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REISHAUER RZ 150 Training

Cnc gear grinder
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RZ 150
CNC Gear Grinder
Training Electronic
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Inventory Nr.:
Serial No.:
Elektronik Kurs
Version:
V09
Comment
All rights reserved. No part of this documentation may be reproduced or passed
on to third parties in any means without explicit written permission of Reishauer.
This document is subject to change (updates, technical improvements) without
prior notice, and Reishauer are not liable for printing errors or conformity of
illustrations.
Note
The training documentations are to be considered as general.
For set-up, operation and maintenance the documentation, which is provided with
the machine, must be used.
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.

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Summary of Contents for REISHAUER RZ 150

  • Page 1 For set-up, operation and maintenance the documentation, which is provided with the machine, must be used. 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 Elektronik Kurs...
  • Page 3 Door Drive, Clamping Pressure* EGB, Aradex* Change Modules Frequency Converter* Toothed Belt Drives Doc on CD Siemens, Diagnosis Error Messages Error Messages Reishauer Axis Designation Axes Kinematic Diagram Block Diagrams Control Principle, PLC* Drives, EGB Electronic Gear Box* Hydraulic Plan...
  • Page 4 RZ 150 Contents Elektronik Kurs...

  • Page 5: Table Of Contents

    RZ 150 Contents Index Electronic Course Program .................. 10 Organisation ......................10 For Your Safety ...................... 11 Classification of Safety Symbols ................. 11 Concept, Function, Technical Data..............13 Overview ......................13 Controller & Data Backup ..................15 To This Chapter ....................15 Short Description HMI 840D ................
  • Page 6 Mechanical Errors ..................89 Load NC Program ..................89 Recording in Two Directions of Travel, Settings ..........93 Secure (save) graphic as BMP ............... 95 Exemple RZ 150 ..................... 97 X-Ax ........................ 97 Z-ax, fast ......................97 Z-ax, low speed ....................98 Amperage Measurements ...................
  • Page 7 RZ 150 Contents Setting of the Measuring Parameters ............. 99 Start Measurement ..................99 Frequency Response Measurement, General ..........108 Why Do We Require This Measurement? ............ 108 Preparation, Set Start-up Bit ................ 108 After the Measurement, Reset Start-up Bit ..........108 Measuring Parameter ................
  • Page 8 Block Diagram...................... 223 Diagram ......................223 Schematics ......................225 Schematics ......................225 Options, Interfaces ....................227 Reishauer List of Options RZ 150 ..............227 Door options ....................228 Communication with EGB ................228 Key print ....................... 229 Assignment Operator Panel ................. 229 Reporting Concept ..................
  • Page 9 Message of new machine data..............249 Diverse ........................251 RZ 150, standard accessories ................251 RZ 150 H - Commands ..................251 RZ 150 M-Commands ..................254 Function in NC- Channel 1 ................254 Function in NC-Channel 2 ................261 RZ150 PLC- Bits ....................

  • Page 10: Electronic Course Program

    RZ 150 Electronic Course Program Organisation Pos : 1 /Sc hul ung/Elektroni k/Allgemei n/Elektroni k Kurs Programm @ 3\mod_1116506748453_2.doc @ 22564 Electronic Course Program Organisation Begin Monday between 8:00 am and 10:00 am: Classes are daily from 8:00 am until 11:30 am and from 12:30 pm until 4:00 pm with a short break each in the morning and in the afternoon.

  • Page 11: For Your Safety

    RZ 150 For Your Safety Classification of Safety Symbols Pos : 3.1 /Sc hul ung/Sc hul ung D oku-Vorlagen/Titel - Sic her heit @ 8\mod_1208498996906_2.doc @ 89811 For Your Safety Classification of Safety Symbols Hier das Kapitel aus Original Bedienungsanleitung einfügen...
  • Page 12 RZ 150 For Your Safety Classification of Safety Symbols Pos : 4 /=========================== @ 0\mod439_2.doc @ 7299 Elektronik Kurs...

  • Page 13: Concept, Function, Technical Data

    RZ 150 Concept, Function, Technical Data Overview Pos : 5.1 /Sc hul ung/Sc hul ung D oku-Vorlagen/Titel - Aufbau, F unkti on, T echnisc he D aten @ 6\mod_1177575108188_2.doc @ 62617 Concept, Function, Technical Data Overview Hier das Kapitel aus Original Bedienungsanleitung einfügen...
  • Page 14 RZ 150 Concept, Function, Technical Data Overview Pos : 6 /=========================== @ 0\mod439_2.doc @ 7299 Elektronik Kurs...

  • Page 15: Controller & Data Backup

    This chapter has been written with regards to the RZ 150. Therefore, the screen shots are related to the RZ 150. Analogously they can also be applied for the RZ 400. Axes configurations, programs, machine data, PLC operands etc. are dif- ferent.

  • Page 16: Short Description Hmi 840D

    RZ 150 Controller & Data Backup Short Description HMI 840D Pos : 7.1.4 /Sc hul ung/Elektroni k/Allgemei n/840D Kurz besc hreibung @ 2\mod1332_2.doc @ 9279 Short Description HMI 840D OP 012 Operator Panel, Operating Pad Display with HMI Advanced Software (Human Machine Interface) Fig.

  • Page 17: Nc Numerical Control

    It is connected to the NCU and has the task to visualizes the processes and ma- chine conditions. The HMI Advanced software and the Reishauer software are the tools to do this. The NCU, the axes and the drives can be parameterized via the software.

  • Page 18: Operating Sections

    RZ 150 Controller & Data Backup Operating Sections Pos : 7.1.5 /Sc hul ung/Elektroni k/Allgemei n/Bedienber eiche bis D atum / Uhr stellen @ 2 \mod1330_2.doc @ 9249 Operating Sections Fig. 4: Operating sections, menu structure Elektronik Kurs...

  • Page 19: Menu Select

    RZ 150 Controller & Data Backup Operating Sections Menu Select With the area switch-over (Menu Select) the selectable operating sections will be displayed in the horizontal SOFTKEY BAR Fig. 5: Menu Select, program MAIN.MPF is loaded Elektronik Kurs...

  • Page 20: Machine, Basic Screen Layout

    RZ 150 Controller & Data Backup Operating Sections Machine, basic screen layout Description of the windows / fields Fig. 6: Machine, basic screen 01 Display operating area 02 Channel status 03 Program status 04 Channel name 05 Alarm and message line...

  • Page 21: Parameter

    RZ 150 Controller & Data Backup Operating Sections Parameter In this area e. g. R-parameter can be displayed or can be changed respectively. Warning R-parameter can contain axis positions. Incorrect inputs can result in collisions or undefined machine conditions! Your own input takes place at your own responsibility.

  • Page 22: Program

    RZ 150 Controller & Data Backup Operating Sections Program Here the NC-programs (e.g. test programs) can be loaded from the hard disk to the NC and vice versa. Should an NC-program be started, it must be first loaded to the NC by pressing Load HD ->...

  • Page 23: Diagnosis

    RZ 150 Controller & Data Backup Operating Sections Diagnosis Under Diagnosis / Alarms all pending alarms will be displayed. Under Diagnosis / Messages the PLC operational messages will be displayed. Under Diagnosis / Alarm log the alarms and messages, that have occurred so far, will be displayed (maximum 150).

  • Page 24: Service Drive

    RZ 150 Controller & Data Backup Operating Sections Service Drive Status display of the enable- and control signals. Fig. 12: Diagnosis /Service display / Service drive Start-up In the basic screen the machine configuration will be displayed. Fig. 13: Basic screen...

  • Page 25: Machine Data

    RZ 150 Controller & Data Backup Operating Sections Machine Data General MD The NC is configured by means of the general MD’s (how many axes, name of axis, number of R-parameter, memory assignment etc.) Fig. 14: Start-up / Machine data / General MD Channel MD With the channel-MD’s it will be defined, as a sample, which axis is in which chan-...
  • Page 26 RZ 150 Controller & Data Backup Operating Sections Axis MD The axis-MD’s contain the axis configuration (which and how many encoders, gear ratios, software end-positions etc.). Fig. 16: Start-up / Machine data / Axis MD Drive Configuration Here you can see the assignment of the logical drive number to the hardware (plug-in location of drive module).

  • Page 27: Plc

    RZ 150 Controller & Data Backup Operating Sections Drive MD Parameterization of controllers. Fig. 18: Start-up / Machine data /Drive MD PLC Status Here the PLC-inputs and outputs, markers and status bit are displayed and can be set and reset respectively.
  • Page 28 RZ 150 Controller & Data Backup Operating Sections Set Date / Clock In this picture you can set and synchronize the clocks of the MMC computer and the PLC. Fig. 20: Start-up / PLC / Set Date/Clock Frequency Response Measurements See description in Maintenance, Measurements.

  • Page 29: Save Data, Configure Archives

    RZ 150 Controller & Data Backup Save Data, Configure Archives Save Data, Configure Archives Data Back-up See description: Ghost Image backup and restore, at the end of this chapter. EXPLANATION The data back-up should not be neglected because a majority of the data are usually stored in the battery-backed RAM of the NCU.
  • Page 30 RZ 150 Controller & Data Backup Save Data, Configure Archives Archive contents (type): Select NC with compensation data. Select as file name NCYYMMDD (YYMMDD = 2 decimal places each for Year Month Day). Example: NC050806 for a NC-archive, dated August 6, 2005.

  • Page 31: Creating Plc Archive

    RZ 150 Controller & Data Backup Save Data, Configure Archives Creating PLC Archive A PLC archive contains the complete PLC program. As long as no defective hardware is present, it is possible to get the PLC started again on a simple and fast way by loading of a PLC-archive.

  • Page 32: Create Tea-File

    RZ 150 Controller & Data Backup Save Data, Configure Archives Create TEA-file TEA = Testing Data Active (Code for machine data , according to Siemens). A TEA file contains machine data of a particular section i.e.: Section Contents General MD Basic configuration of NC-controller incl.

  • Page 33: Diagnosis / Trouble Shooting

    RZ 150 Controller & Data Backup Save Data, Configure Archives Select the MD-section and, if required, the channel or the subject axis and drive respectively. Press S File functions, bring the cursor to the drop down list and open it...
  • Page 34 Before approx. 2003, the program is stored in User cycles. DIRECTORY For machines approx. ex-2004 Transline, the test programs can be automatically loaded with the “Service Reishauer, load test programs“ into the Part DIRECTORY programs. Recognizable by name the of Test_xxxxx.
  • Page 35 RZ 150 Controller & Data Backup Save Data, Configure Archives Fig. 26: Program / User cycles Press Reset Mark desired program. Press Select. SOFTKEY The selected program will be started with Cycle-Start Note After a NCK-reset, or in general, when starting-up the NC/PLC, the correct NC- program will be automatically selected by the PLC.
  • Page 36 RZ 150 Controller & Data Backup Save Data, Configure Archives Administration of Data • Here you will have access to all files within the Siemens Data Management (file F:\dh). • Furthermore, there is access to the floppy disk drive. •...
  • Page 37 RZ 150 Controller & Data Backup Save Data, Configure Archives Fig. 28: Start-up / PLC status / Set date/clock Enter date and time in the input fields, press after each field the Enter. By pressing Accept both clocks will be set to the times entered.

  • Page 38: Set Plc Bit

    RZ 150 Controller & Data Backup Save Data, Configure Archives Set PLC Bit Note Certain bits or also inputs and outputs cannot be set this way, because they will be set during the program run by the PLC-program itself. Fig. 29: Start-up / PLC status or Diagnosis / PLC status Search for the address of the bits (column Operand) with the arrow- or scroll key or enter by hand.

