E7E04 MainDrive 01

Main drive
Product Training Electronics – ROLAND 700 4
4 Main drive..........................................................................................4-3
4.1 Overview current converter ............................................................................... 4-3
4.2 Main drive control concept ................................................................................ 4-4
4.3 Overview of series with 4Q drives .................................................................... 4-6
4.4 Activation of the main drive R700 ..................................................................... 4-7
4.5 Siemens 6 RA 22............................................................................................... 4-10
Overview connection .......................................................................................... 4-11
Overview of the different main drive control systems ......................................... 4-13
R700 from S717 ................................................................................................. 4-14
Parameter setting ............................................................................................... 4-17
Speed alignment................................................................................................. 4-18
Diagnosis, error search ...................................................................................... 4-19
4.6 Baumüller BKF 12............................................................................................. 4-20
Connections overview ........................................................................................ 4-20
Overview of the different main drive controls...................................................... 4-23
Operation of the keypad and Display.................................................................. 4-25
Parameter setting ............................................................................................... 4-25
Speed adjustment............................................................................................... 4-27
Diagnosis, error search ...................................................................................... 4-28
4.7 Instructions to putting into operation............................................................. 4-29
4.8 Main motor ........................................................................................................ 4-30
Inspection and maintenance............................................................................... 4-30
4.9 Brake main motor ............................................................................................. 4-31
Maintenance ....................................................................................................... 4-35
Air gap determination (see Fig. 1 & 3) ................................................................ 4-35
Checking or setting the micro-switch (s. Fig. 2) .................................................. 4-36
4.10 Signal Sensor Main Motor................................................................................ 4-37
Series overview of the signal sensor main motor ............................................... 4-37
Tacho-generator / rev sensor ............................................................................. 4-37
Incremental sensor / Angle sensor ..................................................................... 4-38
© MAN Roland Druckmaschinen AG C 95A 6428 39 - 02.10.2006 4-1

- for certified service technicians only -
Main drive
4 Product Training Electronics – ROLAND 700
4-2 C95A 6428 39 - 02.10.2006 © MAN Roland Druckmaschinen AG

Main drive
4 Main drive
4.1 Overview current converter
Hardware safety circuit

Interface signals
Power supply
Power supply
Power supply
Stromrichter Rectifier
Field Drive Thyristor
supply control modules
y Feldregler y Drehzahlregelung y Ankerspannung

y field control y speed control y armature rectifier
y Temperatur- y Stromregelung y Wechselrichter
überwachung y current control y power inverter
y temperature y Impulsfreigabe
monitoring y impulse release
y Bremsfreigabe
y brake release
speed
field feed- DC-Motor
back
A fully regulated current converter (G000) is used to control the DC machine (M000). So called
reversible current converters are used so as to be able to drive and brake in both torque directions.
In the employed fully digitised current converters a processor assumes the control and regulation
functions.
The nominal rev value arrives in digital form via a serial interface from the real-time computer.
The actual rev value is indicated as an analogue/digital value by a tachometer generator/
incremental sensor.
The following functions can be executed on the integrated keyboard with display on the current
rectifier:
• change settings
• display operation statuses
• read out error memory

Main drive
4.2 Main drive control concept
Run- STOP-
commands commands
SPS (PLC)
Hardware-Sicherkreis -safety circuit

F.O. Loop
RTR
F.O. Loop
UWR
Interface
feedback
Schnittstellenkarte
Interface board
Stromrichter
Rectifier
speed
feed- DC-Motor
back

Main drive
Four-quadrant behaviour
Operation in all four quadrants,

driving and braking with alternating rotation and torque directions
n+
clockwise clockwise
n n
M
M
dynamic accelerate
M- braking II I
III IV dynamic
accelerate
braking M+
n M n
M
anticlockwise anticlockwise
n-
Speed-torque diagram
In braking operation the converter works as an inverse rectifier.

The motor converts the actual kinetic energy of the machine into electrical energy (works as a
generator). The consumed DC voltage is converted into AC voltage by the converter and fed back
into the supply mains. Æ regenerative braking!
The braking operation requires a connection to the mains: the mechanical holding brake is activated
during a power cut and machine standstill.

Main drive
4.3 Overview of series with 4Q drives
R700
Baumüller - BKF12 from series 721
Rated DC current 200/250/330/400A
input voltage
3AC 400 (+15% / – 20%)
field supply
2AC 400 (+15% / – 20%)
Frequency
45 to 65
Simoreg - 6RA22 to series 720
Rated DC current 200/250/400A
input voltage
3AC 400 (+15% / – 20%)
field supply
2AC 400 (+15% / – 20%)
Frequency
45 to 65

Main drive
4.4 Activation of the main drive R700

Â Relay contacts -A343 -K2 must be closed (Stop-Safe-Loop-)
Â Relay contacts -A343 -K1 must be closed (Emergency-Halt-Loop)
Â until S739: UWR- relay on -A566 (-K2, -K4, -K5) must be closed
Â from S740: UWR- relay on -A566 (-K4, -K5) must be closed
Â RTR- relay (-K2 auf -A454) must be closed
Î on terminal 19 high signal
) Pres run command key

