sulting from the user’s neglecting to inform them accordingly.
Page 17: Prohibition Of Modification And Alteration Of Machine
Mounting and/or using non-Reishauer products, as spare parts, tools, accessories and operating agents, not cleared by Reishauer, are not allowed. Neither Reishauer nor the local branch office or the agency of Reishauer are liable for damages resulting from the use of non-original equipment, if not cleared by Reishauer.
Page 18: Authorized Personnel And Competence
Installation, operation and maintenance must be carried out according to Reishauer’s instructions and exclusively by authorized personnel. • Instructions supplied by Reishauer must be read and understood by all the authorized personnel. • Warning and danger signs must not be removed from the machine.
Page 19: Application In Accordance With Regulations
Application in Accordance with Regulations Application in Accordance with Regulations The CNC Gear Grinder RZ 150 is designed for grinding cylindrical gears of either shaft or disk-type shape by the generating grinding method. The working range is defined in the documentation of the machine...
Page 20: Oil Regulations
Oil Regulations The coolant used for grinding and dressing contain substances which might cause allergy. Reishauer is not liable for such incompatibility and allergies of the operator. The operator must take appropriate measures listed below in order to avoid skin contact with the coolant.
Page 21: Risk Of Fire And Deflagration
• Even if a fire is not very likely for standard operating conditions, Reishauer rec- ommends for the equipment of the RZ 150 with an automatic fire alarm and a fire extinguisher unit. •...
Page 22 RZ 150 For Your Safety Risk of Fire and Deflagration Danger – Risk of fire due to grinding process During the grinding process particulate material, and under special conditions, an ignitable oil-air mixture will be formed. Technical defects, (e.g. running hot of defective bearings) or operational errors (e.g.
Page 23 RZ 150 For Your Safety Risk of Fire and Deflagration Fe + 2 H > Fe + H Warning – Toxically gases in case of fire At a fire, besides other things, carbon monoxide (CO) and sulphur dioxide (SO will be set free.
Page 24: Fire- And Deflagration Protection
RZ 150 For Your Safety Fire- and Deflagration Protection Fire- and Deflagration Protection Fire Extinguisher Flap Danger The fire extinguisher flap is integrated into the front door. The fire extinguisher flap is lead-sealed and must be opened for safety reasons only in the case of a fire, in order to fight the fire with the help of a lance or a suitable fire extinguisher.
Page 25: Explosion Flap
Depending on the project, the automatic fire alarm and fire extinguisher unit can be equipped with their own or a centralized controller. Such units are offered by Reishauer AG for the grinding ma- chine as option.
Page 26 RZ 150 For Your Safety Fire Protection Flap / Temperature Feeler In case of a fire the fire protection flap will seal off the air duct between the working area ant the oil mist extraction. The fire protection flap (RAG article no. 211138.00) is integrated as a complete unit into the suction duct.
Page 27: Position Of Fire Protection Flap
RZ 150 For Your Safety Fire Protection Flap / Temperature Feeler Fig. 4: Temperature feeler in working area Temperature feeler Tailstock Machine light Position of Fire Protection Flap The fire protection flap (01) is mechanically connected with the direction pointer (02).
Page 28: Hand Fire Extinguisher
Not part of the standard equipment Warning Fire Risk If the RZ 150 is delivered without Fire Protection Unit, then the customer have to set up a Hand Fire Extinguisher to the machine. If no such automatic fire alarm and fire extinguisher system is installed, a hand fire extinguisher can be used to extinguish a possible fire.
Page 29: Actions In Case Of Emergency
Comply with the further measures according to the organisation. Open Doors in Case of an Emergency Note On the RZ 150 machines there are, for safety purposes, (2) ELAN safety switches installed at the following doors: • Loading door (RAG art.-no. 210705.00), on machine WITHOUT loader, or circular door left (RAG art.-no 332141.00), on machine WITH loader.
Page 30: Situation At Machine Top Side
RZ 150 For Your Safety Actions In Case Of Emergency Situation at Machine Top Side Fig. 7: ELAN Safety switch on machine top side 01 Loading side 02 ELAN safety switch (RAG art.-no. 006200.04) for front door 03 ELAN safety switch (RAG art.-no. 006311.02) on loading side Situation on Loading Side Abb.
Page 31: Situation On Front Door
RZ 150 For Your Safety Actions In Case Of Emergency Unlocking door mechanically Pull unlocking rod (black head). RESULT The door is unlocked and ready to be opened manually. Note For both safety switches the procedure to unlock the doors is identical and will not be described any further.
Page 32: Contact With Coolant Lubricant Or Hydraulic Oil
RZ 150 For Your Safety Contact with Coolant Lubricant or Hydraulic Oil Contact with Coolant Lubricant or Hydraulic Oil First Aid Skin contact with oil/coolant > Take off oil soaked clothes > Rinse oil soaked skin with warm water and soap.
Page 33: For Our Environment
Air purity The RZ 150 is equipped with a the powerful oil mist extractor thus avoiding any il- legal oil mist emission. The oil mist emission is therefore below the allowable limit.
Page 34: Disposal
RZ 150 For our Environment Environmental Compatibility Disposal Note Instructions for the disposal of operating agents and disposal of the machine can be found in this CHAPTER Disposal. 76XXX...
Page 35: Reishauer's Responsibility
For our Environment Reishauer’s Responsibility Reishauer’s Responsibility Reishauer Company is an ISO 9001 certified machine tool manufacturer and it stands for high precision and high production machines. Reishauer also cares for the environment as can be seen by the following measures.
Page 36: What Is Expected From The Customer
RZ 150 For our Environment What is expected from the Customer What is expected from the Customer Environment Compatible Operation Maintenance of the machine and attendance of the coolant according to regula- tions can considerably influence environment compatibility and efficiency of the machine in a positive way: •...
Page 37: Emissions
For our Environment Emissions Emissions Noises The following table shows the noise emission values of the CNC Gear Grinder RZ 150. (complete equipment including grinding oil preparation unit and oil mist extraction unit). Measuring conditions • Measuring device: TESTO 816 (Testo GmbH + Co., D-79849 Lenzkirch) •...
Page 38: Oil Mist
For the machine, which is equipped with other types of grinding oil preparation unit and oil mist extractor, defined by the customer, the emission values might vary. Oil mist The following table shows the oil mist emission values of the CNC Gear Grinder RZ 150. Measuring conditions • Machine is in grinding mode •...
Page 39: Disposal
RZ 150 For our Environment Disposal Disposal Disposal of Operating utilities Generally speaking, operating utilities are considered risky waste according to regulation 91/689/EWG and the user is obligated to dispose them accordingly. In addition, regulations of the specific country in which the machine is used, have to be observed for disposal of waste.
Page 40 RZ 150 For our Environment Disposal 76XXX...
Page 41: Initial Installation
It is the customer’s responsibility to use approved lifting devices only (crane, fork lift, ropes etc.). Reishauer AG accepts no liability for transport damage arising as a result of not following these instructions. The transport of the machine and its components may only be carried out un- der the supervision of a specialist authorized by Reishauer AG.
Page 42: Additional Units/Parts To Be Transported With The Machine
Note The suspension frame plus additional supplementary means must be returned to Reishauer Company within one month after delivery. Otherwise these items will be invoiced to the customer. Unloading and Internal Transportation at Customer’s Site...
Page 43: Internal Transportation At Customer's Site
The firm LKS, Althofstrasse 1, 5432 Neuenhof, Switzerland (www.lks.ch) offers appropriate solutions or services. Supplier’s recommendation For transporting the machine Reishauer AG recommend standard loading equip- ment and resources of the firm: • SpanSet AG...