  • Page 39: Start Mmc And Pcu50 Resp. In The Service Mode

    RZ 150 Controller & Data Backup Save Data, Configure Archives Start MMC and PCU50 resp. in the Service Mode EXPLANATION If the MMC computer will be booted in a normal fashion, then some Windows functions are deactivated. For example the right mouse button does not work.

  • Page 40: Windows Explorer

    RZ 150 Controller & Data Backup Save Data, Configure Archives Windows Explorer Start Explorer • There are different ways to start the Explorer: Simultaneously press Windows and K > Press + E simultaneously (equivalet to the Windows-key on the PC- keyboard).
  • Page 41 RZ 150 Controller & Data Backup Save Data, Configure Archives Fig. 30: Sub-files visible on the left and on the right With the view will be minimized, i.e. the sub-files are only visible at the right. Fig. 31: Sub-files visible only on the right window •...
  • Page 42 RZ 150 Controller & Data Backup Save Data, Configure Archives Fig. 32: Copy PLC-Archive to disk With change into the left window. Mark 3½ floppy (A:). Press + E, mark Paste, press Enter (Alternatively: press + V) drücken). The file will be copied to A:\ and appears afterwards in the right window.
  • Page 43 RZ 150 Controller & Data Backup Save Data, Configure Archives • Task bar not visible, cannot be made visible either. • By pressing of a window will be opened, which displays all tasks. Fig. 34: Task list • Keep pressed and press so many times, until the desired task is framed in blue.

  • Page 44: Step 7 License For Service Laptop With Windows Xp

    RZ 150 Controller & Data Backup Step 7 License for Service Laptop with Windows XP Pos : 7.1.8 /Sc hul ung/Elektroni k/Allgemei n/Step 7 Liz enz en für Ser vic e Laptop mit Wi ndows XP @ 3 \mod_1116499596937_2.doc @ 22517...

  • Page 45: Ghost Backup / Restore, Hd Image

    RZ 150 Controller & Data Backup Ghost BACKUP / RESTORE, HD Image Pos : 7.1.10 /Schulung/El ektr oni k/Allgemein/Ghost Image store and res tor e, allgemei n PCU50.1,2&3 @ 3\mod_1117194728654_2.doc @ 22997 Ghost BACKUP / RESTORE, HD Image Note This chapter describes the procedure how to save from the hard disk an Image to an external PC by means of BACKUP.

  • Page 46: Prepare Machine For Configuration Of Ghost Image

    RZ 150 Controller & Data Backup Ghost BACKUP / RESTORE, HD Image Block Schematic Connection of Computers Fig. 35: Configure Ghost Image with Ethernet connection Prepare Machine for Configuration of Ghost Image Configure Archives File name: max. 8 characters allowed Select in the Siemens HMI under ->...

  • Page 47: Prepare Pc For Data Acceptance

    RZ 150 Controller & Data Backup Ghost BACKUP / RESTORE, HD Image File name: General MD’s ALLG_MD Channel 1, Channel 2 MD’s: CHAN1, CHAN2 Axis-MD’s AX_X, AX_Y, AX_Z, .., AX_B. Drive-MD’s: VSA_X, VSA_Y, VSA_Z, .., VSA_B. Load NC-programs: In HMI under service press the S Load NC programs.
  • Page 48 RZ 150 Controller & Data Backup Ghost BACKUP / RESTORE, HD Image Select Use the following IP address. Window 1 Window 2 10.23.211.99 Press 2 times OK. The IP-address 10.23.211.99 has the advantage, that after the Image configuration the Windows and Explorer can be directly started. Archives can be transferred to the laptop.
  • Page 49 RZ 150 Controller & Data Backup Ghost BACKUP / RESTORE, HD Image Note The above entered IP address must work together with the address, which is set in DOS on PCU50. The first two numbers 10.23.X.X must be identical with the DOS settings.

  • Page 50: Configure Ghost Image, Pcu50 V1 Or V2

    RZ 150 Controller & Data Backup Ghost BACKUP / RESTORE, HD Image Computer Name (Notebook) Windows Start Menu S -> S -> S ETTINGS YSTEM CONTROL YSTEM Enter computer name (e.g.: NB5009) for example: NB5009 Press 2 times OK ...
  • Page 51 RZ 150 Controller & Data Backup Ghost BACKUP / RESTORE, HD Image Please select the operating system to start: SINUMERIK SERVICEMENU (nicht sichtbarer Eintrag) RECOVERY (nicht sichtbarer Eintrag) > At this position you have 3 seconds time to select, with the arrow key, the hid- den entry "SERVICEMENU".

  • Page 52: Restore With Ghost And Tcp/Ip Ethernet Connection

    RZ 150 Controller & Data Backup Ghost BACKUP / RESTORE, HD Image 9 Return to Main Menu 9 Reboot (Warmboot) When rebooting start again Service-Menu 7 Backup/Restore enter password SUNRISE 1 Harddisk Backup/Restore with GHOST 1 Configure GHOST Parameters 6 Manage Network Drives...
  • Page 53 RZ 150 Controller & Data Backup Ghost BACKUP / RESTORE, HD Image Step 1 PLEASE SELECT: 1 Install/Update SINUMERIK System 2 SINUMERIK Tools and Options 3 DOS Shell 4 Start Windows (Service Mode) 5 SINUMERIK System Check 7 Backup/Restore 8 Start PC Link...
  • Page 54 RZ 150 Controller & Data Backup Ghost BACKUP / RESTORE, HD Image For an installation with customer’s Ghost Image File (CD/DVD) Old restore image filename: G:\XXXX New Restore Image filename: G:\image.gho Step 5 PLEASE SELECT: 1 Set Connection Mode PARALLEL (LPT:)
  • Page 55 RZ 150 Controller & Data Backup Ghost BACKUP / RESTORE, HD Image CURRENT NETWORK SETTINGS: Machin Name: PCUxxxxxx User Name: auduser TCPIP, get IP Addresses manually Transport Protocol: Logon to domain: Connected Network Drive: - none - Step 9 PLEASE SELECT:...
  • Page 56 RZ 150 Controller & Data Backup Ghost BACKUP / RESTORE, HD Image 9 Back to previous Menu Old IP Address: XXX XXX XXX XXX New IP Address (PCU50): 10232112 oder 19216801 CURRENT NETWORK SETTINGS (PCU50): Get IP Addresses: manually My IP Address: 10232112 oder 19216801...
  • Page 57 RZ 150 Controller & Data Backup Ghost BACKUP / RESTORE, HD Image 9 Back to previous Menu Step 14 PLEASE SELECT: 1 Change Maschin Name (for Dos Net only) 2 Change User name 3 Toggle Protocol (NETBEUI or TCPIP) 4 Toggle logon to domain (Yes or No)
  • Page 58 RZ 150 Controller & Data Backup Ghost BACKUP / RESTORE, HD Image Step 18 PLEASE SELECT: 1 Harddisk Backup/Restore with Ghost 4 Partitions Backup/Restore with Ghost (locally) 5 ADDM Backup/Restore 9 Return to Main Menu Step 19 PLEASE SELECT: 1 Install/Update SINUMERIK System...
  • Page 59 RZ 150 Controller & Data Backup Ghost BACKUP / RESTORE, HD Image Step 22 PLEASE SELECT: 1 Configure Ghost Parameters 2 Harddisk Backup to G:\ xxxxxx, Mode Local / Network 3 Harddisk Restore from G:\ xxxxxx, Mode Local / Network...
  • Page 60 RZ 150 Controller & Data Backup Ghost BACKUP / RESTORE, HD Image Repeat the connection: usage : C:\TOOLS\WRITHEINI.EXE inifile section name value The command completed successfuly. Microsoft DOS TCP/IP 1.1a The command completed successfuly. Please type in the network password of the user „auduser“...
  • Page 61 RZ 150 Controller & Data Backup Ghost BACKUP / RESTORE, HD Image Step 26 PLEASE SELECT: 1 Set Connection Mode PARALLEL (LPT:) 2 Set Connection Mode LOCAL/NETWORK 3 Change Backup Image Filename 4 Change Restore Image Filename 5 Change Machine Name (for Windows and DOS net)

  • Page 62: Completion Tasks Restore

    RZ 150 Controller & Data Backup Ghost BACKUP / RESTORE, HD Image Image files for restore is G:\XXXXXX\“Machine number“.GHO. Please make sure the directory path exists on the target system ! Continue backup [Y.N] ?  Y Step 29 What kind of disk partitioning do you want?

  • Page 63: Booting With Emergency Boot Disk's Pcu50 V1 Or V2

    RZ 150 Controller & Data Backup Ghost BACKUP / RESTORE, HD Image Booting with Emergency Boot Disk’s PCU50 V1 or V2 Does not function with PCU50.3 Note In case that a booting from the HD is not possible anymore, then a set of three "Emergency Boot Disks"...

  • Page 64: Configure Ghost Image, Starting From Pcu50.3

    RZ 150 Controller & Data Backup Ghost BACKUP / RESTORE, HD Image Configure Ghost Image, starting from PCU50.3 Send Ghost Image from machine to PC. Valid ex version PCU 50.3, since beginning 2006. > Execute Prepare PC for data acceptance, see above.
  • Page 65 RZ 150 Controller & Data Backup Ghost BACKUP / RESTORE, HD Image • “Apply“ • “Yes“ > Computer shuts down and starts WindowsPE with the Backup/Restore conso- • Select Backup/Restore a Disk Image. OPTION • “Next >“ • Enter user name and password of laptop.
  • Page 66 RZ 150 Controller & Data Backup Ghost BACKUP / RESTORE, HD Image • Enter path network to laptop. (NBxxxx = PC-number resp. computer name, 76xxx = machine number) • “Next“ [General] Medium=Disk Action=NetShare_Backup File=76xxx.gho NetShare=\\NBxxxx\D Size=38154MB Date=05-04-2006:09:59:58AM System= • “Options“ -> activate option “Enable splitting“ -> enter value 640.

  • Page 67: Restore With Tcp/Ip Ethernet Connection And Servicecenter

    RZ 150 Controller & Data Backup Ghost BACKUP / RESTORE, HD Image Restore with TCP/IP Ethernet connection and ServiceCenter Valid for PCU50.3 EXPLANATION If the machine still can be started from the HD in ServiceCenter, then a Restore according to simple means is possible without a USB stick.

  • Page 68: Important

    RZ 150 Controller & Data Backup Ghost BACKUP / RESTORE, HD Image Important: The saving of network settings on the USB stick is for the time being not possible. The Emergency Boot System is not functional, if a DVI monitor is directly connected to the DVI interface of the PCU 50.3.

  • Page 69: Ghost Backup / Restore With Pcu50.3

    RZ 150 Controller & Data Backup Ghost BACKUP / RESTORE with PCU50.3 Ghost BACKUP / RESTORE with PCU50.3 Note This chapter describes the procedure how to save from the hard disk an Image to an external data carrier means of BACKUP. An USB stick or a USB HD will be used for the data transfer.

  • Page 70: Prepare Machine For Configuration Of The Ghost Image

    RZ 150 Controller & Data Backup Ghost BACKUP / RESTORE with PCU50.3 Block Schematic Connection of Computers > Connect laptop via Ethernet cable on hub (A1105). Prepare Machine for Configuration of the Ghost Image Configure Archives File name: max. 8 characters allowed Select in the Siemens HMI under ->/ >...