Â to 711: main contactor pulls via output -A354/14 Byte.Bit 19.3
(no auxiliary contactor)
Start up signal on
Feedback from signal tone generator input -A354/3 Byte.Bit 1.0
Â 712 to 716: auxiliary contactor –K252 pulls via output -A354/14 Byte.Bit 19.3
Main contactor pulls
Start up signal on
Â 717 to S739: Start-up signal on
Auxiliary contactor –K252 pulls via output -A354/14 Byte.Bit 19.3
Â from S740: Start-up signal on
-A566.K2 closes and auxiliary contactor –K252 pulls
) Press run command key for the second time

Â RTR relay (-K1 on -A454) pulls
Î on terminal 17 high-signal
Â on MD [BKF12] K1 / [K3] and K2 / [K1] are closed,they open again only when speed =”0“
Â K2 [K1] (MD) forms bypass via +Ax -A343 K1 and K2 (necessary for 4-Quadrant operation)
Â K1 / [K3] (MD) closes circuit to -K022
Â UWR relay on -A566 (-K3) pulls
Â -K022 pulls
Â micro switch –S804 closed by -K022 (contactor brake release)
Î on terminal 18 high-signal
(with R702,R702+L and R703 always “1“ on terminal 18)
Â Regulation release
Â Input -A354/3 Byte 2.0 (brake monitoring) set
0 When Stop-Safe key is pressed, UWR opens a time window (400ms);

if the speed is not reduced, UWR contacts are opened.
0 Current limit switch -A352/13 Byte.Bit 0.7 ; “0“ when forwards; “1“ when reverse
(on Siemens 6RA22 ”Simoreg“)
0 Current limit 150% of the anchor current is allowed during acceleration; 100% when braking
0 Temperature monitor on MD at ca. 80°C with message on Leitstand

4-8
4
current limit
Main drive
-24V -24V -K1 => Relay contact hardware loop,

selection Emergency-Stop, +Ax-A343
[RTR]
Power Output -K2 => Relay contact hardware loop,

Stop-Safety, +Ax-A343
-A352/13 [SPS-Anl.]
Byte.Bit 0.7 RTR => RTR hardware contacts,
-S804 +Ax-A454
ÜWR => ÜWR hardware contacts,
Micro +Ax-A566
switch -K050 => Contactor: current inverter, main drive
+A*-A343
K2 mech. -K252 => Auxiliary contactor for -K050
K1 (UWR)
brake (main contactor)
230VAC Stop E-
safety stop K050
-K021 => Contactor: main drive brake

UWR UWR +A*-A566
-K022 => Contactor: brake release
Product Training Electronics – ROLAND 700
K4 K5 (UWR Relay)
Contactor
brake release
Contactor for
main drive
Power Output -24V RTR RTR +A*-A454
-A354/14 [SPS-Allg.] (add. distrobutor BD)
K1 K2
Byte.Bit 19.2 19.3 RTR
16 17 19 Adapter board A386 20 18 X1

X1
RS485
X1 16 21 22 25 17 19 20 18
SINEC L1 protocol
Interface to ÜWR
GND
X300
B5 [X303]
8
9-pol. SUB-D
U001 Interafce to RTR

B2 [X1] B3 [X11]
Q014 1 3 5 A1
MRO
P24
Function stop
safety
+18V to +30V/max.150mA
unregulated voltage supply
(+AC1C)
SIMOREG 6RA22
Function
Fast stop
X200
Control release
Interface board
B4 [X203]
Relay K2 K1
A2 F454
C95A 6428 39 - 02.10.2006

main contactor ON Ready for 64
Temperature
(+AC1D) operation
P24
monitoring
X1
1 3
X1 4 6 7 8 X1 1 3 6 7
2 4 6
Tacho signal to UWR B5
6 5 X3
1 3 5 K050 Tacho signal from motor

-K252 15000D/h = 3000 1/min.
=180VDC
2 4 6
+A*-A566 K2
+A*-A566
(UWR relay)
A1 (UWR relay)
-A354/02
+A*-A343
(Safty board)
K050 K2 K1 K3
A2 Input
-A354/03
Byte.Bit 3.3 2.7 2.0 2.4
A2 A2
K252 K022
Feedback contactor
brake release
Limit switch:
brake, main drive
Feedback:
main contactor
Temp. monitoring
current inverter
A1 A1
Antriebsteuerung SIMOREG 6RA22.VSD

© MAN Roland Druckmaschinen AG
0V 0V
current limit -24V -24V -K1 => Relay contact hardware loop,
selection Emergency-Stop, +Ax-A343
[RTR]
Power Output -K2 => Relay contact hardware loop,

Stop-Safety, +Ax-A343

-A352/13 [SPS-Anl.]
Byte.Bit 0.7 RTR => RTR hardware contacts,
-S804 +Ax-A454
400VAC until series 736 UWR => UWR hardware contacts,
(with Trafo -T005) Micro +Ax-A566
24VAC from series 737 from S740: switch -K050 => Contactor: current inverter,
Output 19.3 replaced +A*-A343 mech.
K2 (UWR)
main drive
by permanent -24V K1 brake
Stop -K252 => Auxiliary contactor for -K050
E-
safety Stop K050 (main contactor)
-K021 => Contactor: main drive brake