Page 44 RZ 150 Initial Installation Transport Instructions Fig. 11: Machine attached to hoist Distance from bottom edge of machine (without levelling pads) to crane hook: H = 3510 mm Fig. 12: Transport suspension frame on machine Strap, length 1030 mm Chain, length 1435 mm Chain, length 1280 mm Shackle ¾“, 4.75 t with pin d = 22 mm...
Page 45: Prepare Installation Location
RZ 150 Initial Installation Prepare Installation Location Prepare Installation Location Before locating the machine the installation location must be prepared. Mark Position of Heavy Duty Levelling Pads In the following description the heavy duty levelling pads will be abbreviated simply to levelling pads.
Page 46: Transport Machine To Installation Location
The customer is responsible for ensuring that only approved and tested loading equipment (crane, fork-lift truck, ropes etc.) is used. Reishauer AG accepts no liability for transport damage arising as a result of not following these instructions. The transport of the machine and its components may only be carried out under the supervision of a specialist authorized by Reishauer AG.
Page 47: Transport Suspension Gear
Transport instructions, transport suspension gear SUB SECTION is loaned to the customer as a loading device with the RZ 150. To safeguard the horizontal position of the machine during transport the transport suspension gear must always be mounted as shown below, since the carrying strap and the two chains are of different lengths.
Page 48 RZ 150 Initial Installation Transport Machine to Installation Location Move machine to installation site and place down Move machine to installation site. Mount transport suspension gear on crane and machine. Before finally placing it down check whether the leveling pads are positioned as shown in Prepare installation location.
Page 49: Complete Transport
Release machine from suspension gear and return transport suspension gear. Release strap and chains from machine and lift them up carefully. 4. Return complete transport suspension gear to Reishauer. RESULT The machine has been placed down on 3 leveling pads and can now be levelled.
Page 50: Levelling Of Machine
RZ 150 Initial Installation Levelling of Machine Levelling of Machine Measurement set-up for leveling Necessary tools 1 leveling device, which has been calibrated for transshipment, with min. scale value 0.05 mm/m Fig. 17: Measuring position with testing device 01 Measuring position with testing device...
Page 51: Level Machine With Levelling Pads
RZ 150 Initial Installation Levelling of Machine Level machine with levelling pads Note If a levelling pad is lowered it should initially be lowered more than necessary and then raised again to the correct height (adjusting spindle play). Leveling of machine...
Page 52: Transport External Components
RZ 150 Initial Installation Transport External Components Transport External Components Oil Recooling unit for separate Spindle- and Motor Cooling See the transport instructions from the supplier Grinding Oil Preparation System See the transport instructions from the supplier Workpiece Loading and/or Conveyor Systems...
Page 53: Mount Operating Panel In Working Position
RZ 150 Initial Installation Mount Operating Panel in Working Position Mount Operating Panel in Working Position The following section describes the removal of the transport safety devices from the operating panel, suspending it from the crane and fixing it in place.
Page 54: Releasing / Rotating / Fixing The Operating Panel Swivel Arm
RZ 150 Initial Installation Mount Operating Panel in Working Position Attach customer’s loading equipment (2 ropes) to the two M12 ring screws (03), which are screwed onto the top of the operating panel. Suspend the operating panel thus prepared with the loading equipment from the crane.
Page 55: Stop To Restrict The Swiveling Range Of The Operating Panel
RZ 150 Initial Installation Mount Operating Panel in Working Position Swivel the operating panel into the working position: In order to be able to swivel the operating panel (01) around the left-hand front corner of the cover into its actual working position on the operator’s side, the wall joint (08) for the horizontal swivel arm (04) must be dismantled.
Page 56 RZ 150 Initial Installation Mount Operating Panel in Working Position Fig. 21: Rear view of wall joint Wall joint Socket head cap screw, M12x20 > Push rubber collar over wall joint (08) again; see Figure Wall joint for operating panel swivel arm.
Page 57: Removing Transport Safety Devices
RZ 150 Initial Installation Removing Transport Safety Devices Removing Transport Safety Devices Note It is the responsibilty of the customer to make sure, that after an initial installation all removed transportation locks are stored, assorted in groups, at a central locati- on and this way traceable for further, possible internal or external transportations.
Page 58: Remove Transport Safety Device On X- Axis
RZ 150 Initial Installation Removing Transport Safety Devices Remove Transport Safety Device on X- Axis Undo 3 M10 hex nuts (01) on threaded rod (02). Unscrew M10 threaded rod (02) from grinding slide (03). Dismantle safety block (04). Fig. 23: Securing the X- axis (grinding slide drive)
Page 59: Remove Transport Safety Devices On Y- Axis
RZ 150 Initial Installation Removing Transport Safety Devices RESULT X- axis is ready to operate Remove Transport Safety Devices on Y- Axis Take out 1 M6x16 socket head cap screw (01) from the vertical leg of the red safety bracket (03).
Page 60 RZ 150 Initial Installation Removing Transport Safety Devices Fig. 26: Rail, RAG Art. no. 332626.00; Safety device for workpiece turret 01 Socket head cap screw, M10x80 02 Socket head cap screw, M10x30 03 Rail (colour red) 04 Cover RAG Art. no. 332160.00 05 Socket head cap screw, M6x10 Tighten up cover (04) with 3 M6x10 socket head cap screws (05).
Page 61: Remove Transport Safety Devices On W1/W2- Axes
RZ 150 Initial Installation Removing Transport Safety Devices Remove Transport Safety Devices on W1/W2- Axes Fig. 28: Transport safety devices for tailstock and sleeve 01 Upper lock nut, M10 02 Wooden support for tailstock 03 Lower lock nut, M10 04 Hex screw, M10x80...
Page 62: Install The Elbaron Oil Mist Separator Unit
By the customer’s own central system; Option ”Connection to central system“. In this description the installation of the separately packed oil mist separator (Elbaron RH 200 DV) on the RZ 150 machine is described. Weight of oil mist separator: approx. 80 kg Attach oil mist separator (01) to the 4 lifting eyes (02) with 4 ropes and lift with the crane.
Page 63: Final Preparation And Installation
RZ 150 Initial Installation Final preparation and installation Maschine komplettieren und anschliessen Final preparation and installation EXPLANATION The machine is ready for operation provided the machine has been levelled, completed and installed and the geometrical machine axes tests have been veri- fied in the quality assurance papers.
Page 64 RZ 150 Initial Installation Final preparation and installation > Mount „Adapter“ (01), RAG Art. no. 211099.00 with ready-mounted key holder on: „LH round door“ (02), RAG Art. no. 332141.00. Caution: Between the underside of the ”Adapter“ and the top of the “LH round door“...
Page 65: Tolerances For Levelling The Machine
Connecting Oil Recooling Unit for Separate Spindle- and Motor Cooling EXPLANATION Reishauer gear grinding machines are equipped with an oil recooling unit for separate spindle- and motor cooling. Note The activities described in the following steps may only be carried out by specialist personnel.
Page 66 RZ 150 Initial Installation Final preparation and installation Value Pressure Connection Connection Function [l/min] [MPa] machine 50.6 16 - 17 SV15ZLCF Return line to cooling unit 76XXX...
Page 67: Quality Assurance Machine Installation
RZ 150 Initial Installation Quality Assurance Machine Installation Quality Assurance Machine Installation Record Measured Values Levelling of Machine Fig. 32: Measuring position with testing device for level checking 01 Measuring position with testing 02 Mounting surface of workpiece device spindle...
Page 68 RZ 150 Initial Installation Quality Assurance Machine Installation 76XXX...