  • Page 71: Prepare Memory Medium For Data Transfer

    RZ 150 Controller & Data Backup Ghost BACKUP / RESTORE with PCU50.3 In the Siemens HMI under ->/ > ->/ SERVICES SERIES START Configure PLC-archive. File name with following format: PLYYMMDD (YearMonthDay) Example: PL060723P Under -> START MACHINE DATA Configure TEA- files (Axis- and drive MD’s for all axes incl.
  • Page 72 RZ 150 Controller & Data Backup Ghost BACKUP / RESTORE with PCU50.3 • Perform settings as above. • Press Start • Press Yes > Computer is shutting down and starts WindowsPE with the Backup/Restore console. Select entire HD Backup/Restore •...

  • Page 73: Check Ghost Image

    RZ 150 Controller & Data Backup Ghost BACKUP / RESTORE with PCU50.3 [General] Medium=Disk Action=NetShare_Backup File=76xxx.gho NetShare=\\NBxxxx\D Size=38154MB Date=05-04-2006:09:59:58AM System= • Press Options -> activate Enable splitting-> enter value 640. OPTION • Press Finish • Ghost starts and writes an image of the entire hard disk in several splitted image files.

  • Page 74: Restore With Usb Boot And Usb Data Carrier Stick

    RZ 150 Controller & Data Backup Ghost BACKUP / RESTORE with PCU50.3 Restore with USB Boot and USB data carrier stick EXPLANATION If booting from HD is not possible anymore, then booting must be done from USB- boot stick. With restore an IMAGE will be transmitted to a new HD.

  • Page 75: Important

    RZ 150 Controller & Data Backup Ghost BACKUP / RESTORE with PCU50.3 Important: The Emergency boot system does not function in case that a DVI monitor is directly connected to the DVI interface of the PCU 50.3. Only the VGA mode via a DVI->VGA-adaptor, is possible.

  • Page 76: Software Status

    Software status EXPLANATION The software versions are stored in PDM under the machine number as SW_LOG.txt file. Selection of the Software Versions In the HMI under the Reishauer Software versions are listed. VERSION Software Reishauer Example RZ150 Example RZ400 Actual HMI-/NC-program V03.10 (1476)
  • Page 77 RZ 150 Controller & Data Backup Ghost BACKUP / RESTORE with PCU50.3 Balance System Parameter Sample RZ150 Sample RZ400 Actual Parmam File BSjjmmtt.bck Bs041119.bck PBTM_041209.bck Danfoss parameter list version See F:\users\proj\Danfoss\RZ400 Danfoss\RZ400_Vlt2800_VXXX (8.03 .._V015 Danfoss parameter Sample RZ150 Sample RZ400...

  • Page 78: Overall Reset Plc

    RZ 150 Controller & Data Backup Overall Reset PLC Pos : 7.1.15 /Schulung/El ektr oni k/Allgemein/Urlösc hen PLC @ 3 \mod_1117172745554_2.doc @ 22823 Overall Reset PLC Overall Reset of NC and of PLC Set transportation lock of hard disk to “Operating“ (A1250).

  • Page 79: Rz150 Software Update Hmi-, Nc- And Plc-Software

    Controller & Data Backup RZ150 Software Update HMI-, NC- and PLC-Software Pos : 7.1.17 /Schulung/El ektr oni k/RZ150/RZ 150 Softwar eupdate MM I-, NC- und PLC-Software @ 7\mod_1194515089544_2.doc @ 76693 RZ150 Software Update HMI-, NC- and PLC-Software Source: AA9210 software update MMI_NC, version 024 of October 2007...
  • Page 80 RZ 150 Controller & Data Backup RZ150 Software Update HMI-, NC- and PLC-Software > The old HMI will be deleted by the batch-file and replaced by the new HMI. Start F:\user\Reg.bat in order to register the Opti Guide. > Appearing messages, if any, can be acknowledged with OK.
  • Page 81 RZ 150 Controller & Data Backup RZ150 Software Update HMI-, NC- and PLC-Software Create NSK files This procedure is necessary if the file Mgud.def was modified, e.g. after the installation of a newer NC / HMI version. Start PCU in service mode.

  • Page 82: Installation Of The New Nc-Software

    RZ 150 Controller & Data Backup RZ150 Software Update HMI-, NC- and PLC-Software = English (GB) = French = Italian = Dutch = Swedish = Finnish = Spanish = Portuguese = Czech = Hungarian = Polish = Turkish = Russian...
  • Page 83 RZ 150 Controller & Data Backup RZ150 Software Update HMI-, NC- and PLC-Software Installation of the HW project Starting at version 1_092 (Rz150) and version 3_067 (RZ400) respectively, the PLC software no longer will be delivered as an all inclusive packet, but as separate HW- and SW-projects.

  • Page 84: Rz150 Software Update Hmi-, Nc- And Plc-Software

    Controller & Data Backup RZ150 Software Update HMI-, NC- and PLC-Software Pos : 7.3 /Sc hul ung/Elektroni k/RZ 150/R Z 150 Softwareupdate MMI-, NC- und PLC-Softwar e @ 7\mod_1194515089544_2.doc @ 76693 RZ150 Software Update HMI-, NC- and PLC-Software Source: AA9210 software update MMI_NC, version 024 of October 2007...
  • Page 85 RZ 150 Controller & Data Backup RZ150 Software Update HMI-, NC- and PLC-Software > The old HMI will be deleted by the batch-file and replaced by the new HMI. Start F:\user\Reg.bat in order to register the Opti Guide. > Appearing messages, if any, can be acknowledged with OK.
  • Page 86 RZ 150 Controller & Data Backup RZ150 Software Update HMI-, NC- and PLC-Software Create NSK files This procedure is necessary if the file Mgud.def was modified, e.g. after the installation of a newer NC / HMI version. Start PCU in service mode.

  • Page 87: Installation Of The New Nc-Software

    RZ 150 Controller & Data Backup RZ150 Software Update HMI-, NC- and PLC-Software = English (GB) = French = Italian = Dutch = Swedish = Finnish = Spanish = Portuguese = Czech = Hungarian = Polish = Turkish = Russian...
  • Page 88 RZ 150 Controller & Data Backup RZ150 Software Update HMI-, NC- and PLC-Software Installation of the HW project Starting at version 1_092 (Rz150) and version 3_067 (RZ400) respectively, the PLC software no longer will be delivered as an all inclusive packet, but as separate HW- and SW-projects.

  • Page 89: Maintenance, Measurements

    RZ 150 Maintenance, Measurements Amperage Measurement General Pos : 9.1 /Sc hul ung/Sc hul ung D oku-Vorlagen/Titel, El ek-Kapi tel 07 @ 3\mod1365_2.doc @ 9789 Maintenance, Measurements Pos : 9.2 /Sc hul ung/Elektroni k/Allgemei n/Strommess ung en allgemein @ 3\mod_1116507439578_2.doc @ 22575...
  • Page 90 RZ 150 Maintenance, Measurements Amperage Measurement General EXPLANATION With each actuating of the Cycle Start the following actions take place: Text: Indication to possible risks. Axis travels to the measuring start position, to the positive end position. (The measurement starts when pressing K...
  • Page 91 RZ 150 Maintenance, Measurements Amperage Measurement General Perform Measurement MENU SELECT -> D -> S -> M TART RIVES ERVO ERVO RACE EASUREMENTS Select Start (start of recording) and after approx. 1 sec. SOFTKEY SERVO TRACE Press the Cycle Start.
  • Page 92 RZ 150 Maintenance, Measurements Amperage Measurement General Format and Storage Location of Amperage Measurements EXPLANATION The amperage measurements are saved on the harddisk as Siemens-Standard- and Bitmap- files. Siemens standard format is a Siemens own vector format (*.mp1), which can be displayed only on Siemens controller.

  • Page 93: Recording In Two Directions Of Travel, Settings

    RZ 150 Maintenance, Measurements Amperage Measurement General EXPLANATION Graph1 shows the condition, which was recorded during the start-up. Graph2 shows the current condition. In this case the amperage (amounts) are almost identical, because the machine was running only for a few hours.
  • Page 94 RZ 150 Maintenance, Measurements Amperage Measurement General X-flag Y-flag Full view Scale Measure- File Service Drive User Display Axis ment functions axis view Save Graphics 1 in Siemens Format Dispaly current graphics with S Display. OFTKEY Select S File function.

  • Page 95: Secure (Save) Graphic As Bmp

    RZ 150 Maintenance, Measurements Amperage Measurement General Select Graph1. SOFTKEY Enter with M the lines, acceleration time, idle run current. ARKER Secure (save) graphic as BMP -> G -> G ISPLAY RAPHIC RAPHIC - Graphic will be displayed with file name in title bar.
  • Page 96 RZ 150 Maintenance, Measurements Amperage Measurement General Enter file name e.g. STR9_X, Enter, Save - The Bitmap print will be saved under F:\DH\DG.dir\Bitmap.dir. Check the written Files at Siemens Level -> M -> D -> B MENU SELECT ERVICES ANAGE...

  • Page 97: Exemple Rz 150

    RZ 150 Maintenance, Measurements Amperage Measurement General Exemple RZ 150 X-Ax 4m/min., full range Z-ax, fast Difference current UP / DOWN Elektronik Kurs...

  • Page 98: Z-Ax, Low Speed

    RZ 150 Maintenance, Measurements Amperage Measurement General Z-ax, low speed Difference current UP / DOWN Pos : 9.3 /=========================== @ 0\mod439_2.doc @ 7299 Elektronik Kurs...

  • Page 99: Amperage Measurements

    RZ 150 Maintenance, Measurements Amperage Measurements Pos : 9.4 /Sc hul ung/Elektroni k/RZ 150/R Z 150 Strommess ungen @ 3\mod1374_2.doc @ 9319 Amperage Measurements With the amperage measurements the axes are evaluated for mechanical faults. The Following Failures Can Be Detected •...
  • Page 100 RZ 150 Maintenance, Measurements Amperage Measurements Amperage Measurement X-axis Signal selection Trace: Axis-/spindle name: Signal selection: Trace 1: Torque-prod current nominal value i(q) Trace 2: Position actual value meas. system 1 Trace 3: No signal Trace 4: No signal Measuring parameter Meas.
  • Page 101 RZ 150 Maintenance, Measurements Amperage Measurements Amperage Measurement Y-axis Signal selection Trace: Axis-/spindle name: Signal selection: Trace 1: Torque-prod current nominal value i(q) Trace 2: Position actual value meas. system 1 Trace 3: No signal Trace 4: No signal Measuring parameter Meas.
  • Page 102 RZ 150 Maintenance, Measurements Amperage Measurements Amperage Measurement Z-axis Danger 1. C3-axis must be positioned at 0.000° or at 180.000°! 2. The drive pin of the C1- and C2-axis must be installed! 3. The measurement must be done on both the C1- and C2-axis!
  • Page 103 RZ 150 Maintenance, Measurements Amperage Measurements Amperage Measurement W1-axis Signal selection Trace: Axis-/spindle name: Signal selection: Trace 1: Torque-prod current nominal value i(q) Trace 2: Position actual value meas. system 1 Trace 3: No signal Trace 4: No signal Measuring parameter Meas.
  • Page 104 RZ 150 Maintenance, Measurements Amperage Measurements Amperage Measurement W2-axis Signal selection Trace: Axis-/spindle name: Signal selection: Trace 1: Torque-prod current nominal value i(q) Trace 2: Position actual value meas. system 1 Trace 3: No signal Trace 4: No signal Measuring parameter Meas.
  • Page 105 RZ 150 Maintenance, Measurements Amperage Measurements Amperage Measurement C3-axis Signal selection Trace: Axis-/spindle name: Signal selection: Trace 1: Torque-prod current nominal value i(q) Trace 2: Position actual value meas. system 1 Trace 3: No signal Trace 4: No signal Measuring parameter Meas.
  • Page 106 RZ 150 Maintenance, Measurements Amperage Measurements Amperage Measurement C4-axis Signal selection Trace: Axis-/spindle name: Signal selection: Trace 1: Torque-prod current nominal value i (q) Trace 2: Position actual value meas. system 1 Trace 3: No signal Trace 4: No signal Measuring parameter Meas.
  • Page 107 RZ 150 Maintenance, Measurements Amperage Measurements Amperage Measurement A-axis Signal selection Trace: Axis-/spindle name: Signal selection: Trace 1: Torque-prod current nominal value i (q) Trace 2: Position actual value meas. system 1 Trace 3: No signal Trace 4: No signal Measuring parameter Meas.