UWR UWR +A*-A566 -K022 => Contactor: brake release
K4 K5 (UWR Relay)
Main drive
Contactor for
brake release
Contactor for
Power Output -24V RTR RTR +A*-A454
-A354/14 [SPS-Allg.] (Add. distributor BD)
K1 K2
Byte.Bit 19.2 19.3 RTR
16 17 19 X1 20 Adapter board A386 18 X1

X1 20 21 22 25 9 24 18
RS485
Interface to UWR
X601
GND
with USS-Protocol
9-pol. SUB-D
Interface to RTR
X602
C 95A 6428 39 - 02.10.2006

Control
release
Q014 1 3 5 G000
+24V/100mA
not stabilised
Fast stop
function
X15
X15
Incremental encoder
3.9493
X9
BKF 12 X8 and X9 signal

to UWR
K3 64
Interface board
Relay K1
Stop safety function

Ready for F454 Temp. are electrically
main cont. ON connected in parallel
15-pol. SUB-D
operation monitoring
X8
X1 4 6 X1 39 41 X1 31 32
2 4 6
X1/A2
1 3
6 5 Incremental encoder
signal from motor
1 3 5 K050
-K252
2 4 6
+A*-A566 K2
+A*-A566
(UWR relay)
A1 (UWR relay)
-A354/02
+A*-A343
(Safety board)
K050 K2 K1 K3
A2 Input
-A354/03
Byte.Bit 3.3 2.7 2.0 2.4
A2 A2
Main drive
K252 K022
Feedback contactor
barke release
Limit switch:
brake, main drive
Feedback:
maon contactor
Temp. monitoring
current inverter
A1 A1
4
Antriebsteuerung BAUMUELLER BKF12.VSD

0V 0V
4-9
Main drive
4.5 Siemens 6 RA 22
2 3
1. Firmware prom
2. End terminals
activation
3. Display with keypad
4. Potentiometer R1 - R4

Main drive
Overview connection
Interface board Z1011 on R700 SIMORG current converter to series 715
Significance of the jumpers Significance of the rotating switches S1-S4

• W1: plug jumper “top“,
from HW9 (bus end resistor R15 out) • S1/S4: S1=3
i •
•
W2: no significance
W3: no significance • S2/S3:
S4=9(interface RS232 active)
S3=0
S2=0
• CST1-CST2: in position CST1 (slave address of the SIMORG)
(CST = chip select)
• TTY/RS232: no significance!
Significance of the LED D2 – LED D5 DIP switch position SW1

! • LED D2(Run)“1“:
blinking Z1011 is o.k.
ON: 1/4/6
OFF: 2/3/5/7/8
off serious error on Z1011
• LED D3(DPR)“2“:
glows DPR is being processed
off no telegram on either of the
interfaces, basic device error
• LED D4(SINEC)“3“:
off no significance since interface LED D3, D4, D5 blinking together:
RS232 inactive
illegal switch position of S1/S4, S3/S2 and SW1
• LED D5(DUST)“4“:
on Interface RTR receiving valid
telegram
off no interface traffic
blinking reception error (fatal error)

Main drive
Interface board on R700 SIMORG current converter from series 716
Jumper J1 in position ”on“ Significance of the rotating switches S1-S3
• S1(data transfer speed): =0
i •
•
S2(interface address):
S3(interface address):
=0
=0
LED D1: Voltage supply (+5V)

o.k. the –24V are converted on the interface
board to +5V (U1)
LED D3 and LED D4 display the following during data transfer:

D3 D4
! blinking 1x/sec.
OFF
OFF
blinking 4x/sec.
Communication with SIMOREG is o.k.
Communication with Leitstand is o.k.
blinking 4x/sec. OFF no data exchange with SIMOREG
OFF ON no or missing communication with Leitstand
The CPU interfaces start an internal self test for RAM,DPR and EPROM during the start-up
phase:
D3 D4
! ON
ON
OFF
blinking 4x/sec.
Reset
RAM error
blinking 4x/sec. ON DPR error
OFF ON EPROM error

Main drive Main drive Main drive Main drive Main drive Main drive
contactor off brake release off contactor off fast stop Stop safety fast stop current limit selection
[RTR]
Relay board - Power -A358/18 [UWR]
1
Power Output -24V -24V -24V -24V