Page 69: Maintenance
Spare Parts Only those spare parts, which have been specified by Reishauer, may be used. When exchanging pipes, hoses and screwed fittings it is important to ensure that the correct pressure rating (wall thickness, material) is used.
Page 70: Secure Machine
RZ 150 Maintenance Secure Machine Secure Machine Validity The entire section is valid in the general sense for all maintenance and repair work on the machine: Utilize Personal Safety Lock EXPLANATION During maintenance and repair work the machine, must be secured – whenever possible –...
Page 71: Electrostatic Sensitive Components
RZ 150 Maintenance Electrostatic Sensitive Components Electrostatic Sensitive Components Note When handling such components the following cautionary measures must be heeded and followed: • In principle electronic components should only be touched if it is unavoidable because of the type of work to be carried out •...
Page 72: Restart And Test Machine After Securing
RZ 150 Maintenance Restart and Test Machine After Securing Restart and Test Machine After Securing Validity The entire section is valid in the general sense for all maintenance- and repair work on the machine: Sequence Before restarting Check complete and correct execution of operations.
Page 73: Check And Maintain Machine
RZ 150 Maintenance Check and Maintain Machine Check and Maintain Machine General All checks and maintenance activities are summarized in the following mainte- nance list. In addition the two maintenance tags 332584.00 and 332670.00 attached to the machine contain the most important checks and maintenance tasks (minimum maintenance).
Page 74: Maintenance Lists
RZ 150 Maintenance Check and Maintain Machine Maintenance Lists The messages displayed on the screen are shown in italics. Abbreviations: bB: As necessary Intervention Interval Activity Description of activity Type / kind Amount points (mainte- Remarks value nance tag #)
Page 75 RZ 150 Maintenance Check and Maintain Machine Intervention Interval Activity Description of activity Type / kind Amount points (mainte- Remarks value nance tag #) Outlet container, Dismantle cover, remove grinding RAG Art no. 500 h Clean grinding oil return sludge.
Page 76 RZ 150 Maintenance Check and Maintain Machine Intervention Interval Activity Description of activity Type / kind Amount points (mainte- Remarks value nance tag #) Z-axis 5000 h Check, Repairs, Z-axis, ex- RAG Art no. 1 pcs. SECTION tension if change toothed belt.
Page 77 RZ 150 Maintenance Check and Maintain Machine 76xxx...
Page 78: Lubricate Machine
For all lubrication below, the following types of grease are to be used: • NLGI 2 • Recommended by Reishauer - Klüber Klüberplex BEM34-132 Grease Gun Grease gun as standard accessory article no. 519614.00, (per stroke 0.5 cm Lubricate X- Axis With grease gun inject 15 cm grease.
Page 79: Lubricate Y- Axis
RZ 150 Maintenance Lubricate Machine Lubricate Y- Axis With grease gun inject 4 cm grease. (8 injection strokes) Y-axis grease distributor Fig. 34: Y-axis grease distributor A grease distributor is provided for the Y- axis spindle and guides. It is situated in the grinding head below the grinding wheel and is covered with a plastic sleeve.
Page 80: Lubricate Revolver For C1/C2- Axis
RZ 150 Maintenance Lubricate Machine Lubricate Revolver for C1/C2- Axis With grease gun inject 5 cm grease. (10 injection strokes) Revolver C1/C2-axis grease distributor Fig. 36: Revolver grease distributor A grease distributor is provided for the revolver guides. This is situated behind the service hatch below the work space.
Page 81: Cleaning Of Machine
RZ 150 Maintenance Cleaning of Machine Cleaning of Machine In spite of generously designed flushing equipment, residual deposits from swarf and all kinds of dirt can build up, which require manual cleaning. The machine and its peripherals operate particularly reliably if they are manually cleaned periodically by the operator.
Page 82 RZ 150 Maintenance Cleaning of Machine Warning – damage to property and injuries to personnel If cleaning is carried out improperly, damage to property, personnel injury as well as fire can occur! • NEVER use compressed air (risk of dirt penetrating into bearings and guides).
Page 83: Clean Outlet Container In Grinding Oil Return Line
RZ 150 Maintenance Clean Outlet Container in Grinding Oil Return Line Clean Outlet Container in Grinding Oil Return Line Tools Required • Set of Allen keys • Cleaning cloths • Waste container for grinding sludge Work Sequence Prepare machine and material Have ready the necessary tools and round cord if required, RAG Art.
Page 84: Check Runout Of Fixture
RZ 150 Maintenance Clean Outlet Container in Grinding Oil Return Line Check Runout of Fixture Checking ring Magnetic stand with dial indicator Fig. 40: Concentricity check of clamping device Figure of clamping device is only an example to provide a general idea of the situation.
Page 85: Check Emergency Stop Circuit
RZ 150 Maintenance Check Emergency Stop Circuit Check Emergency Stop Circuit Fig. 41: Machine control panel and operator panel Emergency stop button Switch (controller) ON The coolant filtration system has its own emergency-off circuit. Starting position: The machine is switched on and is referenced.
Page 86 RZ 150 Maintenance Check Emergency Stop Circuit Machine control panel Loader control Protection fence for Loader electrical panel loader enclosure 76XXX...
Page 87: Repairs
The working sequences described must be followed. • Any specially-listed special tools must be used. • Only the specified cleaning and operating media may be used. • Only spare parts, which have been specified by Reishauer, are to be used. 76xxx...
Page 88: Hydraulic System - Drain Accumulator
Before starting any repair work the entire hydraulic section must be depressurized. Procedure Before the shut-off faucet can be opened with the lever, the safety disk must be rotated. Abb. 42: Hydraulic panel, RZ 150 01 Accumulator 02 Lever shut-off valve 03 Hex. screw with washer...
Page 89: Re-Establishing The Readiness To Operate
RZ 150 Repairs Hydraulic System - Drain Accumulator RESULT The hydraulic section is now depressurized and ready for repair work. Re-establishing the readiness to operate Warning accumulator safety The shut-off valve of hydraulic accumulator must be secured with safety disk before restarting the machine again.
Page 90: Toothed Belt Drives
For correctly tensioning the toothed belt the inherent frequency of a belt, which has been made to vibrate, is measured. For this purpose a belt tension measuring de- vice is required. Reishauer AG uses for example: Clavis Belt Tension Meter from Integrated Display Systems Limited. See: www.clavis.co.uk Note The servo drive motors are equipped with absolute encoders.
Page 91: W1 / W2- Axis, Exchange Toothed Belts
RZ 150 Repairs W1 / W2- Axis, Exchange Toothed Belts W1 / W2- Axis, Exchange Toothed Belts Toothed belt: RAG Art. no.: 534672.00 Frequency: 52 Hz ± 1 Hz Required Tools • Belt tension measuring unit • Set of Allen keys...
Page 92 RZ 150 Repairs W1 / W2- Axis, Exchange Toothed Belts RESULT The belt drive of W1 / W2 –axis is exposed Belt changing / belt tensioning Fig. 43: C3 axis in position + 205° for changing belt on the W1 axis...
Page 93: Restarting After Exchange Of Toothed Belt
RZ 150 Repairs W1 / W2- Axis, Exchange Toothed Belts Restarting After Exchange of Toothed Belt > Remove all external equipment, i.e. auxiliary and repair equipment, tools, loose nuts and bolts etc. from the machine. > Switch on machine and test after securing according to...
Page 94: X- Axis, Exchange Toothed Belt
RZ 150 Repairs X- Axis, Exchange Toothed Belt X- Axis, Exchange Toothed Belt Toothed belt: RAG art. no.: 534568.00 Frequency: 120 Hz ± 2 Hz Required Tools • Belt tension measuring unit • Set of Allen keys Work Sequence Prepare machine and materials Have the necessary tools and toothed belt ready.