  • Page 108: Frequency Response Measurement, General

    RZ 150 Maintenance, Measurements Frequency Response Measurement, General Pos : 9.6 /Sc hul ung/Elektroni k/Allgemei n/Fr equenzg ang messsung allgemei n @ 3 \mod_1116507852062_2.doc @ 22606 Frequency Response Measurement, General Why Do We Require This Measurement? EXPLANATION With the frequency response measurement in the speed control loop or position control loop it is possible to draw some conclusions concerning the condition of the mechanics.
  • Page 109 RZ 150 Maintenance, Measurements Frequency Response Measurement, General Measurement Reference Frequency Response, Speed Control Loop Start-up -> Drives/Servo -> speed control loop Select with Axis + or Axis - the axis, which must be measured. SOFTKEY Select for drive test travel enable: Without PLC.
  • Page 110 RZ 150 Maintenance, Measurements Frequency Response Measurement, General Move axis with JOG into the middle of the travel stroke. The axis travels some mm in the plus direction during the measurement. Select Jog. Set Override to 100%. Set the corresponding bits for axes with clamping, see tables e.g.
  • Page 111 RZ 150 Maintenance, Measurements Frequency Response Measurement, General Bode diagram EXPLANATION The frequency response will be displayed in a Bode diagram. The X-axis shows the frequency in logarithmical representation. The first diagram shows the amplitude response of the reaction of the axis in a logarithmical dB representation.
  • Page 112 RZ 150 Maintenance, Measurements Frequency Response Measurement, General Overshoot The amplitude must not exceed + 3dB in the useable frequency range. If the amplitude is excessively higher (over + 3dB), then the reason can be: • Faulty setting of filter.
  • Page 113 RZ 150 Maintenance, Measurements Frequency Response Measurement, General Evaluate the Suppression with Marker Bode diagrams speed control loop, evaluation limit values, table of RZ400. Measuring parameter Unit Limit frequency fg 46 (130) Overshoot max Suppression max 1*) value not easy to define...
  • Page 114 RZ 150 Maintenance, Measurements Frequency Response Measurement, General Format and Storage Location of Frequency Responses EXPLANATION The frequency responses are saved on the harddisk as Siemens Standard and Bitmap Files. Siemens- Standard Format is a Siemens own vector format (*.mp1), which can only be displayed on a Siemens controller.

  • Page 115: Measuring Parameter

    RZ 150 Maintenance, Measurements Frequency Response Measurement, General Measurement Position Control Loop Select the following menu with SOFTKEY   TART DRIVES ERVO POSITION CONTROL LOOP Measuring Parameter Elektronik Kurs...
  • Page 116 RZ 150 Maintenance, Measurements Frequency Response Measurement, General Start Measurement Select M EASUREMENT TART Verify the note with Ok. Press NC- Start. Select Display . SOFTKEY under LRK1_X. ATA FUNCTIONS Load File Record to Marker , positioning of M DISPLAY ARKER Set X- marker at approx.
  • Page 117 RZ 150 Maintenance, Measurements Frequency Response Measurement, General Select SAVE GRAPHIC Enter file name e.g. LRK1_X, Enter, S - The bitmap print will be saved under F:\DH\DG.dir\Bitmap.dir\*.bmp. Pos : 9.7 /=========================== @ 0\mod439_2.doc @ 7299 Elektronik Kurs...

  • Page 118: Frequency Response - Measurements

    RZ 150 Maintenance, Measurements Frequency Response – Measurements Pos : 9.8 /Sc hul ung/Elektroni k/RZ 150/R Z 150 Fr equenzg ang messungen @ 3\mod1373_2.doc @ 9389 Frequency Response – Measurements With the frequency response measurement the transmission behavior of the speed control loop and the position control loop respectively are identifiedy and some conclusions can be drawn concerning the condition of the mechanics.

  • Page 119: Evaluation Of Measuring Diagrams

    RZ 150 Maintenance, Measurements Frequency Response – Measurements Evaluation of Measuring Diagrams Example graphic Note The amplitude shall not exceed + 3dB in the useable frequency range. If the amplitude is excessively higher (over + 3dB), then the reason can be: Faulty setting of filter Power transmission from motor to axis is loose or too flexible.
  • Page 120 RZ 150 Maintenance, Measurements Frequency Response – Measurements Frequency Response Test X-axis Speed Control Loop X-axis Measuring Parameter (standard parameter) Amplitude mm/min Band width 4000 Averaging Tuning time 1000 Offset mm/min Bode Diagram Speed Control Loop X-axis Limit frequency Suppression...
  • Page 121 RZ 150 Maintenance, Measurements Frequency Response – Measurements Position Control Loop X-axis Measuring Parameter (Standard parameter) Amplitude Band width Averaging Tuning time 1000 Offset mm/min Bode Diagram Position Control Loop X-axis Limit frequency Suppression Elektronik Kurs...
  • Page 122 RZ 150 Maintenance, Measurements Frequency Response – Measurements Frequency Response Test Y-axis Speed Control Loop Y-axis Measuring Parameter (Standard parameter) Amplitude mm/min Band width 4000 Averaging Tuning time 1000 Offset mm/min Bode Diagram Speed Control Loop Y-axis Limit frequency Suppression...
  • Page 123 RZ 150 Maintenance, Measurements Frequency Response – Measurements Position Control Loop Y-axis Measuring Parameter (Standard parameter) Amplitude mm/min 0.005 Band width Averaging Tuning time 1000 Offset mm/min Bode Diagram Position Control Loop Y- axis Limit frequency Suppression Elektronik Kurs...
  • Page 124 RZ 150 Maintenance, Measurements Frequency Response – Measurements Frequency Response Test Z-axis Speed Control Loop Z-axis Measuring Parameter (standard parameter) Amplitude mm/min Band width 4000 Averaging Tuning time 1000 Offset mm/min Bode Diagram Speed Control Loop Z-axis Limit frequency Suppression...
  • Page 125 RZ 150 Maintenance, Measurements Frequency Response – Measurements Position Control Loop Z-axis Measuring Parameter (standard parameter) Amplitude mm/min 0.005 Band width Averaging Tuning time 1000 Offset mm/min Bode Diagram Position Control Loop Z-axis Limit frequency Suppression Elektronik Kurs...
  • Page 126 RZ 150 Maintenance, Measurements Frequency Response – Measurements Frequency Response Test B-axis Mount flywheel mass. MD 32620 FFW_MODE=0. Speed Control Loop B-axis Measuring Parameter (standard parameter) Amplitude mm/min Band width 4000 Averaging Tuning time 1000 Offset Bode Diagram Speed Control Loop B-axis...
  • Page 127 RZ 150 Maintenance, Measurements Frequency Response – Measurements Speed Control Loop B-axis Measuring Parameter (standard parameter) Amplitude mm/min Band width Averaging Tuning time 1000 Offset Bode Diagram Speed Control Loop B-axis (Spindle) Limit frequency Suppression Frequency Response Test A-axis Note In order to release the clamping the test bit DB348.DBX0.4 must be set to 1.
  • Page 128 RZ 150 Maintenance, Measurements Frequency Response – Measurements Speed Control Loop A-axis Measuring Parameter (standard parameter) Amplitude 0.025 Band width 2000 Averaging Tuning time 1000 Offset 0.05 Bode Diagram Speed Control Loop A-axis Limit frequency Suppression Elektronik Kurs...
  • Page 129 RZ 150 Maintenance, Measurements Frequency Response – Measurements Position Control Loop A-axis Measuring Parameter (standard parameter) Amplitude Degr Band width Averaging Tuning time 1000 Offset 0.05 Bode Diagram Position Control Loop A- axis Limit frequency Suppression Note In order to release the clamping, the test bit DB348.DBX0.4 must be set to 0.
  • Page 130 RZ 150 Maintenance, Measurements Frequency Response – Measurements Danger Prior to the measurement make sure, that the C3-axis can rotate freely e.g. the flaps must be in working position and the meshing probe must be in parking posi- tion. Speed Control Loop C3-axis...
  • Page 131 RZ 150 Maintenance, Measurements Frequency Response – Measurements Position Control Loop C3-axis Measuring Parameter (standard parameter) Amplitude Degr 0.01 Band width Averaging Tuning time 1000 Offset 0.05 Bode Diagram Position Control Loop C3-axis Limit frequency Suppression Note For the execution of the measurement the test bit DB357.DBX0.4 must be set to 0.
  • Page 132 RZ 150 Maintenance, Measurements Frequency Response – Measurements Frequency Response Test C4-axis Speed Control Loop C4-axis Measuring Parameter (standard parameter) Amplitude 0.05 Band width 4000 Averaging Tuning time Offset Bode Diagram Speed Control Loop C4-axis Limit frequency Suppression Elektronik Kurs...
  • Page 133 RZ 150 Maintenance, Measurements Frequency Response – Measurements Position Control Loop C4-axis Measuring Parameter (standard parameter) Amplitude Degr 0.01 Band width Averaging Tuning time 1000 Offset Bode Diagram Position Control Loop C4-axis Limit frequency Suppression Elektronik Kurs...
  • Page 134 RZ 150 Maintenance, Measurements Frequency Response – Measurements Frequency Response Test W1-axis Speed Control Loop W1-axis Measuring Parameter (standard parameter) Amplitude mm/min Band width 4000 Averaging Tuning time 1000 Offset mm/min Bode Diagram Speed Control Loop W1-axis Limit frequency Suppression...
  • Page 135 RZ 150 Maintenance, Measurements Frequency Response – Measurements Position Control Loop W1-axis Measuring Parameter (standard parameter) Amplitude 0.005 Band width Averaging Tuning time 1000 Offset mm/min Bode Diagram Position Control Loop W1-axis Limit frequency Suppression Frequency Response Test W2-axis Speed Control Loop W2-axis...
  • Page 136 RZ 150 Maintenance, Measurements Frequency Response – Measurements Pos : 11.1 /Schulung/El ektr oni k/RZ 150/RZ 150 Motor/M asss tab wec hs eln @ 7\mod_1194516013253_2.doc @ 76709 Elektronik Kurs...