1 1
1

K3B K2B K4B K5B -A352/13 [SPS-Anl.]
3 3 3 3
Byte.Bit 0.7
X82 3 1 X82 8
3 6 5 4 9 8 7 10 8
13 -S804
R700 to S716
-S010 Micro
L R -F452 -F453
-XB29.A358
-XB29.A358
-XB29.A358
-XB29.A358
-XB29.A358
-XB29.A358
+BA T> T> switch
X8 6 X8 5 X8 4 X8 9 X8 8 X8 7 X8 10 mech.
-XB15.A352
14 M000 brake
7 K2 7
K1 +A*-A343 X82 4 2 X82 9
Stop (UWR)
E- stop 8 8 44
safety
K050
X6 18 X6 17 X6 16 X6 21 X6 20 X6 19 X6 22
X4 21 X4 20 X4 19 X4 22 43
X4 16 R702
+A*-A345 DELETED IN
1 R703
(SPS)
CASE OF
-24V R702+L
X37 4 X11 3 X11 4 X11 2 X11 1
2 1 R702
X2 1 X2 3
Contactor
ONLY R703
Contactor
2
main drive
brake release
R702+L
3 2
230VAC Power Output
-24V K1 K2 +A*-A454
-A354/14 [SPS-Allg.] 2 3
Byte.Bit 19.2 19.3 (Add. distributor BD)
X2 2 X2 4
4
3
16 17 19 Adapter board A386 20 18 X1
X1
RS485
-XB16.A354
X1 16 21 22 25 17 19 20 18
SINEC L1 Protocol
Interface to UWR
GND
X300
B5 [X303]
C 95A 6428 39 - 02.10.2006

8
9-pol. SUB-D
U001 Interface to RTR

B2 [X1] B3 [X11]
A1
Stop safety
function
Fast stop
function
P24
+18V to +30V/max.150mA
unregulatedvoltage supply.
control release
(+AC1C)
SIMOREG 6RA22
X200
Interface board
B4 [X203]
MRO [Z1011 until S715]
Relay K2 K1 F454
X003
main cont. ON
A2 Ready for Temperature 64
8
(+AC1D) operation Monitoring
P24
X1
1 3
X1 4 6 7 8 X1 1 3 6 7
7

6
6 5 X3
Q014 1 3 5 13
5
Overview of the different main drive control systems
K050
14
X37 3 X11 8 X11 5 X5 2 X3 14 16 15 11
Tacho signal from Motor
17
+A*-A345 15000D/h = 3000 1/min. =180VDC
18
(SPS)
2 4 6
X4
X11 9 X11 10 X11 12 X8 20 X8 12 13 16 15 14 9
3
+A*-A345
(SPS)
20 12 13 16 15 14 9
X4 15 X4 14
-A354/02
-A354/02
X6 15 14
-XB3.A354
(SSafety board)
(Safety board)
1 Input Input
1 3 5 K2
2 -A354/03 -A354/03
-K252 Byte.Bit 3.3 Byte.Bit 2.3 2.4 2.7 2.6 2.5 2.0
1
Feedback contactor Temperature monitoring
X8
2 4 6 K1
+A*-A343 (UWR)
break release
3
2
Main drive
A1 A2 A2
FROM
K050 K252 K022 3 717
-K050 => Contactor: curr. inverter, main drive SERIES
Brake release
manually
Feedback:
main contactor
Current inverter
Main drive:
warning
125°C
switch-off
140°C
Limit switch:
brake, main drive
A2 -K252 => Aux. contactor for -K050 (main cont.) A1 A1

4
Antriebsteuerung R700_S716-.VSD
-K022 => Contactor: brake release 0V 0V
4-13
4
4-14
-24V -24V -24V -24V
Main drive
Current limit selection

[RTR]
6 5 6 +A*-A566
5
K2 K4 K5 (UWR Relay) Power Output
K3 6 5
6 5
-A352/13 [SPS-fed.] X82 3 1 X82 8
X1 3 X1 6 X1 5 X1 4 X1 9 X1 8 X1 7 X1 10 Byte.Bit 0.7
13 -S804
-S010 -F452 -F453
L R Micro
+BA T> T>
8 switch
X8 6 X8 5 X8 4 X8 9 X8 8 X8 7 X8 10
mech.
14 M000
brake
7 7
+A*-A343 X82 4 2 X82 9
K1 K2
(UWR)
-XB15.A352
8 Stop 8 44
E-stop
safety
R700 from S717
K050
X6 18 X6 17 X6 16 X6 21 X6 20 X6 19 X6 22
X4 21 X4 20 X4 19 X4 22 43
X4 16 R702
+A*-A345 DELETED IN
1 R703
(SPS)
CASE OF
-24V R702+L
X37 4 X11 3 X11 4 X11 2 X11 1
2 1 R702
X2 1 X2 3
Contactor
ONLY R703
Contactor
2
main drive
brake release
R702+L
3 2
230VAC Power Output -24V
-A354/14 [SPS-Allg.]
K1 K2 +A*-A454
2 3
Byte.Bit 19.2 19.3 (Add. distributor BD)
X2 2 X2 4
4
3
X1 16 17 19 Adapter board A386 20 18 X1
RS485
-XB16.A354
X1 16 21 22 25 17 19 20 18
SINEC L1 Protocol
Interface to UWR
GND
X300
8 B5 [X303]
9-pol. SUB-D
U001 Interface to RTR