Page 95 RZ 150 Repairs X- Axis, Exchange Toothed Belt Fig. 5: Belt cover , x-axis 05 Belt cover fixation 06 Belt cover Remove the 4 screws (05) with Allen key. Remove belt cover (06). RESULT The belt drive of X-axis is exposed.
Page 96: Restarting After Exchange Of Toothed Belt
RZ 150 Repairs X- Axis, Exchange Toothed Belt EXPLANATION If it is possible to succeed in installing the new toothed belt without turning the toothed wheel, it is only necessary to check the axis position and it is not neces- sary to realign it.
Page 97: Y- Axis, Exchange Toothed Belt
RZ 150 Repairs Y- Axis, Exchange Toothed Belt Y- Axis, Exchange Toothed Belt Toothed belt: RAG Art. no.: 534569.00 Frequency: 60 Hz ± 1 Hz Required Tools • Belt tension measuring unit • Set of Allen keys Work Sequence Prepare machine and materials Have the necessary tools and toothed belt ready.
Page 98: Restarting After Exchange Of Toothed Belt
RZ 150 Repairs Y- Axis, Exchange Toothed Belt EXPLANATION If it is possible to succeed in installing the new toothed belt without turning the toothed wheel, it is only necessary to check the axis position and it is not neces- sary to realign it.
Page 99 RZ 150 Repairs Y- Axis, Exchange Toothed Belt RESULT The machine can continue to produce. Note – recalibration of axes For the description of how to recalibrate axes see TRAINING DOCUMENTATION chanical repairs AA0510. 76xxx...
Page 100: Z- Axis, Exchange Toothed Belt
RZ 150 Repairs Z- Axis, Exchange Toothed Belt Z- Axis, Exchange Toothed Belt Toothed belt: RAG Art. no.: 534568.00 Frequency: 120 Hz ± 2 Hz Required Tools • Belt tension measuring unit • Set of Allen keys • Fork spanner •...
Page 101 RZ 150 Repairs Z- Axis, Exchange Toothed Belt Fig. 3: Z drive Fig. 4: Z drive 04 Belt hatch 05 Belt 06 Z drive fixing 07 Belt tensioning screw EXPLANATION Belt tension can be measured through the hole in belt without having to remove the drive unit.
Page 102: Restarting After Exchange Of Toothed Belt
RZ 150 Repairs Z- Axis, Exchange Toothed Belt RESULT The toothed belt has been exchanged and is properly tensioned Restarting After Exchange of Toothed Belt > Remove all external equipment, i.e. auxiliary and repair equipment, tools, loose nuts and bolts etc. from the machine.
Page 103: Bellows
RZ 150 Repairs Bellows Bellows Danger of crushing There is a risk of serious or even life-threatening injury from crushing if the vertical axes are driven down unintentionally. > The vertical axes have to be brougth down to their lowest end position before dismantling the bellows.
Page 104: C1 / C2- Axis, Exchange Bellows And V-Rings
RZ 150 Repairs C1 / C2- Axis, Exchange Bellows and V-rings C1 / C2- Axis, Exchange Bellows and V-rings Bellows: RAG Art. no.: 331202.00 Required tools • Set of Allen keys Work Sequence Prepare machine and materials Have the necessary tools and bellows (2 pcs.) ready.
Page 105 RZ 150 Repairs C1 / C2- Axis, Exchange Bellows and V-rings 01 Hex socket head set screw with 02 Labyrinth ring 328312.00 point, M6x16 03 V-ring, dia.125-135 04 V-ring, dia. 185-195 05 Hex socket head setscrew, M5x8 06 Socket head cap screw, M4x10 07 Ring 328313.00...
Page 106: Restarting After Exchanging Bellows
RZ 150 Repairs C1 / C2- Axis, Exchange Bellows and V-rings > Clean grease off underside of the bellows to ensure good contact with the sealant on the intermediate plate (15). > Also clean the grease off the upper inside face of the bellows at the con- tact surface with ring gauge (10).
Page 107: X- Axis, Exchange Bellows
RZ 150 Repairs X- Axis, Exchange Bellows X- Axis, Exchange Bellows Bellows: RAG Art. no.: 534576.01 Required Tools • Set of Allen keys Work Sequence Prepare machine and materials Have the necessary tools and bellows (2 pcs.) ready. Move X-axis to the maximum X+ position, if possible.
Page 108: Exchanging The Bellows
RZ 150 Repairs X- Axis, Exchange Bellows Exchanging the Bellows Fig. 3: Situation of bellows on X- axis Fig. 4: Bellows with positioning cams 05 Socket head cap screw, M6x20 06 End piece 07 Positioning hole in end piece 08 Bellows 09 Positioning cams on bellows Remove 2 M6x20 socket head cap screws (05) with Allen key.
Page 109: Restarting After Exchanging Bellows
RZ 150 Repairs X- Axis, Exchange Bellows Restarting After Exchanging Bellows Prepare machine for further production > Remove all external items, i.e. auxiliary and repair equipment, tools, loose ma- terials for screwed connections etc. from the machine. > Switch on machine and test after securing according to Maintenance.
Page 110: Exchange Of Window In Grinding Door
Exchange of Window in Grinding Door Note - ageing, loss of strength The RZ 150 is equipped with a polycarbonate front panel. This material is loosing over time its original strength due to the influence of the grinding oil. For safety reasons this window must be exchanged every 3 years.
Page 111 RZ 150 Repairs Exchange of Window in Grinding Door Change front panel Fig. 46: Window in grinding door 01 Frame 02 Fixing screws Remove screws (02) with Allen key. Remove frame (01). Remove old window and dispose according the the country-specific regula- tions.
Page 112: Exchange Machine Lighting
RZ 150 Repairs Exchange Machine Lighting Exchange Machine Lighting Machine lamp 24 V DC: RAG art. no.: 006444.05 Required Tools • Square spanner Work Sequence Prepare machine and materials Have tools and machine lamp ready. Move the axes in setting-up mode so that accessibility to the machine lighting is ensured.
Page 113 RZ 150 Repairs Exchange Machine Lighting Fig. 48: Rear maintenance hatch 04 Maintenance hatch fixing 05 Rear maintenance hatch Loosen the two maintenance hatch fixings (04) with square spanner. Lift out the maintenance hatch cover. Fig. 49: Machine lighting 06 Machine lighting...
Page 114: Y- Axis, Exchange Telescopic Covers
RZ 150 Repairs Y- axis, Exchange Telescopic Covers Y- axis, Exchange Telescopic Covers Telescopic covers: RAG art.-no.: 331174.00 Required Tools • Standard tool • Set of Allen keys between 4 - 8 mm Work Sequence Prepare machine and materials Have tools and telescopic covers ready.
Page 115 RZ 150 Repairs Y- axis, Exchange Telescopic Covers Detach left side of front telescopic cover Fig. 50: Hex socket screws on the left side of the telescopic cover 04 M6x12 hex socket screws Remove the 3 hex socket screws (04) on the inside and 1 hex socket screw (04) on the outside of the belt housing.
Page 116 RZ 150 Repairs Y- axis, Exchange Telescopic Covers Detach right side of front telescopic cover Fig. 51: Hex socket screws on the right-hand side of the front telescopic cover 05 M6 x12 hex socket screw Remove the 6 M6x12 hex socket screws (05).