  • Page 137: Setup Axes

    RZ 150 Setup axes Exchange Motor / Scale Setup axes Exchange Motor / Scale Source: AA9400 exchange motor/scale, version 010 of 13.02.2007 This document describes the necessary procedure in order to have, after exchanging of a motor or a scale, a correct axis position displayed.
  • Page 138 RZ 150 Setup axes Exchange Motor / Scale The B-axis has, as the only measuring system, an incremental rotary encoder with one (1) reference mark. The axes W1, W2, A and C3 have only one absolute motor measuring system and these axes therefore, must not be referenced to a 2nd measuring system.
  • Page 139 RZ 150 Setup axes Exchange Motor / Scale Plug-in and secure cable for motor and encoder Activating/deactivating of user agreement Press Reset Change to the Siemens machine screen Select JOG + REFP Press User agreement SOFTKEY Place the cursor on the desired axis and activate/deactivate user agreement with the...
  • Page 140 RZ 150 Setup axes Exchange Motor / Scale Assemble new motor: see Mount motor (motor with toothed belt) Toothed belt tension: 120Hz Switch on machine  The controller recognises by means of the serial number of the encoder that another motor is installed.
  • Page 141 RZ 150 Setup axes Exchange Motor / Scale Meas. arbor 187485 Fixture xxxxxx.xx Axis distance x + 112.500mm Value (example) Value (measured) Radius fixture 80.000 mm Radius fixture .... mm Radius measuring 15.000 mm Radius measuring .... mm arbor arbor Distance 50.000 mm...
  • Page 142 RZ 150 Setup axes Exchange Motor / Scale Pictures and explanations Scale cover Exchange Y-axis motor The same procedure as for the X-axis Toothed belt tension: 80Hz Exchange Y-axis scale Deactivate the user agreement of the Y-axis Shut-down machine Dismount scale cover and dismount scale...
  • Page 143 RZ 150 Setup axes Exchange Motor / Scale Establish zero point displacement x: Only spindle as basis, without grinding wheel or flange Offset 55.000 mm Radius measuring arbor + 15.000 mm B-axis motor + ……… mm Measured distance Actual Y-position: Actual Y-pos.-display...
  • Page 144 RZ 150 Setup axes Exchange Motor / Scale Measured distance: This distance will be entered as a positive value, if the basis surface is further out when compa- red with the measuring arbor cylinder (as drawn in graphics) Actual Y-pos.-display: Will be entered with a sign e.g.
  • Page 145 RZ 150 Setup axes Exchange Motor / Scale Measure (gauge) Z-axis: Meas. arbor 187485.00 Z-position SW end pos. 100.500 max. position 100.000 min. position mech.end pos. Spindle plane surface SW end pos. 0.000 Value (example) Value (measured) -0.500 Offset 221.000 mm Offset 221.000 mm...
  • Page 146 RZ 150 Setup axes Exchange Motor / Scale Deactivate the user agreement of the W1/W2-axis Move C3-axis to 205 or –30 degree (for W1-/W2-motor) Secure tailstock by supporting against uncontrolled downwards motion Deactivate the user agreement of the W1/W2-axis Shut-down machine with main switch...
  • Page 147 RZ 150 Setup axes Exchange Motor / Scale Switch on equipment Perform single axis referencing  The value of MD 34100 will be accepted and MD34210 changes to 2 Activate the user agreement of W1/W2-axis Configure NC-archive Wx = 0.000mm Wx = 0.000mm...
  • Page 148 RZ 150 Setup axes Exchange Motor / Scale Mount new motor: see Mount motor (motor with coupling) Switch on machine  The controller recognizes by means of the serial number of the encoder that another motor is installed. An invalid axis position will be displayed.
  • Page 149 RZ 150 Setup axes Exchange Motor / Scale Activate the user agreement of the A-axis Configure NC-archive Meas. value 1 Meas. value 2 Meas. arbor 187485.00 B-axis motor Detailed view Grinding wheel Meas. arbor flange Dial indic. Additional information for exchange of A-axis motor (Retrofitting to newer type)
  • Page 150 RZ 150 Setup axes Exchange Motor / Scale ATTENTION: In case that the motor (155515.01/1FK6042-6AF71-1EH0-ZQ31) will be exchanged with a newer type (155725.02/FK7042-5AF71-1EH2), than certain machine data need to be adjusted. For machines with NC-core, starting as of 06.04.15, it is sufficient to enter the new motor code (see next page).
  • Page 151 RZ 150 Setup axes Exchange Motor / Scale Leave the machine data page -> The question, if the Bootfile should be safed, to be answered with Yes. Exchange C3-axis motor Deactivate the user agreement of the C3-axis Position the C3-axis to 180 degrees.
  • Page 152 RZ 150 Setup axes Exchange Motor / Scale Mount the new C4-axis in the same position. Plug-in and secure cable of motor and encoder Mount dressing device Mount cooling oil lines and purged air line Switch on machine  The controller recognizes by means of the serial number of the encoder that another motor is installed.
  • Page 153 RZ 150 Setup axes Exchange Motor / Scale B-axis motor Max. possible move on plane surface Fixture or magnetic Checking flange 107349.00 base Activate the user agreement of the C4-axis Configure NC-archive Pos : 12 /=========================== @ 0\mod439_2.doc @ 7299...
  • Page 154 RZ 150 Setup axes Exchange Motor / Scale Pos : 13.1 /Schulung/El ektr oni k/Allgemein/Instandhaltung, Baugruppen taus chen @ 3 \mod_1116593071375_2.doc @ 22734 Elektronik Kurs...

  • Page 155: Maintenance, Change Modules

    RZ 150 Maintenance, Change Modules Balance System VM24 Maintenance, Change Modules Pos : 13.2.1 /Schulung/El ektr oni k/Allgemein/Balanc e System 01 Funktion & SW Versionen @ 3\mod_1120123634775_2.doc @ 24754 Balance System VM24 Balancing Unit and Touching Control Unit, Concept and...

  • Page 156: Safety

    RZ 150 Maintenance, Change Modules Balance System VM24 BMK USA Designation A2000 PC10900 Rack with electronic boards with evaluation electronics A2001 Balancing unit A2002 Touching control unit A2003 Communication unit A2004 Power supply (main supply) A2007 E11013-1 Amplifier for acoustic sensor (touching control)
  • Page 157 RZ 150 Maintenance, Change Modules Balance System VM24 Software EPROM Versions RS232 Data transmission Date 2000 2002 8.2004 5.2005 Version tot. 6.04 Display Balancer 1 71 C-22 Touch Detector 1 70 A-14 Multilink i/o 1 70 K-10 Profibus Data transmission Datum 10.2006...

  • Page 158: Mount Balancing Head & Transducer (Vibration Pickup)

    RZ 150 Maintenance, Change Modules Balance System VM24 Pos : 13.2.3 /Schulung/El ektr oni k/Allgemein/Balanc e System 02 Aus wuc htkopf & Schwi ngungsaufnehmer montier en @ 3\mod_1120133108217_2.doc @ 24820 Mount Balancing Head & Transducer (Vibration Pickup) Note Position of transmitter unit to receiver balancing head Distance: 0.8 mm ±...
  • Page 159 RZ 150 Maintenance, Change Modules Balance System VM24 11. Open cover. 12. Remove setting gauge. 13. Install plastic protection ring. Mounting of Vibration Transducer (B2000) Note The vibration transducer is fixed to the stator housing with a magnet. After a possible grinding wheel crash the magnet locating surface must be cleaned.

  • Page 160: Switch On And Test Balancer System

    RZ 150 Maintenance, Change Modules Balance System VM24 Pos : 13.2.5 /Schulung/El ektr oni k/Allgemein/Balanc e System 03 ei nsc hal ten und testen @ 3\mod_1120124336915_2.doc @ 24787 Switch on and Test Balancer System Warning – Electric shock The supply module A2004 will be supplied with 230VAC voltage, when equipment is switched on.
  • Page 161 RZ 150 Maintenance, Change Modules Balance System VM24 Wait until on the display in the display field the word Neutral position ap- pears. This takes approx. 2 minutes. Put focus with F3 and F4 to the AUTOM. SOFTKEY Press ENTER.
  • Page 162 RZ 150 Maintenance, Change Modules Balance System VM24 Fig. 39: For machines with very low sensivity it might be necessary to increase GAIN. Touching Control Signal Scratch with a piece of metal (e.g. screw driver) with limited force at the grind- ing wheel.

  • Page 163: Exchange Eprom And New Start, Enabling

    RZ 150 Maintenance, Change Modules Balance System VM24 Pos : 13.2.7 /Schulung/El ektr oni k/Allgemein/Balanc e System 04 EPROM wec hs eln und befähigen @ 3\mod_1120124392194_2.doc @ 24798 Exchange EPROM and New Start, Enabling Warning – Electric shock Possible injuries and damages to persons or to material.
  • Page 164 RZ 150 Maintenance, Change Modules Balance System VM24 Touching Board A2002 [PC10900-3] > Plug in EPROM with actual software Plug in EPROM left aligned with notch towards right. notch Fig. 41: Elektronik Kurs...
  • Page 165 RZ 150 Maintenance, Change Modules Balance System VM24 Multilink Board Print A2003 [PC10900-2] > Plug in EPROM with actual software Plug in EPROM with notch towards right notch External Operating Unit A2015 [E10907] > Plug in EPROM with actual software notch Insert all boards.
  • Page 166 RZ 150 Maintenance, Change Modules Balance System VM24 Switch on Power Supply > Switch on power supply on BS A2004 [PC10900-1]. einschalten. • During start-up the software version will be displayed on the VM20 display. • Afterwards, the balancing picture appears automatically.

  • Page 167: Transfer Balance System Parameter

    RZ 150 Maintenance, Change Modules Balance System VM24 Pos : 13.2.9 /Schulung/El ektr oni k/Allgemein/Balanc e System 05 Parameter übertrag en Ver.8.1 @ 3\mod_1120124466831_2.doc @ 24809 Transfer Balance System Parameter Note As of 2005 deliveries, two versions of cable connection for the data transfer do exist.

  • Page 168: Version Ex-2005, Connect Mmc With Balance (A2004 And A2015)

    RZ 150 Maintenance, Change Modules Balance System VM24 Version ex-2005, Connect MMC with Balance (A2004 and A2015) > Set two rotary switches on black box according to illustration. A2015 PAGE SINUMERIK 840D VM24 DVI / VGA PCU50.3-C Phone Line 1.5GHz, 512 MB COM2 WinXP Pro Emb.
  • Page 169 RZ 150 Maintenance, Change Modules Balance System VM24 Mark back-up, press Enter - Menu VM 20 appears, the display is ready for the transfer of parameters. Start Balance Backup Program  P  B  execute > in Windows: S...
  • Page 170 RZ 150 Maintenance, Change Modules Balance System VM24 Select the corresponding Restore-File F:/users/parameter/Balance/…/PBTM_yymmdd.bck. Use always the file with the most current date. Note Notice the Readme-File (Readme.txt) of the newest version (Vxxx). > Select Work and Setup. Select Restore. Elektronik Kurs...

  • Page 171: Backup, Save Parameter In File (For Information)

    RZ 150 Maintenance, Change Modules Balance System VM24 After successful Restore the above window with Restore Ok will appear. Leave the program via Exit. Check at random parameters according to parameter list. Note The parameters are transferred to the Balance System. Now some parameters should be checked at random.
  • Page 172 RZ 150 Maintenance, Change Modules Balance System VM24 > Select Cards Search. > If all 4 units (panel 1, balancing unit1, touch control 1 and multi-link I/O 1) are listed, then Backup can be selected. Elektronik Kurs...