B2 [X1] B3 [X11]
A1
MRO
P24
+18V tos +30V/max.150mA
unregulated power supply
(+AC1C)
SIMOREG 6RA22
Stop safety
function
Fast stop
function
X200
Control release
Interface board
B4 [X203]
Relay K2 K1 F454
X003
A2 Ready for
C95A 6428 39 - 02.10.2006

main switch ON Temperature 64
8
(+AC1D)
P24
X1
1 3
X1 4 6 7 8 X1 1 3 6 7
7

6
6 5 X3
Q014 1 3 5 13
5
K050
14
X37 3 X11 8 X11 5 X5 2 X3 14 16 15 11
Tacho signal from motor
17
+A*-A345 (SPS) 15000D/h = 3000 1/min. =180VDC
18
2 4 6
X4
X11 9 X11 10 X11 12 X8 20 X8 12 13 16 15 14 9
+A*-A345
(SPS)
20 12 13 16 15 14 9
X4 15 X4 14
-A354/02
X6 15 14
-XB3.A354
(safety board)
1 Input
1 3 5 K2
2 -A354/03
-K252 Byte.Bit 3.3 2.3 2.4 2.7 2.6 2.5 2.0
1
Temperature monitoring
X8
2 4 6 K1
+A*-A343 (UWR)
3
2
A1 A2 A2
K050 -K050 => Contactor: current converter, main drive K252 K022
Feedback cont.
brake release
Brake release
manually
Feedback:
main contactor
Current
converter
Main drive:
warning
125°C
switch-off
140°C
Limit switch:
brake, main drive
A2 -K252 => Aux. contactor for -K050 (main cont.) A1 A1


-K022 => Contactor: break release 0V 0V
Main drive
Keypad and display operation
The display of the Siemens Simoreg 6RA22

current converter consists of a 3-digit 7-segment
display (H1-H3). The selection keys “higher“
(S2) and “lower“ (S3), symbolised by up- and
down-arrows, are to the left of the 7-segment
display. Left of those is the selection key (S1).
Fig.: Display Simoreg
Selection key Significance of potentiometers R1-R4

i • Switching among parameter numbers,
parameter values and index number • R1 rough adjustment (tacho)
• Acceleration of a setting process that was • R2 fine adjustment (tacho)
initiated by the higher or lower key. • R3 n-actual (!! May not be changed !!)
• Acknowledgement of an error message. • R4 I-actual (!! May not be changed!!)
Higher or Lower key

• Selection of a different parameter number.
• Selection of a different parameter value.
• Selection of a different index number.
• Stop of a selected function via parameter
P051.

Main drive
Adjustment of the field current load resistors
The current converter load must be set so that the motor field current value (IFN) is greater than 50%
of the current converter field current value (IFN) !
load resistors P076

Original to be removed I FN
Motor × 100%
current converter I GFN
PN [kW] IAN [A] IFN [A] IAN [A] IFN [A] [%]
90 3,3 R52
200 5 R52
250 5 R52
400 10 R52
The load resistances are located on board A2 as shown below:
Location of load resistances for devices from

30A to 250A:
Location of load resistances for devices from

400A to 600A:

Main drive
Parameter setting
The SIMOREG 6RA22 current converter must
Personal
be loaded with machine-specific parameters. Computer
The following tools are necessary:
•
9pol 1:1-cable RS232/485
PARAFIN, installed on a notebook and converter
• adjustment hardware (converter/lines).

9pol 1:1-cable
B2 B3 interface module
Siemens 6RA22
See that only the valid set of parameters

i is loaded !!
[currently on a diskette]
First, however, save the “old“ parameter set, if
available [Upload]!
Not only does the electrical connection with the
converter have to be right, but also the setting
of the communication parameters and the
adjustment of the interface components.
Below see the relevant communication
parameters of the 6RA22:
Since only few parameters differ from the originally loaded values it is possible to make changes
i by hand (see also Checklist, Point 5, i Part Diagnosis, Error search)
Parameter number Parameter value Description

P051 --20 Release setting
P097 019 Serial interface mode of operation
Caution!
! It is absolutely necessary to observe the correct
sequence of parameters
Both of the employed interface components MAN-Roland (communication computer Siemens main
drive A0734) and Z1011 (Siemens original) contain further coding switches that define different
interface parameters.
The interface components must have the following settings.
MAN-Roland Z1011(Siemens)
S1 to 0 SW1 (mode) 1-1;2-0;3-0;4-1;5-0;6-1;7-0;8-0 (DIP-switch)
S2 to 0 S1 to 3 / S4 to 9 (SINEC+No)
S3 to 0 S2,S3 both to 0 (Dust+No)

Main drive
Speed alignment
• Set the DIP switch, in the real-time
computer on the memory extension board in
slot 9, to position 5
The speed is displayed in the position
displaying the 100s (top display) and in the
position displaying 10s (bottom display) of the
7-segment display.
The actual value displayed on the Leitstand 0
EF 12
D 3
and on the trend display (+BA3A) on DW 1 are C 4
B 5
rounded of to 100 s/h. A
9 87
6
• R1 adjustment:
! Pointer of the potentiometer to position ”half-
past-three“
adjust R1 only during machine standstill
• Start press in idles speed of 3000 [s/h]. ‘Idle rev speed’ is set on the LEITSTAND in
menu ”DR Machine – Rev speeds“
(nominal rev speed)
• R2 fine adjustment:
Compare actual rev speed on the trend
display (+BA3A) with nominal rev speed Check adjustment at rev speeds of
(Leitstand).
( 8000 [s/h] & 13000 [s/h] ) and correct if
The exact actual rev speed is determined
necessary
on the RTR RAM board.(tens )
CAUTION:
Make adjustment of rev speed with R2 if
!! The values become smaller when turning
necessary
the pots clockwise. !!
If the adjustment range of R2 is insufficient,
stop machine and turn R1 clockwise and
repeat adjustment procedure.
RTR RAM board pos. 5 displays the hundreds Setting tolerance: max. +/- 20 s/h
i and tens range of the actual rev value
The following functions are DISABLED, if the basic rev speed is below or above 3000 s/h:
! • feeder coupling
• autom. production “ON“
“ON“