Page 117 RZ 150 Repairs Y- axis, Exchange Telescopic Covers Dismantle Lower Guard Strip (08) on Y- Axis (Shift Slide) EXPLANATION Before the lower guard strip (08) can be dismantled it is first necessary to loosen – but not to completely remove the 5 hex socket screws (09) from bracket (10).
Page 118: Exchange The Rear Telescopic Cover
RZ 150 Repairs Y- axis, Exchange Telescopic Covers Mount New Front Telescopic Cover 1. Spread new sealant (Hylomar paste) on the cleaned surfaces. 2. Insert new front telescopic cover (03) carefully. Fix the right end of the front telescopic cover (03) provisionally onto the B axis with the 6 M6x12 hex socket screws (05) (do not yet tighten up).
Page 119 RZ 150 Repairs Y- axis, Exchange Telescopic Covers Loosen the 4 hex socket screws (12) on the right side of the telescopic cover. RESULT The rear telescopic cover is now free to be dismantled, it is only held in position on both sides now by the sealant mass (Hylomar paste).
Page 120 RZ 150 Repairs Y- axis, Exchange Telescopic Covers Remount Belt Cover on Y- Axis Clean seating surface of the belt cover (01) before mounting. Insert the round cord cover in the slot of the belt housing. Mount belt cover (01) on belt housing with screws (02).
Page 121: Error Messages
RZ 150 Error Messages Evaluate Alarms and Messages Error Messages Evaluate Alarms and Messages Safety If an error occurs on the machine, then increased caution is required. In extreme cases humans can be endangered due malfunction of the machine. Danger of injury due to moving parts! Mortal danger can exist, because of malfunction of the controller or wrong manipu- lation on the software or components.
Page 122: Alarms, Messages And Alarm Protocols
RZ 150 Error Messages Alarms, Messages and Alarm Protocols Alarms, Messages and Alarm Protocols Display of Alarms Select K Menu select (10) on computer panel. Select S Diagnosis. OFTKEY Select S Alarms. OFTKEY Fig. 55: Display of alarms Display of messages Select Menu select (10) on computer panel.
Page 123: Display Of Alarm Log (Protocol)
Close window with End help. SOFTKEY RESULT This way you receive comprehensive information about alarms. Note The alarm texts, issued by Reishauer, contain often references to BMK's (device designation codes). This way experts can localize defective elements very effi- cient. 76xxx...
Page 124: Cancel Of Alarms
RZ 150 Error Messages Cancel of Alarms Cancel of Alarms Acknowledgment of Minor Errors EXPLANATION Minor errors can be repaired by the operator. Example: The grinding oil preparation is not switched on. Correct and repair the displayed error, i.e. switch-on the device.
Page 125: Type Of Errors
RZ 150 Error Messages Cancel of Alarms Type of Errors Errors will be recognized by: • NC (Numerical Control), i.e. dragging error or • PLC (Programmable Logic Controller) i.e. limit switch defective. During the operation if an error is recognized, the machine reacts depending upon...
Page 126: Organization Alarms And Messages
RZ 150 Error Messages Organization Alarms and Messages Organization Alarms and Messages Alarm Groups (Excerpts from Siemens Documentation Diagnosis manual 840D_DA.pdf)) NC Alarms The alarms are divided in groups of alarms. • General alarms • Computer coupling alarms • Axis specific alarms •...
Page 127: Delete Alarms
RZ 150 Error Messages Organization Alarms and Messages Table 2: MMC-alarms / messages 100'000 – 100’999 Basic system 101'000 – 101’999 Diagnosis 102'000 – 102’999 Services 103'000 – 103’999 Machine 104'000 – 104’999 Parameter 105'000 – 105’999 Programming 106'000 – 106’999 Reserve 107'000 - 107999 109'000 –...
Page 128: Assistance By Reishauer Customer Service
Error Messages Organization Alarms and Messages Assistance by Reishauer Customer Service If the fault cannot be repaired by the customer’s own means, then the Reishauer customer service is at your disposal. The following information's must be available for the customer service: •...
Page 129: Modification Protocol
RZ 150 Error Messages Organization Alarms and Messages Modification Protocol Version Date Error-No. Description Name V1.0 07.07.04 Initial issue Grab/Haller V 1.071 13.09.04 New error descriptions for: A100, A101, A112, Halter A113, A119, A141, A194, A236, A237, A238, A239, A352, A353, A354 V 1.072...
Page 130: Description Of Plc Alarms
RZ 150 Error Messages Description of PLC Alarms 700000 A0FC201 Main supply: over voltage (F102, F103, F104) Explanation Possible cause Remedy It will be checked if An over voltage existed and > Check the input voltage and the corresponding the surge diverter is...
Page 131 RZ 150 Error Messages Description of PLC Alarms 700016 A16FC203 Supply 24V: circuit-breaker for switches not ok (F307) Explanation Possible cause Remedy Automatic circuit Automatic circuit breaker > Switch on automatic circuit breaker (F307) breaker (F307) is (F307) is inactive >...
Page 132 RZ 150 Error Messages Description of PLC Alarms 700019 A19FC203 Supply 24V: signal exchange not ok (F321) Explanation Possible cause Remedy Automatic circuit Automatic circuit breaker > Switch on automatic circuit breaker (F321) breaker (F321) is (F321) is inactive > If automatic circuit breaker (F321) tripped again, the not ok.
Page 133 RZ 150 Error Messages Description of PLC Alarms 700024 A24FC204 Control cabinet air conditioner 2 or circuit-breaker not ok (F403/Q403,A403) Explanation Possible cause Remedy Motor circuit protec- Motor circuit protector > Switch on motor circuit protector (Q403) tor (Q403) or air (Q403) is inactive >...
Page 134 RZ 150 Error Messages Description of PLC Alarms 700041 M9FC206 Opening of doors not allowed, X-axis not stopped Explanation Possible cause Remedy > Wait until all axes come to a still stand, before Message The X-axis is in motion opening the protection doors.
Page 135 RZ 150 Error Messages Description of PLC Alarms 700046 M14FC206 Opening of doors not allowed, C1-axis not stopped Explanation Possible cause Remedy Message The C1-axis is in motion > Wait until all axes come to a still stand, before During the move-...
Page 136 RZ 150 Error Messages Description of PLC Alarms 700051 M19FC206 Opening of doors not allowed, C4-axis not stopped Explanation Possible cause Remedy > Wait until all axes come to a still stand, before Message The C4-axis is in motion opening the protection doors...
Page 137 RZ 150 Error Messages Description of PLC Alarms 700057 M25FC207 Foot pedal switch pushed through Explanation Possible cause Remedy Message The acknowledgement foot > Check why the authorization foot pedal switch The acknowledge- pedal switch (S701) is (S701) is being pushed through. If there exists no...
Page 138 RZ 150 Error Messages Description of PLC Alarms 700100 M32FC205 Emergency circuit: safety relay or 0V E-stop switch circuit not ok (A506) Explanation Possible cause Remedy Although a safety The safety relay (A506) is > Replace safety relay (A506) related element...
Page 139 RZ 150 Error Messages Description of PLC Alarms 700103 A35FC205 Emergency stop: filtration system Explanation Possible cause Remedy Safety circuit is E-stop oil filtration system > Check why E-stop is pressed. interrupted at is pressed. If there exists no danger for humans and machine, location E-stop oil then unlock e-stop button for oil filtration system.
Page 140 RZ 150 Error Messages Description of PLC Alarms 700107 A39FC205 Emergency circuit: supply 24V not ok (F512) Explanation Possible cause Remedy Automatic circuit Automatic circuit breaker > Switch on automatic circuit breaker (F512) breaker (F512) is (F512) is inactive > If automatic circuit breaker (F512) tripped again, the not ok.