  • Page 173: Parameter List

    RZ 150 Maintenance, Change Modules Balance System VM24 > Save parameter under PBTM_yymmdd.bck (year, month, day) After successful backup the status Backup OK will be behind each card. Leave the program via Exit. Check at random parameters according to parameter list.
  • Page 174 RZ 150 Maintenance, Change Modules Balance System VM24 • Press BUTTON • Enter password for level installer : [F1, F2, F2, F1] • Press Enter  Message Access level installer appears • Press BUTTON • SETUP SYSTEM CONFIGURATION  (= ON) ALANCING UNIT ...
  • Page 175 RZ 150 Maintenance, Change Modules Balance System VM24  (= ON) PRINT SCREEN  (= AUT) TYPE OPERATOR ACCESS  AU+ATK (= ON) CREEN PAGE EXIT Parameterization of balancing unit • Press BUTTON • Enter password for level supplier: [Key, Key, F1, F4, Page] •...

  • Page 176: Setting Of Balancing Parameters

    RZ 150 Maintenance, Change Modules Balance System VM24  (= LINEAR) RIVER OTORS  No-Link (= MINI-NOL) COLLECTOR TYPE  (= START) EXECUTION  (= FAST) NEUTRAL CYCLE MODE AST MENU Setting of vibration transducer • ETUP ALANCING UNIT VIBRATION TRANSDUCER ...

  • Page 177: Parameterization Of The Touch Control

    RZ 150 Maintenance, Change Modules Balance System VM24 Check the parameter changes balancing unit 1 • Press BUTTON • Enter passwortd for level installer: [F1, F2, F2, F1] • Press Enter  Message Access level installer appears. • ARAMETER ALANCING UNIT PARAMETER CHANGES ...
  • Page 178 RZ 150 Maintenance, Change Modules Balance System VM24 Setting of Automatic Touch Control Parameter • Press Key. BUTTON • Enter password for level installer: [F1, F2, F2, F1] • Press Enter.  Message Access level installer appears. Setting of Reset Behaviour •...
  • Page 179 RZ 150 Maintenance, Change Modules Balance System VM24 Setting of Screen Display • Press BUTTON • ETUP OUCH ONTROL NIT CONTROL PARAMETER SCREEN DISPLAY  (= 200) CALE RANGE  (= 10) FFSET VIBRATIONS  (= 100) CALE RANGE ...
  • Page 180 RZ 150 Maintenance, Change Modules Balance System VM24 Activate parameters Note The parameters of the serial interface will be accepted and activated with the switching off and switching on. Pos : 13.3 /=========================== @ 0\mod439_2.doc @ 7299 Elektronik Kurs...

  • Page 181: Configuring Electronic Gear Box (Egb) (A1100) Aa0370

    RZ 150 Maintenance, Change Modules Configuring Electronic Gear Box (EGB) (A1100) AA0370 Pos : 13.4 /Schulung/El ektr oni k/Allgemein/EGB AA0310 Konfiguration Wälz modul @ 3\mod_1114173532490_2.doc @ 20073 Configuring Electronic Gear Box (EGB) (A1100) AA0370 EXPLANATION When exchanging an electronic gear box, it must be made sure, that the data in are correct.

  • Page 182: Wiring

    RZ 150 Maintenance, Change Modules Configuring Electronic Gear Box (EGB) (A1100) AA0370 Wiring For the configuration the HMI computer must be connected with the EGB (WM) computer connection COM1 (A1100.21) of the electronic gearbox via an enclosure (interface converter) A1 150 or A8651.
  • Page 183 RZ 150 Maintenance, Change Modules Configuring Electronic Gear Box (EGB) (A1100) AA0370 Fig. 45: Variation 1, wiring with electronic gear box Elektronik Kurs...

  • Page 184: Start Service Mode On Mmc

    RZ 150 Maintenance, Change Modules Configuring Electronic Gear Box (EGB) (A1100) AA0370 SINUMERIK 840D DVI / VGA PCU50.3-C Phone Line 1.5GHz, 512 MB COM2 WinXP Pro Emb. Sys Parameter Transfer, RS232 => HD 40GB - SATA 4xUSB 24VDC Hard Disk...

  • Page 185: Check Connection

    RZ 150 Maintenance, Change Modules Configuring Electronic Gear Box (EGB) (A1100) AA0370 EXPLANATION The hyper terminal configuration file WM.ht is saved on the MMC. Path for WM.ht F:\users\proj\Wm\ E:\Winnt.40\Profiles\Administrator\Start Menu\Programs\accessories\HyperTer.\ C:\Program Files\Accessories\ Win 95 Check connection > Press [CTRL] + [X] KEYS - Text starts to run through, after approx.

  • Page 186: Transfer Configuration File

    RZ 150 Maintenance, Change Modules Configuring Electronic Gear Box (EGB) (A1100) AA0370 Fig. 49: Hyper terminal is ready for transfer of configuration files The configuration file can be transferred only if prompt [VxWorks Boot]: is EXPLANATION visible. The scrolling of the text must stop at the prompt in order to transfer the text file.

  • Page 187: Transfer Text File

    RZ 150 Maintenance, Change Modules Configuring Electronic Gear Box (EGB) (A1100) AA0370 Article number Installation file Configuration file Type VMOD P5 006864.01 (230 VAC) RAG_Install.bat Wm_Konfig.txt 006864.02 (120VAC) VMOD C6 Wm_Konfig_c6.txt 007495.01 (230 VAC) Waelzmodul_c6_Install.bat 007495.02 (120 VAC) VMOD C6 Wm_Konfig_c6_eeE.txt...

  • Page 188: Front Plate A1100.21

    RZ 150 Maintenance, Change Modules Configuring Electronic Gear Box (EGB) (A1100) AA0370 Front plate A1100.21 Computer VMOD-P5 (variation 1) Fig. 50: Front plate A1100.21 After successful booting the LED 1 must blink at a fast pace and the LED 2 slowly.

  • Page 189: Front Plate A1100.21 Computer Vmod-C6

    RZ 150 Maintenance, Change Modules Configuring Electronic Gear Box (EGB) (A1100) AA0370 Front plate A1100.21 computer VMOD-C6 (Variation 2/3) LED Color Signification Computer internal Reset Green Power supply OK Yellow Activities on IDE-bus Booting of computer In a normal operation mode only the green LED 1 is illuminated. Is the LED 3 illuminated, the com- puter is defective or a BIOS setting is incorrect.

  • Page 190: In Case Of An Error

    RZ 150 Maintenance, Change Modules Configuring Electronic Gear Box (EGB) (A1100) AA0370 In case of an error Did a problem occur? No connection: > In case of an error, check the configuration input and network hardware (Hub and Ethernet cable).

  • Page 191: Windows 95 Configuration Data (Example)

    RZ 150 Maintenance, Change Modules Annex EGB Windows 95 configuration data (example) [VxWorks Boot]: c '.' = clear field; '-' = go to previous field; ^D = quit boot device : lnPcNet processor number : 0 host name : mmc-10...

  • Page 192: Start And Configure Hyperterminal

    RZ 150 Maintenance, Change Modules Annex EGB Start and configure HyperTerminal  P  A  C  H l/WM.ht TART ROGRAMS CCESSORIES OMMUNICATIONS YPER ERMINA Setting of interface parameter: Fig. 51: Name WM (Electronic Gear Box = Wälz Modul) Connect to COM2, on MMC computer Fig.
  • Page 193 RZ 150 Maintenance, Change Modules FTP repair COM2 Properties, Port settings Fig. 53: COM2 Properties WM (EGB) properties, settings, features Fig. 54: WM Properties, Settings Save settings in: F:\users\proj\WM\Wm.ht Pos : 13.5 /Schulung/El ektr oni k/Allgemein/EGB FTP repair @ 9\mod_1216097864359_2.doc @ 93573...

  • Page 194: Ftp Repair

    RZ 150 Maintenance, Change Modules FTP repair FTP repair FTP repair is a point in the menu under: Data, RAG service, FTP repair Error message 700500 FTP repair will be applied for the error message: 700500 - A160FC232 Controller for electronic gearbox not ready Function After clicking of FTP repair the “F:\user\ftp_repair.bat“...

  • Page 195: Battery Exchange

    RZ 150 Maintenance, Change Modules FTP repair Fig. 56: Keyboard with PS2-connection Fig. 57: Y-cable for PS2-keyboard Battery Exchange Shut-down main switch Disassemble electronic gearbox computer Exchange battery according to picture Lithium battery BR2335 Fig. 58: Location of the Lithium battery BR2335 in the computer...
  • Page 196 RZ 150 Maintenance, Change Modules FTP repair Fig. 59: BIOS setting must be changed, continue at 5) Fig. 60: Setting in BIOS is OK, continue at 9) Press F2> (this way you reach the BIOS setting) Adjust System Time and System Date with +, -, tab the date format is...

  • Page 197: Problems

    RZ 150 Maintenance, Change Modules FTP repair Fig. 61: Press F10, acknowledge question with Enter Fig. 62: Settings completed. Electronic gearbox computer should boot in a properly manner. Problems > If the computer is not booting (the 4th red status-LED is illuminated, longer than 30sec) ->...
  • Page 198 RZ 150 Maintenance, Change Modules FTP repair Pos : 13.7 /=========================== @ 0\mod439_2.doc @ 7299 Elektronik Kurs...

  • Page 199: Exchange C1 / C2 - Drive Components (A520X)

    RZ 150 Maintenance, Change Modules Exchange C1 / C2 – Drive Components (A520X) Pos : 13.8 /Schulung/El ektr oni k/RZ 150/RZ 150 C1-C 2 Antrieb tauschen @ 3\mod1377_2.doc @ 9399 Exchange C1 / C2 – Drive Components (A520X) Note The C2-axis will be used as reference for all axes settings (X, Y, Z, A).

  • Page 200: Parameterization Of Aradex A5201, Option

    RZ 150 Maintenance, Change Modules Exchange C1 / C2 – Drive Components (A520X) Parameterization of Aradex A5201, Option Usually this step is not required, because the replacement amplifier will be deli- vered already parameterized as spare part. Parameters such as number of pole pair of motor, increments of encoders etc.
  • Page 201 RZ 150 Maintenance, Change Modules Exchange C1 / C2 – Drive Components (A520X) Start F:\users\proj\Aradex\Aradex.exe. Execute step 1. to 5. 1. Select and open interface COM2. 2. Open 3. Select data for RZ150 etc. 4. Set parameter 5. Save values.

  • Page 202: Block Diagram C'-Controlling

    RZ 150 Maintenance, Change Modules Exchange C1 / C2 – Drive Components (A520X) C1..2-Alignment & Phase Tuning of Aradex EXPLANATION In order that the motor turns uniformly, the three-phase system of the amplifier must be tuned. The controller measures the actual speed. The value Cs1StoerFreq[V] is the speed error signal, which will be tuned to a minimum via the settings at the amplifier.
  • Page 203 RZ 150 Maintenance, Change Modules Exchange C1 / C2 – Drive Components (A520X) Referencing C1 Close circular doors and start-up equipment. DB352.DBX1.0 = 1 Execute single axis referencing. –. Select referencing mode, select C1-axis, press + or 60 70 60 70 [ .
  • Page 204 RZ 150 Maintenance, Change Modules Exchange C1 / C2 – Drive Components (A520X) Phase Adjustment C1-axis 1. Minimize Interference Voltage with Offset at Revolution 1 Connect the serial cable again to A5201 X8. Open in Aradex.exe interface (COM2). Enter the following lines in the MDA-box (or start TEST_C1.MPF):...
  • Page 205 RZ 150 Maintenance, Change Modules Exchange C1 / C2 – Drive Components (A520X) Note No adjustment of the scaling error is required in case that the interference voltage was already in the basic setting (206) below 0.1V. Also adjust scaling, as described above, until minimum has been reached (interference voltage smaller than 0.1V).