Main drive
Diagnosis, error search

Problem:
Machine does not run or
• Error message on Leitstand:
“SPS: MD: Brake does not release“
•
Check following voltages:
! 1. supply anchor (output)
2. field voltage CAUTION!
3. field current Field current is switched off if motor standstill
Check-list:
1. Unregulated voltage between terminals 16
and 21 to +AC1C available (ca. 25V)?
2. When P00=8: ca. 25V between terminals

19 and 21 available? (see Point 4)
3. Voltage between terminals 17 and 21 Alternative to measuring

(between 15....30V) available P15
Anzeige der Zustände der diditalen Ein- und Ausgänge
17 18
! RTR activates terminal 17 only just before

machine start up!
19 20 K1 K2
4. Operation statuses (P00) (operation statuses 01 to 04 are checked before every machine start up!)
08: not ready for operation, i.e. terminal 19 =“0“ (EMERGENCY OFF is activated)
07: ready for operation, i.e. terminal 19 = ”1“ (no EMERGENCY OFF is activated)
06: not used
05: not used
04: Field current supply not o.k.(F14); P76 o.k.?, R52 removed to +AC1D ?
03: Current supply 1U-1V-1W (right rotating field) not o.k. (F04)?
02: Mains conditions
-Mains frequency outside 45...65Hz(F03)
-Mains current out of tolerance of +/- 20%
-with weak mains: P51=99 and L33=xx1 or xx2 or xx3 set,
to minimise net problems;
L33=022 is a recommendation for the
operation of diesel generators!
01: No regulator release?
-Voltage between terminals 18 and 21 o.k.?
-Check micro switch–S804 ’brake release’
-Hardware K1 on +AC1D for activation
-Contactor –K022 check ’brake release’
5. Checking the SIMOREG parameters (according to list 039C696938) or reading values from
diskette ‘Main drive parameters’, file ‘7xx.LST’ (general list of parameters) or file ‘7xx.ADI’ (List
of parameter differences).
! P51 = 20 must be set to change parameters.

Main drive
4.6 Baumüller BKF 12

Connections overview
X8 X9 X602 X601
1. Pin description on next page

2. Firmware-Prom interface board
3. Firmware-Prom drive
4. Display with keypad
5. Connecting terminals control system

Main drive
• Operation display on the interface board

H101 yellow no own telegram received for more than 1s
H102 red no telegram on bus for more than 5s
H103 green communication with current converter (basic board of the
device) o.k.
German English
Geräteoberseite Top side of device
Transformator Transformer
Zwischenblech Intermediate plate
Rechnerkarte CPU board
Schnittstellenkarte Interface board
Kunsstoffabdeckung Plastic cover
Stecker für Imkrementalgeber-Anschluß Incremental encoder connection
Stecker für RS485-Anschluß RS485 connection

Main drive
• Operation display on the adapter board (3.9329 A)

H101 green Regulator release (X1/A1:18)
H102 green Stop-Safe binary input (X1/A1:17)
German English
Kunststoffabdeckung Plastic cover
Adapterplatine (SIEMENS 6RA22 kompatibel) Adapter board (SIEMENS 6RA22 compatible)
Rechnerkarte CPU board
Zwischenblech Intermediate plate
Anschlüsse für Feld- und Elektronikversorgung circuit points for field and electronic supply
Feldgerät field device
Anschlüsse für Lüfter
Stecker für Imkrementalgeber-Anschluß Incremental encoder connection
Stecker für RS485-Anschluß RS485 connection

[RTR]
6 5 6 +A*-A566 Power Output -24V -24V -24V -24V

5
(UWR Relay)