Page 141 RZ 150 Error Messages Description of PLC Alarms 700110 A42FC205 Emergency circuit: supply 3x400V not ok (Q526) Explanation Possible cause Remedy Motor protection Motor protection switch > Switch on motor protection switch (Q526) switch (Q526) is not (Q526) is inactive >...
Page 142 RZ 150 Error Messages Description of PLC Alarms 700118 A50FC206 Loading door not unlocked Explanation Possible cause Remedy Although the relay The relay (K617) is not > Check wiring (wire breakage) (K617) is being actuated. > Replace relay (K617) controlled, the The relay (K617) is actu- >...
Page 143 RZ 150 Error Messages Description of PLC Alarms 700122 A54FC206 Door performance check not ok (A710) Explanation Possible cause Remedy It will be monitored The acknowledgement is > Release acknowledge switch (S701) that the acknowl- still active. The acknowl- edgement will not...
Page 144 RZ 150 Error Messages Description of PLC Alarms 700125 A57FC206 Protection area of loader not closed Explanation Possible cause Remedy The protection area Loader protection area is > Close loader protection area of loader is not open closed Wiring (interface to sub- >...
Page 145 RZ 150 Error Messages Description of PLC Alarms 700200 A64FC207 Axes authorization: safety relay not ok (A710) Explanation Possible cause Remedy Although the au- Both the channels > Release authorization foot pedal switch (S701) thorization foot (S13/S14 and S23/S24) again and afterwards press again.
Page 146 RZ 150 Error Messages Description of PLC Alarms 700216 A80FC212 Operator panel: Temperature too high (B1233) Explanation Possible cause Remedy The temperature in Alarm temperature limit is > Adjust alarm temperature limit (increase) the operating panel set too low (Adjustment is too high.
Page 147 RZ 150 Error Messages Description of PLC Alarms 700225 A89FC213 Pneumatics: Air pressure purged air not ok (B1301) Explanation Possible cause Remedy Pressure for purged Pressure reducing valve > Open pressure reducing valve to reach approx. 3 air measuring (25V6) is set wrong.
Page 148 RZ 150 Error Messages Description of PLC Alarms 700300 A96FC215 Hydraulics: circuit-breaker not ok (Q1501) Explanation Possible cause Remedy Motor protection Motor protection switch > Switch on motor protection switch (Q1501) switch (Q1501) is (Q1501) is inactive > If motor protection switch (Q1501) tripped again, the not ok.
Page 149 RZ 150 Error Messages Description of PLC Alarms 700304 A100FC215 Hydraulics: Oil main pressure is too high or switch is not ok (B1504) Explanation Possible cause Remedy An over pressure Hydraulic control pump > Adjust hydraulic control pump (M1500) according to...
Page 150 RZ 150 Error Messages Description of PLC Alarms 700310 A106FC217 Collet 2 clamping not ok (B1701, Y1701) Explanation Possible cause Remedy Although that the Pressure switch (B1701) > Adjust pressure switch (B1701) correct. Pressure output to control set incorrect. switch must switch-off at pressure below 10 bar (Di- valve (Y1701) is ode red).
Page 151 RZ 150 Error Messages Description of PLC Alarms 700313 A109FC217 Three point support 2 not ok (B1703, Y1706) Explanation Possible cause Remedy During the grinding Workpiece badly clamped > Unclamp and clamp workpiece again process the three (Workpiece not seated point support moni- correct).
Page 152 RZ 150 Error Messages Description of PLC Alarms 700316 A112FC220 Balancing unit: Error Cp340 after sending command Explanation Possible cause Remedy The communication Line interference > Re-start machine building group Building group error > Message to RAG CP340 announces after a sending task an error.
Page 153 RZ 150 Error Messages Description of PLC Alarms 700321 A117FC220 Balancing unit: Time-out confirmation protocol Explanation Possible cause Remedy The job protocol of Balancing unit is defective > Message to RAG the PLC is not being acknowl- edged by the bal- ancing device in the preset time.
Page 154 RZ 150 Error Messages Description of PLC Alarms 700325 A121FC223 Meshing probe did not reach park position or limit switch defective (B2801) Explanation Possible cause Remedy Timeout meshing The retract motion is too > Increase the speed of the retract movement (adjust probe retract.
Page 155 (i.e. grinding in single step) must be completed first (see menu guidance The operating step) is not yet completed. Reishauer MMI). Subsequently, the operating mode mode automatic change is introduced and the new mode of operation operation has been ->...
Page 156 (i.e. grinding in single step) must be completed first (see menu guidance The operating step) is not yet completed. Reishauer MMI). Subsequently, the operating mode mode single opera- change is introduced and the new mode of operation tion has been ->...
Page 157 RZ 150 Error Messages Description of PLC Alarms 700352 M116FC61 Operation mode change active Explanation Possible cause Message The request for an operating mode change has been recognized and the operating mode change is active. (i.e. in the automatic operation mode the machine goes thru A new operating the emptying run).
Page 158 RZ 150 Error Messages Description of PLC Alarms Explanation Possible cause Remedy Wiring between air flow > Check wiring sensor (B3310) and meas- urement amplifier (A3310) defective Wire breakage on input > Check wiring PLC (see electr. diagram) Air flow sensor (B3310) >...
Page 159 RZ 150 Error Messages Description of PLC Alarms 700409 A137FC227 Grinding oil pressure or switch B3500 not ok (B3500) Explanation Possible cause Remedy Although grinding Oil flow not sufficient > Clean oil line oil has been re- (plugged oil line or main >...
Page 160 RZ 150 Error Messages Description of PLC Alarms 700412 A140FC227 Oil pressure system : Error in thermal switch of pumps Explanation Possible cause Remedy The thermal protec- Oil pressure system is > See documentation of the corresponding sub- tion switch (pumps)
Page 161 RZ 150 Error Messages Description of PLC Alarms 700415 A143FC227 Oil pressure system : Error in fresh oil level Explanation Possible cause Remedy The level „fresh oil“ Oil pressure system is > See documentation of the corresponding sub- of the oil pressure...
Page 162 RZ 150 Error Messages Description of PLC Alarms 700419 A147FC227 Cooling oil circuit 2: Oil flow not ok Explanation Possible cause Remedy At the moment > there is no second oil cooling circuit in operation (separate grinding spindle air conditioner).
Page 163 RZ 150 Error Messages Description of PLC Alarms 700423 A151FC227 Oberlin-Filter Warning Explanation Possible cause Remedy For the Oberlin filter Oberlin-Filter is defective > See documentation „Sub-supplier device“ (grinding a warning is being oil preparation) displayed Cable grinding machine / >...
Page 164 RZ 150 Error Messages Description of PLC Alarms 700426 A154FC231 Relay for emergency retract not ok (K4121,K4122) Explanation Possible cause Remedy With the relay Wire breakage on Input > Check wiring (K4121) the emer- PLC (see electr. diagram) gency retract is Wire breakage to the relay >...
Page 165 RZ 150 Error Messages Description of PLC Alarms 700500 A160FC232 Controller for electronic gearbox not ready Explanation Possible cause Remedy During machine Wire breakage on Input > Check wiring speed up it will be PLC (see electr. diagram) checked, if elec- Mains to electronic gearbox >...
Page 166 RZ 150 Error Messages Description of PLC Alarms 700504 A164FC232 C1-axis: Intermediate circuit supply not ok Explanation Possible cause Remedy At impulse enabling Main supply drive (A5201) > Check wiring and main supply (600VDC / 24VDC) of the C1-axis it will...