  • Page 206: Danfoss Vlt2800, Setting Of Parameter, Dressing

    RZ 150 Maintenance, Change Modules Danfoss VLT2800, Setting of Parameter, Dressing Pos : 13.10 /Sc hul ung/El ektroni k/R Z150/RZ 150 D anfoss @ 3\mod1378_2.doc @ 9339 Danfoss VLT2800, Setting of Parameter, Dressing Exchange of Defective Frequency Converter Shut-down machine with main switch 2Q102.
  • Page 207 RZ 150 Maintenance, Change Modules Danfoss VLT2800, Setting of Parameter, Dressing Frequency Converter A2015 50 H z HMI PCU50 COM2 RS232 - A8651 / A1150 BALANCE INPUT BAL_DISP Schnittstellenwandler Converter ARADEX ARADEX A8651_FC_Danfoss.dsf Turn the switch on the interface converter (A1150) to position DANFOSS.

  • Page 208: List Of Parameter, Which Deviate From Basic Settings

    RZ 150 Maintenance, Change Modules Danfoss VLT2800, Setting of Parameter, Dressing List of Parameter, Which Deviate From Basic Settings Note Access to all parameters: Press simultaneously QuickMenu and +. KEYS A8600 Standard A8600 OPTION Menu Text according to Works setting...

  • Page 209: Reset Device Back To The Works Setting (Factory Setup)

    RZ 150 Maintenance, Change Modules Danfoss VLT2800, Setting of Parameter, Dressing A8600 Standard A8600 OPTION Menu Text according to Works setting Type 28xx RP120 and Type 28xx SERVAX operating instruction RP161 RP- 160-3 U 5 Voltage Parameter 103 360 V...

  • Page 210: Parameterization Micromaster 440 (A8600) (Option)

    RZ 150 Maintenance, Change Modules Danfoss VLT2800, Setting of Parameter, Dressing Pos : 13.12 /Sc hul ung/El ektroni k/R Z150/RZ 150 Mi kr omas ter Parameter Uebertragung @ 7 \mod_1194354891781_2.doc @ 76603 Parameterization Micromaster 440 (A8600) (Option) Note Prerequisite: Doors closed and locked, equipment switched on Reset to factory pre-settings: •...
  • Page 211 RZ 150 Maintenance, Change Modules Danfoss VLT2800, Setting of Parameter, Dressing • Press in order to process the parameter • Select index with • Press in order to process the selected index of the parameter • Change the value with •...

  • Page 212: Parameter List

    RZ 150 Maintenance, Change Modules Danfoss VLT2800, Setting of Parameter, Dressing Load parameters into unit (50Hz, display in [kW]): • Start DriveMonitor • Establish connection: Data -> establish USS-Online connection • Press Start > It will be searched for the unit and if found, to be opened.
  • Page 213 RZ 150 Maintenance, Change Modules Danfoss VLT2800, Setting of Parameter, Dressing Menu A8600 Micromaster 440 Text acc. to operating manual P0100 Europe/North America (settings for Japan, Korea, 2 North America [kW], 60 Hz Brasil) P0100 Europe/North America (settings for remaining count-...
  • Page 214 RZ 150 Maintenance, Change Modules Danfoss VLT2800, Setting of Parameter, Dressing Menu A8600 Micromaster 440 Text acc. to operating manual P1715 Amplification factor current controller 0.029 P1717 Integration time current controller 2.0 ms Communication P2000 Reference frequency 267 Hz P2002 Reference current 8.20 A...

  • Page 215: Coding Siemens

    RZ 150 Maintenance, Change Modules Coding Siemens Pos : 13.14 /Sc hul ung/El ektroni k/R Z150/RZ 150 C odier ung Siemens @ 3 \mod1381_2.doc @ 9419 Coding Siemens Note The following codings to be set according the schematics: MPI – Bus plug (switch): Set bus beginning and end to “ON“;...

  • Page 216: Codings Electronic Gear Box (Egb) Rack

    RZ 150 Maintenance, Change Modules Coding Siemens A4100: Coding for 400V Coding for 415V Coding for 480V ON OFF Codings Electronic Gear Box (EGB) Rack Hardware Configuration of the VMEbus Boards of the EGB CPU- card JANZ VMOD-P5: A1100.21 Version 2.x S1 0 VMOD-P5 V2.x...
  • Page 217 RZ 150 Maintenance, Change Modules Coding Siemens Version 1.x (old version) Fix soldered (J12) VMOD-P5 Note The communication module VMOD-COM on the lowest insert slot of the CPU- card can not be configured. Heidenhain VMEbus- Counter Cards Coding axis counter card (C1, C2) A1100.33:...

  • Page 218: Janz Vmod-Io/E Building Group Bracket (Bracket Of Da / Io- Modules)

    RZ 150 Maintenance, Change Modules Coding Siemens Coding axis counter card (C1, B, Y, Z) A1100.37: DIP- switch S1: 1 2 3 4 5 6 7 8 • Jumper J1 / J2 open: 1 2 3 4 5 6 7...

  • Page 219: Modulbus- Modules On The Building Group Bracket

    RZ 150 Maintenance, Change Modules Coding Siemens MODULbus- Modules on the Building Group Bracket DA Converter JANZ VMOD-16A2 (nominal value for Aradex axis amplifier C1 and C2) A1100.29.1 and A1100.29.2 • Jumper configuration for ± 10V. • Jumper J1 open.

  • Page 220: Sensor Interface A1100.73

    RZ 150 Maintenance, Change Modules Coding Siemens Sensor Interface A1100.73 • Jumper JP1 and JP2 must be set as shown in figure below. (Pin 1 and 2 connected) Pos : 14 /=========================== @ 0\mod439_2.doc @ 7299 Elektronik Kurs...

  • Page 221: Error Messages

    RZ 150 Error Messages Evaluate Alarms and Messages Pos : 15.1 /Schulung/Schulung D oku- Vorl agen/Titel - F ehl er mel dungen @ 8\mod_1208501966671_2.doc @ 89921 Error Messages Evaluate Alarms and Messages Hier das Kapitel aus Original Bedienungsanleitung einfügen Elektronik Kurs...
  • Page 222 RZ 150 Error Messages Evaluate Alarms and Messages Pos : 16 /=========================== @ 0\mod439_2.doc @ 7299 Elektronik Kurs...

  • Page 223: Block Diagram

    RZ 150 Block Diagram Diagram Pos : 17 /Schulung/Elektr oni k/Allgemein/Bl oc ksc hema @ 3\mod_1118208660922_2.doc @ 23384 Block Diagram Diagram In this chapter the functional principle of the machine are explained with the help of block diagrams. Consisting of: •...
  • Page 224 RZ 150 Block Diagram Diagram Pos : 18 /=========================== @ 0\mod439_2.doc @ 7299 Elektronik Kurs...

  • Page 225: Schematics

    RZ 150 Schematics Schematics Pos : 19.1 /Schulung/El ektr oni k/Allgemein/Sc hemata @ 3\mod_1118308744915_2.doc @ 23533 Schematics Schematics Pos : 19.2 /Schulung/Pl atz halter für Zeic hnungen und Sc hemata @ 8\mod_1204279863718_2.doc @ 86743 A C H T U N G...
  • Page 226 RZ 150 Schematics Schematics Pos : 21.1 /Schulung/El ektr oni k/Allgemein/Opti onen, N ahtstellen @ 3\mod_1118308982567_2.doc @ 23566 Elektronik Kurs...

  • Page 227: Options, Interfaces

    RZ 150 Options, Interfaces Reishauer List of Options RZ 150 Options, Interfaces Pos : 21.2 /Schulung/El ektr oni k/RZ 150/RZ 150 Opti onslis te @ 3\mod1382_2.doc @ 9359 Reishauer List of Options RZ 150 Version: V2.0 Date : 02.11.2005 The machine configuration and its equipment will be defined by the machine data.

  • Page 228: Door Options

    RZ 150 Options, Interfaces Reishauer List of Options RZ 150 Door options Option datum: MD14510[100] PLC-address: DB20.DBW200 Data type: Integer Description: Schematic block 600 Valid as of: PLC V1.050  Value Function Description, Remark Protection doors will not be processed...

  • Page 229: Key Print

    RZ 150 Options, Interfaces Reishauer List of Options RZ 150 Key print Option datum: MD14510[113] PLC-address: DB20.DBW226 Data type: Integer Description: There are two versions of the key prints (A1240). Schematic block 1200 Valid as of: PLC V1.050  Value Function...

  • Page 230: Reporting Concept

    RZ 150 Options, Interfaces Reishauer List of Options RZ 150 Reporting Concept Option datum: MD14510[116] PLC-address: DB20.DBW232 Data type: Integer Description: Defines which path is used to display the PLC error messages. Valid as of: PLC V1.050  Value Function...

  • Page 231: Hydraulic Unit (Prewarning Oil Level)

    RZ 150 Options, Interfaces Reishauer List of Options RZ 150 Hydraulic Unit (Prewarning Oil Level) Option datum: MD14510[122] PLC-address: DB20.DBW244 Data type: Integer Description: Defines the switching property of the level switch Schematic block 1500 Valid as of: PLC V1.072 ...

  • Page 232: Balancing

    RZ 150 Options, Interfaces Reishauer List of Options RZ 150 Balancing Option datum: MD14510[107] PLC-address: DB20.DBW214 Data type: Integer Description: Defines the attached balancing system. Schematic block 2000 Valid as of: PLC V1.050  Value Function Description, Remark Balancing will not be processed...

  • Page 233: Stack Lights

    RZ 150 Options, Interfaces Reishauer List of Options RZ 150 Stack Lights Option datum: MD14510[105] PLC-address: DB20.DBW210 Data type: Integer Description: Defines the installed stack lights. The functions description of the respec- tive stack lights can be found in pdm.documentation 21086200_SU.

  • Page 234: Customer-Specific Operating Data Acquisition

    RZ 150 Options, Interfaces Reishauer List of Options RZ 150 Customer-specific operating data acquisition Option datum: MD14510[115] PLC-address: DB20.DBW230 Data type: Integer Description: Processing of customer-specific operating data Valid as of: see description  Value Function Description, Remark No Qd-Server...

  • Page 235: Meshing

    RZ 150 Options, Interfaces Reishauer List of Options RZ 150 Meshing Option datum: MD14510[108] PLC-address: DB20.DBW216 Data type: Integer Description: Defines if a meshing device is installed or not. Schematic block 2800 Valid as of: PLC V1.050  Value Function...

  • Page 236: Oil Mist Extraction Unit

    RZ 150 Options, Interfaces Reishauer List of Options RZ 150 Oil Mist Extraction Unit Option datum: MD14510[101] PLC-address: DB20.DBW202 Data type: Integer Description: Defines the connected oil mist extractor. Schematic block 3300 Valid as of: PLC V1.050  Value Function Description, Remark Oil mist extractor will not be processed.

  • Page 237: Grinding Oil Unit 1

    RZ 150 Options, Interfaces Reishauer List of Options RZ 150 Grinding Oil Unit 1 Option datum: MD14510[102] PLC-address: DB20.DBW204 Data type: Integer Description: Defines the connected grinding oil unit. Schematic block 3500 Valid as of: PLC V1.050  Value Function Description, Remark Grinding oil unit will not be processed.

  • Page 238: Grinding Oil Unit 3

    RZ 150 Options, Interfaces Reishauer List of Options RZ 150 Grinding Oil Unit 3 Option datum: MD14510[121] PLC-address: DB20.DBW242 Data type: Integer Description: Defines if a wash-off unit for cooling of the machine base is installed. Valid as of: PLC V1.063 ...