K3 K2 5
K4 6
K5 5 -A352/13 [SPS-Anl.]
6

Byte.Bit 0.7
X1 3 X1 6 X1 5 X1 4 X1 9 X1 8 X1 7 X1 10
X8 6 X8 5 X8 4 X8 9 X8 8 X8 7 X8 10 X82 3 1 X82 8
8
13 -S804
7 7 -S010
K1 K2 +A*-A343 L R -F452 -F453 Micro
Stop +BA T> T>
E- (UWR) switch
8 safety 8
-XB15.A352
Stop
R700 from S721
14 M000 mech.
brake
X6 18 X6 17 X6 16 X6 21 X6 20 X6 19 X6 22 X82 4 2 X82 9
X4 16 X4 21 X4 20 X4 19 X4 22 X28 8
44
+A*-A345 +A*-A344
(SPS) (Machine control) K050
X37 4 X11 3 X11 4 X11 2 X11 1 X33 8
43
X2 1 X2 3 R702
DELETED IN
1 R703
CASE OF
3 3 R702+L
-24V
K1 K2 R702
2 2 +A*-A454 2 1
(Add. distributor BD) ONLY R703
brake
release
2
Contactor
Contactor
X2 2 X2 4
main drive
R702+L
400VAC Power Output
-A354/14 [SPS-Allg.]
Byte.Bit 19.2 19.3
L1 L3
3 4
16 17 19 X1 20 Adapter board A386 18 X1
-XB16.A354
X1 20 21 22 25 9 24 18
RS485
Interface to UWR
X601
GND
with USS-Protocol
9-pol. SUB-D
C 95A 6428 39 - 02.10.2006

Interface to RTR
X602
Control
release
G000
X15
X15
+24V/100mA
not stabilised
-24V Incremental encoder
3.9493
X9
Fast stop
function
BKF 12 signal to UWR
Stop safty function

Relay K1 K3 F454 64 X8 and X9
Interface board
connected electrically in parallel

main contactor ON Ready for Temperature
15-pol. SUB-D
Overview of the different main drive controls
operation
X8
monitoring
X1 4 6 X1 39 41 X1 31 32
-Q014 1 3 5
X1/A2
1 3
6 5 X3 Incremental encoder
13
signal from motor
K050
14
2 4 6 X37 3 X11 8 X11 5 X5 2 X3 14 16 15 11
17
-T005 0 400
+A*-A345 (SPS)
18
X4
0 24 X11 9 X11 10 X11 12 X8 20 12 13 16 15 14 9
+A*-A345
(SPS)
20 12 13 16 15 14 9
X4 15 X4 14
-A354/02
X6 15 14
-XB3.A354
(Safety board)
1
1 3 5
Input
K2
2 -A354/03
-K252 Byte.Bit 3.3 2.3 2.4 2.7 2.6 2.5 2.0
1
Temperature monitoring
X8
2 4 6 K1
+A*-A343 (UWR)
3
2
A1 A2 A2
Main drive
K050 K252 K022

Feedback contactor
brake release
Brake release
manually
Feedback:
main contactor
Current inverter
Main drive:
warning
125°C
switch-off
140°C
Limit switch:
brake, main drive
A2 -K050 => Contactor: current converter, main drive A1 A1

0V 0V
-K252 => Aux. contactor for -K050 (main contactor)
4
-K022 => Contactor: break release
4-23
4
4-24
-24V
Main drive

[RTR]
+A*-A566 (UWR Relais)
6 5 6 +A*-A566 Power Output -24V -24V -24V -24V
5
K2 K4 K5 (UWR Relay)
K3 5 6 5 -A352/13 [SPS-Anl.]
6 4
Byte.Bit 0.7
X1 3 X1 6 X1 5 X1 4 X1 9 X1 8 X1 7 X1 10
X8 6 X8 5 3 X8 9 X8 8 X8 7 X8 10 X82 8 X82 3 1
X8 4
8
44
13
7 7 -S010
K1 K2 -S804 -F452 -F453 L R R702
+A*-A343 T> T> K050 +BA DELETED IN
fast stop micro R703
8 (UWR) 1 CASE OF
8 switch
-XB15.A352
stop safety 43 R702+L
R700 from S737
M000 14
brake
X6 16
R702
X6 18 X6 17 X6 21 X6 20 X6 19 X6 22 X82 9 X82 4 2
2 ONLY R703
X89 6 X89 16 X89 14 X89 12 X89 18 X28 8 X82 21
R702+L
9
+A*-A345 +A*-A344 +A*-A345
(SPS) 3 (M/C control) (SPS)
X8
X90 7 X86 1 X80 19 X35 1 X35 3 X33 8 X87 1
24VAC X2 1 X2 3
X7 1
6 6 +A*-A375
-24V 1
K1 K2 +A*-A454 (Mounting plate) up to series 738
Reserve]
5 5 2
3
[from S739:
(Add. distributor BD)
contactor
X2 2 X2 4
brake release
contactor main drive
X35 2 X35 4 X15 2 from series 739
from series 739

Solenoid valve Y244
suction air, quick
airation
Power Output 4
-A354/14 [SPS-Allg.] +A*-A345
Byte.Bit 19.2 19.3 (SPS)
X86 6 X86 4 X87 2
3 4
16 17 19 X1/A2 20 Adapter board 3.9320 18 X1/A2
-XB16.A354
X1 20 21 22 25 9 24 23
RS485
Interface to UWR
X601
GND
withUSS-Protocol
9-pol. SUB-D
Interface to RTR
X602
controller
enable
G000
X15
X15
+24V/100mA
not stabilised
-24V Incremental encoder
3.9493
X9
BKF 12
Stop safety
Fast stop
F454 signal to UWR
Relais K1 K3 64 X8 und X9
Interface board
are parallel connected
C95A 6428 39 - 02.10.2006