Page 167 RZ 150 Error Messages Description of PLC Alarms 700507 A167FC232 C1-axis: Prewarning temperature power amplifier (A5201) Explanation Possible cause Remedy At impulse enabling Main supply drive (A5201) > Check wiring and main supply (600VDC) of the C1-axis it will is defective...
Page 168 RZ 150 Error Messages Description of PLC Alarms 700511 A171FC232 C2-axis: Alarm motor temperature (M5201) Explanation Possible cause Remedy At impulse enabling Supply drive (A5202) is > Check wiring and supply (600VDC). of the C2-axis it will defective be monitored, if a Cooling of the motor >...
Page 169 RZ 150 Error Messages Description of PLC Alarms 700514 A174FC232 C2-axis: Encoder not ok (B5204) Explanation Possible cause Remedy At impulse enabling Supply drive (A5202) is > Check wiring and supply (600VDC) of the C2-axis it will defective be monitored, if the Wiring encoder (B5204) is >...
Page 170 RZ 150 Error Messages Description of PLC Alarms 700518 A178FC232 C2-axis: Revolution = 0 not ok (A5202) Explanation Possible cause Remedy At doors open and Supply drive (A5202) is > Check wiring and supply (600VDC) inactive agreement defective the drive power Wire breakage on Input >...
Page 171 RZ 150 Error Messages Description of PLC Alarms 700527 A187FC233 P-axis defined nominal value is too large Explanation Possible cause Remedy It will be checked, One of the increment keys > Select increment size keys 1 or 10 that the default...
Page 172 RZ 150 Error Messages Description of PLC Alarms 700602 A194FC241 RP-dressing: Rotation speed too high, or monitor defect [A8613] Explanation Possible cause Remedy The revolution Output frequency of the > Check parameterization and wiring of the frequency monitoring for the...
Page 173 RZ 150 Error Messages Description of PLC Alarms 700616 A208FC36 A-axis clamping not ok (B4801, Y4800) Explanation Possible cause Remedy Although the PLC- Pressure switch (B4801) > Reset pressure control switch correctly. Pressure output to „unclamp set incorrect or is defective.
Page 174 RZ 150 Error Messages Description of PLC Alarms 700626 A218FC37 C3-axis not raised (B5700, Y5701) Explanation Possible cause Remedy Although the PLC- Wire breakage to valve > Check wiring output to „relief of (Y5701). C3- axis“ is active Wire breakage on Input >...
Page 175 RZ 150 Error Messages Description of PLC Alarms 700630 A222FC37 Swing covering flaps into working position Explanation Possible cause Remedy Before moving the Operating error -> C3-Axis > First swing the covering flaps into the working posi- C3- axis, it will be...
Page 176 RZ 150 Error Messages Description of PLC Alarms 700703 A227FC37 Covering flaps did not reach dressing position or limit switch is defective (B5704) Explanation Possible cause Remedy Timeout covering The flap motion is too slow. > Increase the speed of the flap motion (adjust the...
Page 177 RZ 150 Error Messages Description of PLC Alarms 700709 A233FC39 B-axis grinding wheel cover is not mounted (S5002, S5003) Explanation Possible cause Remedy A moving command The grinding wheel cover is > Close grinding wheel cover for the grinding open.
Page 178 RZ 150 Error Messages Description of PLC Alarms 700712 A236FC222 Fire extinguisher active Explanation Possible cause Remedy An emergency Fire in the machine > See documentation „”sub-supplier devices“ (fire retract due to a fire extinguisher system) alarm has been Wire breakage on Input >...
Page 179 A240FC169 Axis designation not possible, axis is currently des- ignated to channel 2 Explanation Possible cause Remedy Various NC- NC-program error > Contact authorized Reishauer personnel channels want to access the same axis. 700717 A241FC169 Axis designation not possible, axis is currently des- ignated to channel 1...
Page 180 RZ 150 Error Messages Description of PLC Alarms 700725 A249OB82 Communication Balancing unit not ok (X931) Explanation Possible cause Remedy The serial commu- Connection cable is defec- > Check cables tive or not plugged in. nication (RS232) from CP340 to the balancing unit is defective.
Page 181 -> error Bit 0-5 700808 A264FC211 E-G task for instruction management not defined Explanation Possible cause Remedy NC-program error > Contact authorized Reishauer personnel 700809 A265FC211 E-G recipient for PLC channel 1 not allowed Explanation Possible cause Remedy NC-program error >...
Page 182 Description of PLC Alarms 700815 A271FC211 E-G recipient for PLC not allowed Explanation Possible cause Remedy NC-program error > Contact authorized Reishauer personnel 700816 A272FC211 E-G instruction from PLC not allowed Explanation Possible cause Remedy NC-program error > Contact authorized Reishauer personnel...
Page 183 Remedy For this error there Incorrect help file > Obtain correct help file via RAG. is no special error Error should actually never > Contact authorized Reishauer personnel description avail- appear. able. 700825 A281FC211 E-G error: function not implemented Explanation...
Page 184 Description of PLC Alarms 700826 A282FC211 E-G error: Exception not managed Explanation Possible cause Remedy Severe error in Error should actually never > Contact authorized Reishauer personnel electronic gearbox. appear. 700827 A283FC211 E-G error: Calling protocol wrong Explanation Possible cause Remedy NC-program error >...
Page 185 A293FC211 E-G error: AM option is not available Explanation Possible cause Remedy The automatic AM is a special option for > Obtain an AM- function via the Reishauer – sales meshing is not this machine department. supported by the electronic gearbox.
Page 186 A294FC211 E-G error: AM not possible without teach-in Explanation Possible cause Remedy Incorrect operation > Execute first a learning cycle. NC-program error > Contact authorized Reishauer personnel 700907 A295FC211 E-G error: Servo loop enable not allowed due to en- coder error Explanation Possible cause Remedy...
Page 187 A300FC211 E-G error: AM proposed number of teeth not al- lowed Explanation Possible cause Remedy For the measuring NC-program error > Contact authorized Reishauer personnel the entered number of teeth must be between min. 2 and max. 100. 700913 A301FC211 E-G error: H-command not allowed...
Page 188 Possible cause Remedy Does error occur during > Check lubricant pressure (fine filter) cooling grinding with high speeds, > Contact authorized Reishauer personnel than the drive is defective. In rare cases the grinding > Check automatic meshing. pressure can become too large i.e.
Page 189 Wire breakage > Check encoder cable and plug connection. Limit frequency of measur- > Reduce speed of axis. ing system exceeded. > Contact authorized Reishauer personnel. Supply measuring system > Check supply. too small. Distance of reading head > Adjust correct distance.
Page 190 700922 A310FC211 E-G, hardware or software exception occurred Explanation Possible cause Remedy Depending on Not sufficient memory > Contact authorized Reishauer personnel. context, overall available for computaion of message for severe the H commands. errors of the elec- tronic gearbox.
Page 191 Wire breakage > Check encoder cable and plug connection. Limit frequency of measur- > Reduce speed of axis. ing system exceeded. > Contact authorized Reishauer personnel. Supply measuring system > Check supply. too small. Distance of reading head > Adjust correct distance.
Page 192 > Clean encoder or exchange. the encoder signal Limit frequency of measur- > Reduce speed of axis. is below the stan- ing system exceeded. > Contact authorized Reishauer personnel. dard, valid limits. Supply measuring system > Check supply. too small. Distance of reading head >...
Page 193 > Check lubricant pressure (fine filter) cooling grinding with high speeds, > Check cooling than the drive is defective. > Contact authorized Reishauer personnel In rare cases the grinding > Check automatic meshing. pressure can become too large i.e. due to faulty meshing.