  • Page 239: Scale X-Axis

    RZ 150 Options, Interfaces Reishauer List of Options RZ 150 Scale X-axis Option datum: MD14510[117] PLC-address: DB20.DBW234 Data type: Integer Description: Defines if a X-axis scale is attached or not. Schematic block 4300 Valid as of: PLC V1.050  Value Function Description, Remark Scale X-axis not available.

  • Page 240: W1/W2-Axis

    RZ 150 Options, Interfaces Reishauer List of Options RZ 150 W1/W2-axis Option datum: MD14510[109] PLC-address: DB20.DBW218 Data type: Integer Description: Defines which of the tailstocks are attached. Schematic block 5300 Valid as of: PLC V1.050  Value Function Description, Remark...

  • Page 241: Workpiece Identification External Loader

    RZ 150 Options, Interfaces Reishauer List of Options RZ 150 Workpiece Identification External Loader Option datum: MD14510[134] PLC-address: DB20.DBW268 Data type: Integer Description: Workpiece identification external loader. The 32-bit workpiece identification is only available, if the loader interface is performed with the Profibus.

  • Page 242: Dressing Device

    RZ 150 Options, Interfaces Reishauer List of Options RZ 150 Dressing Device Option datum: MD14510[112] PLC-address: DB20.DBW224 Data type: Integer Description: Defines, with what kind of dressing device the machine is equipped. Pre- dominant the RP 120 is being used, which operates with dressing disks within the diameter range of 123.0 mm.

  • Page 243: Oil Volume Monitoring Input Unit

    RZ 150 Options, Interfaces Reishauer List of Options RZ 150 Oil Volume Monitoring Input Unit Option datum: MD14510[142] PLC-address: DB20.DBW284 Data type: Integer Description: Selection of input unit in percentage or in liter. Valid as of: NC/MMI V05.01 PLC V01.090 ...

  • Page 244: Geometrical Offset C1- To C4-Axis In X-Direction

    RZ 150 Options, Interfaces Reishauer List of Options RZ 150 Geometrical Offset C1- to C4-axis in X-direction Option datum: MD14514[7] PLC-address: DB20.DBD796 Data type: Real Description: Geometrical offset C1-axis to C4-axis in X-direction Valid as of: NC/MMI V01.00 Value Function...

  • Page 245: Geometrical Offset C2- To C4-Axis In Y-Direction

    RZ 150 Options, Interfaces Reishauer List of Options RZ 150 Geometrical Offset C2- to C4-axis in Y-direction Option datum: MD14514[10] PLC-address: DB20.DBD808 Data type: Real Description: Geometrical offset C2-axis to C4-axis in Y-direction Valid as of: NC/MMI V01.00 Value Function...

  • Page 246: Driving Pin Position C1 Center Sleeve

    RZ 150 Options, Interfaces Reishauer List of Options RZ 150 Driving Pin Position C1 Center Sleeve Option datum: MD14514[13] PLC-address: DB20.DBD820 Data type: Real Description: Driving pin position C1 center sleeve. Valid as of: NC/MMI V01.00 Value Function Description, Remark...

  • Page 247: Pivot Point Offset Dressing Device In Relation To Basis Surface In Y-Direction

    RZ 150 Options, Interfaces Reishauer List of Options RZ 150 Pivot Point Offset Dressing Device in Relation to Basis Surface in Y-direction Option datum: MD14514[16] PLC-address: DB20.DBD832 Data type: Real Description: Pivot point offset dressing device in relation to basis surface in Y-direction.

  • Page 248: Width Of Dressing Device Housing

    RZ 150 Options, Interfaces Reishauer List of Options RZ 150 Width of Dressing Device Housing Option datum: MD14514[19] PLC-address: DB20.DBD844 Data type: Real Description: Width of dressing device housing Valid as of: NC/ MMI V02.07 Value Function Description, Remark MD_b_GehC4_AbGr...

  • Page 249: Message Of New Machine Data

    RZ 150 Options, Interfaces Reishauer List of Options RZ 150 Message of new machine data Note For workload optimization, the applicant for new machine data must provide the following, completed data: 1. Name of the machine datum / option. 2. Type of data.
  • Page 250 RZ 150 Options, Interfaces Reishauer List of Options RZ 150 Pos : 23.1 /Schulung/El ektr oni k/Allgemein/Di vers es @ 3\mod_1118309031797_2.doc @ 23577 Elektronik Kurs...

  • Page 251: Diverse

    RZ 150 Diverse RZ 150, standard accessories Diverse Pos : 23.2 /Schulung/El ektr oni k/RZ 150/RZ 150 Nor malzübehör Werkzeug mit Mc @ 5\mod_1155642827406_2.doc @ 45063 RZ 150, standard accessories Article No. Quantity Description 155489.00 Tool cabinet 519614.00 Hand grease gun 006032.43...
  • Page 252 RZ 150 Diverse RZ 150 H - Commands Read-in Function in NC-channel 1 Command lock Inquire C speed Inquire C- axis info Transfer positioning speed Spindle rotation standard Spindle rotation current-optimized Spindle halt Abs. positioning positive Abs. positioning negative Abs. positioning on shortest way...
  • Page 253 RZ 150 Diverse RZ 150 H - Commands Read-in Function in NC-channel 1 Command lock Torque enabling Inquiry reference position cont. indexing Transmitt reference position cont. indexing Move to next indexing position Move by k pitch Set frequency / set upper wave...

  • Page 254: Rz 150 M-Commands

    RZ 150 Diverse RZ 150 M-Commands Read-in Function in NC-channel 1 Command lock H100 Pos : 23.4 /Schulung/El ektr oni k/Allgemein/RZ M-Befehle @ 3\mod1385_2.doc @ 9369 RZ 150 M-Commands Function in NC- Channel 1 Read R-Par Function in NC-channel 1...
  • Page 255 RZ 150 Diverse RZ 150 M-Commands Read R-Par Function in NC-channel 1 Command lock ON value must be allocated! Switch on Jog-mode Pre-select Jog-Inc Axis pre-selection for Jog Handwheel on Handwheel off Limiting of Jog-Inc RP-dressing on (1-99) Touching control on (1-99)
  • Page 256 RZ 150 Diverse RZ 150 M-Commands Read R-Par Function in NC-channel 1 Command lock Test switch of pneumatic options 0 = assignment via H79 1 = acts on spindle 1 2 = acts on spindle 2 Blow out workholding fixture on...
  • Page 257 RZ 150 Diverse RZ 150 M-Commands Read R-Par Function in NC-channel 1 Command lock 2= only spindle C2 will be applied 3= both spindles are applied M100 M101 M102 M103 M104 M105 M106 M107 M108 Grinding oil off M109 Grinding oil on...
  • Page 258 RZ 150 Diverse RZ 150 M-Commands Read R-Par Function in NC-channel 1 Command lock M119 Activate reset-key M120 Handwheel superimposing on M121 Handwheel superimposing off M122 Sensor monitoring on M123 Sensor monitoring off M124 Cover flap in dressing position M125...
  • Page 259 RZ 150 Diverse RZ 150 M-Commands Read R-Par Function in NC-channel 1 Command lock M158 NC-Start at NC-function key M159 No NC-Start at NC-function key M160 Reset Halt key M161 Start enable NC-Channel 2 M162 Axis override to 100 %...
  • Page 260 RZ 150 Diverse RZ 150 M-Commands Read R-Par Function in NC-channel 1 Command lock M195 M196 User must unload workpiece manually M197 User has workpiece manually unloaded M198 M199 M200 Error box on M201 Error box off M202 Comment box on...

  • Page 261: Function In Nc-Channel 2

    RZ 150 Diverse RZ 150 M-Commands Read R-Par Function in NC-channel 1 Command lock M234 M235 M236 M237 M238 M239 M240 M241 M242 M243 M244 M245 M246 M247 M248 M249 Function in NC-Channel 2 Command Read- R-Par Function in NC-Channel 2...
  • Page 262 RZ 150 Diverse RZ 150 M-Commands Command Read- R-Par Function in NC-Channel 2 in lock These are System-M-commands. In order that they are recognized correctly by the PLC, the ON value must be allocated! Switch on Jog-mode Pre select Jog-Inc...
  • Page 263 RZ 150 Diverse RZ 150 M-Commands Command Read- R-Par Function in NC-Channel 2 in lock 1 = acts on spindle 1 2 = acts on spindle 2 Switch test of pneumatic options 0 = assignment via H79 1 = acts on spindle 1...
  • Page 264 RZ 150 Diverse RZ 150 M-Commands Command Read- R-Par Function in NC-Channel 2 in lock External loader enable part gripping M100 M101 M102 M103 M104 M105 M106 M107 M108 M109 M110 M111 M112 M113 M114 M115 Elektronik Kurs...
  • Page 265 RZ 150 Diverse RZ 150 M-Commands Command Read- R-Par Function in NC-Channel 2 in lock M116 M117 M118 M119 M120 M121 M122 M123 M124 M125 M126 Lock start NC-channel 2 M127 Set error bit $A_IN[5] M128 Advance AM probe M129...
  • Page 266 RZ 150 Diverse RZ 150 M-Commands Command Read- R-Par Function in NC-Channel 2 in lock M155 M156 M157 M158 M159 M160 M161 Start enabling NC-channel 2 M162 M163 M164 M165 M166 M167 M168 M169 M170 M171 M172 M173 M174 M175...
  • Page 267 RZ 150 Diverse RZ 150 M-Commands Command Read- R-Par Function in NC-Channel 2 in lock M194 M195 M196 M197 M198 M199 M200 M201 M202 M203 M204 M205 M206 M207 M208 M209 M210 M211 M212 M213 M214 M215 M216 M217 M218...

  • Page 268: Rz150 Plc- Bits

    M246 M247 M248 M249 Pos : 23.5 /Schulung/El ektr oni k/RZ 150/RZ 150 PLC-Bits @ 4\mod_1143624183953_2.doc @ 36043 RZ150 PLC- Bits Note The list below is for information only and can be used for diagnosis purposes. Contents subject to change. Relevant is always the current PLC-project.

  • Page 269: Test Functions

    RZ 150 Diverse RZ150 PLC- Bits DB327.DBX0.0 B Processing fire extinguisher DB328.DBX0.0 B Processing automatic meshing DB333.DBX0.0 B Processing oil extraction unit DB335.DBX0.0 B Processing grinding oil unit DB341.DBX0.0 B Processing axes power supply DB341.DBX0.2 B Safety test On (SI generally switch on) DB341.DBX0.3 B...
  • Page 270 RZ 150 Diverse RZ150 PLC- Bits DBxxx.DBX0.2 SI On DBxxx.DBX0.3 Measuring system 2 Pos : 24 /=========================== @ 0\mod439_2.doc @ 7299 Elektronik Kurs...

  • Page 271: Notes

    RZ 150 Notes RZ150 PLC- Bits Pos : 25.1 /Schulung/Schulung D oku- Vorl agen/Titel, Kapitel 12, N otizen @ 3\mod1370_2.doc @ 9749 Notes ===== Ende der Stüc kliste ===== Elektronik Kurs...
  • Page 272 Reishauer AG Gear Grinding Machines Diamond and CBN Tools Industriestrasse 36 CH-8304 Wallisellen Tel +41 (0)44 832 22 11 Fax +41 (0)44 832 23 90 info@reishauer.com www.reishauer.com 09 Printed in Switzerland Subject to change without notice ELEKTRONIK KURS...

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