Page 194 Wire breakage > Check encoder cable and plug connection. Limit frequency of measur- > Reduce speed of axis. ing system exceeded. > Contact authorized Reishauer personnel. Supply measuring system > Check supply. too small. Distance of reading head > Adjust correct distance.
Page 195 > Clean encoder or exchange. the encoder signal Limit frequency of measur- > Reduce speed of axis. is below the stan- ing system exceeded. > Contact authorized Reishauer personnel. dard, valid limits. Supply measuring system > Check supply. too small. Distance of reading head >...
Page 196 RZ 150 Error Messages Description of PLC Alarms 701010 A330FC211 E-G, C1 Commutate will be repeated Explanation Possible cause Remedy Internal error num- If the axis is field-specific at ber, will not be the dead point during displayed commuting, then the output...
Page 197 Possible cause Remedy 701024 A344FC211 E-G, Receiving error Cp340 Explanation Possible cause Remedy NC- program- or hardware > Contact authorized Reishauer personnel error 701025 A345FC211 E-G, Sending error Cp340 Explanation Possible cause Remedy NC- program- or hardware Contact authorized Reishauer personnel...
Page 198 Description of PLC Alarms 701030 A350FC211 E-G, Connection interruption, timeout Explanation Possible cause Remedy Program or hardware error. > Contact authorized Reishauer personnel No response from elec- > Contact authorized Reishauer personnel tronic gearbox to ECHO- command. Supply electronic gearbox >...
Page 199 RZ 150 Error Messages Description of PLC Alarms 701102 A354FC220 Balancing procedure unsuccessful interrupted Explanation Possible cause Remedy A second balancing Grinding wheel is fully > Spinning of grinding wheel for several minutes process will be sucked with oil and has a started automati- "oil bag"...
Page 200 RZ 150 Error Messages Description of PLC Alarms 76XXX...
Page 201: Measurements Geometry
The following geometry measurements are also used to determine all kinds of pos- sible geometry errors. If the required tolerances are exceeded as a general rule the Customer Service Department at Reishauer must be contacted. The geometric alignment of the machine axes are carried out during the machine installation by Reishauer’s specialist personnel.
Page 202: Axes Designation Machine Rz 150
The plus signs ("+") in the figure below indicate the positive direction of movement of the respective axes, according to the machine coordinate system (see lower right corner of the figure). Fig. 57: Axes designation of RZ 150 machine Axis Designation...
Page 203: Axes Definition
Axes Designation Machine RZ 150 Axes Definition The designation of the axes of the RZ 150 is based on definitions of ISO 841/DIN 66217. As per definition of an NC-axis, either a linear or a rotative unit can be moved or ro- tated via program/control relative to its base or support.
Page 204: Axial And Radial Runout Of The C1 / C2 Axes (Workpiece Spindle)
Slowly rotate the C1- or C2- axis. Observe the value of the maximum dial indicator amplitude during 1 revolution. The limit for axial runout is a maximum of 0.0015 mm Note Contact Reishauer Customer Service Department, in case that the permissible tolerance has been exceeded. 76XXX...
Page 205 Note the value of the maximum dial indicator amplitude during 1 revolution. The limit for the radial runout is a maximum of 0.002 mm Note Contact Reishauer Customer Service Department, in case that the permissible tolerance has been exceeded. 76xxx...
Page 206: Parallelism Of Workpiece Spindle Axes (C1 / C2) To Their Guides
RZ 150 Measurements Geometry Parallelism of Workpiece Spindle Axes (C1 / C2) to their Guides Parallelism of Workpiece Spindle Axes (C1 / C2) to their Guides Dial indicator with magnetic base Plug gauge 187485.00 Workpiece axis (C-axis) 100 mm Fig. 60: C1 / C2 guides Mount plug gauge 187485.00 on the workpiece spindle (C1 / C2) and...
Page 207 Permissible: 0.015 mm/100 mm Measured value with Z = +101.000 mm Parallelism in Y direction Permissible: 0.015 mm/100 mm Measured value with Z = +101.000 mm Note Contact Reishauer customer service department, in case that the permissible tolerance has been exceeded. 76xxx...
Page 208: Axial And Radial Runout Of Grinding Spindle Location Surface
Slowly rotate the grinding spindle. Observe the value of the maximum dial indicator amplitude during 1 revolution. The limit for the runout is a maximum of 0.003 mm Note Contact Reishauer customer service department, in case that the permissible tolerance has been exceeded. 76XXX...
Page 209 Slowly rotate grinding spindle. Observe the value of the maximum dial gauge amplitude during 1 revolution. The limit for the runout is a maximum of 0.003 mm Note Contact Reishauer customer service department, in case that the permissible tolerance has been exceeded. 76xxx...
Page 210: Axial And Radial Runout On C4- Axis (Dressing Device)
RZ 150 Measurements Geometry Axial and Radial Runout on C4- Axis (Dressing Device) Axial and Radial Runout on C4- Axis (Dressing Device) Bring C4- axis into dressing position. Fit diamond wheel onto dressing device. Adjust swivel axis profiling device to 0°.
Page 211 RZ 150 Measurements Geometry Axial and Radial Runout on C4- Axis (Dressing Device) Note Contact Reishauer customer service department, in case that the permissible tolerance has been exceeded. Measurement of radial runout End of shaft of dressing tool Fig. 65: Measurement of radia runout of C4-axis (view from behind maintenance hatch) Position the probe against the ground shaft end of the dressing tool.
Page 212: Parallelism Of Tailstock Sleeves (W1 / W2) To Workpiece Axes (C1 / C2)
RZ 150 Measurements Geometry Parallelism of Tailstock Sleeves (W1 / W2) to Workpiece Axes (C1 / C2) Parallelism of Tailstock Sleeves (W1 / W2) to Workpiece Axes (C1 / C2) Mount plug gauge 144370.00 in tailstock sleeves W1 or W2.
Page 213: Calculation Of Eccentricity
Measurement 2 (Z = + 101.000 mm) Permissible: 0.020 mm Measured value at W2 = + 330.000 mm Permissible: 0.015 mm Measured value at W2 = + 175.000 mm Note Contact the Reishauer customer service department, in case that the permissible tolerances have been exceeded. 76xxx...
Page 214 RZ 150 Appendix Parallelism of Tailstock Sleeves (W1 / W2) to Workpiece Axes (C1 / C2) 76XXX...
Page 215: Appendix
RZ 150 Appendix Maintenance Plan Appendix Maintenance Plan Fig. 67: Drawing RAG: 33267000 76xxx...
Page 216 RZ 150 Appendix Maintenance Plan Abb. 68: Drawing RAG: 33258401 76XXX...
Page 217 RZ 150 Appendix Maintenance Plan 76xxx...
Page 218 RZ 150 Appendix Maintenance Plan 76XXX...
Page 219 Reishauer AG Reishauer AG Industriestrasse 36 Diamond and CBN Tools Division CH-8304 Wallisellen Industriestrasse 25 Tel. +41 (0)44 832 22 11 CH-8304 Wallisellen Fax +41 (0)44 832 23 90 Tel. +41 (0)44 832 22 11 reishauer@reishauer.com Fax +41 (0)44 832 22 86 www.reishauer.com...

REISHAUER RZ 150 Maintenance And Service Instructions

Documentation of Machine

For Your Safety

For Our Environment

Initial Installation

Maintenance

Repairs

Error Messages

Measurements Geometry

Appendix

Quick Links

Need help?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for REISHAUER RZ 150

Summary of Contents for REISHAUER RZ 150

Table of Contents