main contactor ready for temperature
15-pol. SUB-D
X8
ON
X2 5 4 3 X1 39 41 X1 31 32
X1/A2
4 6 1 3
6 5 X3 Incremental encoder
Q014 1 3 5 13
signal from motor
K050 X87 15 X86 16 X92 15 X86 3 X72 3 X72 2 X87 5 X70 2
14
X92 11 9 X92 7
+A*-A345 (SPS)
8 X90 5
2 4 6
X89 10
X80 23 X4 8 X4 6 5 4 X8 13 12
X86 9 X86 11
+A*-A345
(SPS)
8 6 5 4 13 12 9
X89 4 X89 2
-A354/02
X6 15 14
-XB3.A354
-XB10.A354
(Safety board)
1
1 3 5
Input Input
K2
2 -A354/08 -A354/03
-K252 Byte.Bit 13.7 13.5 13.4 13.3 2.4 2.3 2.0
1
X8
temperature monitoring
2 4 6 K1
+A*-A343 (UWR)
3
2
A1 A2 A2
K050 K252 K022
feedback contactor
brake release
current rectifier
main motor:
warning
125°C
shut off
140°C
feedback
main contactor
brake release
by hand
micro switch brake
A2 -K050 => main contactor A1 A1

-K252 => auxiliary contactor for -K050 0V 0V Antriebssteuerung R700_S737.VSD

-K022 => contactor release brake
Main drive
Operation of the keypad and Display

The display of the Baumüller BKF12 current
converter consists of a 4-digit 7-segment display
and eight status LEDs.
Significance of the operation and error

display
H15(rd) overload point
H16(rd) current limit
H17(ye) moment direction 2
H18(gn) moment direction 1
H19(ye) speed n=0(P078)
H20(gn) regulation release
H21(rd) regulation lock
H22(rd) error or message
(display of P159 display)
Three selection keys under the 7-segment
display:
• Mode
• higher lower
To activate keyboard/display press selection

keys “higher“ or “lower“ for ca. 1 sec.
Parameter setting
Preparation:
The parameters are set via MRO software “PARAFIN V.2.41“
On this Baumüller drive communication takes place via the service interface on the front board
which is designed as a normal RS232 interface. It is connected by a simple 9-pol 1:1 cable and
Adapter3 from 9-pol to 25 Pol Dsub.
Baumüller
BKF12
P123
Personal adapter 3
Computer
RS232
9pol 1:1-cable
Connect the PC with the converter and start the 9pol DSUB 25pol DSUB
socket plug
! software. Please observe point 2.4) Using
PARAFIN with Windows 3.1x/9x/NT 4.0 in the 1 8
PARAFIN documentation. 2 3
3 2
4 20
5 7
6 6
7 4
8 5
9 22
1:1-cable BKF12
Connections of the adapter for the BKF12
(Adapter 3)

Main drive
1. Version Check
see instructions “Parafin V2.41“
2. Release of the service interface CAUTION!

Set P104 to 17hex (keyboard release) This release must take place for each download
Set P001 to *.1, and upload.
(see manual BKF12)
3. UPLOAD This is so for safety reasons. The old set of

i Always first complete upload and then save
data.
parameters is still available.
(possibly for comparison / for MRO)
(see instructions Parafin)
4. Parameter download CAUTION!

(Security download) The uploaded parameters are compared with the
Conducting a downloads is described in original ones during the security download.
detail in PARAFIN Operation Manual which
is attached to each PARAFIN program. Use
parameter set attached to the machine main
drive.
5. Locking the service interface CAUTION!

! The communication source must be set
back to >*.3< (P001) after the transmission
This operation may not be forgotten. Otherwise
the converter cannot be used in the machine!
of the parameters, so as to enable again
control via the interface board. To do so
proceed as described above (see point 2).
6. Switch off machine

(with main switch)
- wait ca. 30s
- switch on again.
- compare parameters

Main drive
Speed adjustment
• The real-time computer contains a DIP
switch on the memory extension board in
slot 9. The DIP switch is to be set to position
5.
Now the hundreds appear (top display)
and the tens (bottom display) indicating the rev
speed in the 7-segment display.
The actual value display on the Leitstand 0
EF 12
D 3
and on the trend display (+BA3A) on DW 1 C 4
B 5
are rounded off to 100 s/h. A
9 87
6
• Start the machine at an idle speed of 3000 ‘Idle speed’ setting takes place on the
LEITSTAND in menu
[s/h].
”DR Machine – speed“
•
i •
Set key parameter 104 to value 17 (keyboard
release)
Compare actual rev speed on the trend
display (+BA3A) with nominal rev speed Compare and if necessary correct the following
(Leitstand). speeds: ( 8000 [s/h] and 13000 [s/h] ).
The exact actual rev speed is determined on Max. deviation of actual rev speed (RTR):
the RTR RAM board.(tens) ±20 s/h at the given rev speeds.
• Maximum value for P142:
! P142 = 3150
• If a higher value is determined, check
mechanical drive (e.g. belt tension).
• Set P001 communication source
(can be changed by keyboard only )
to`*.1` (Service PC).
• Use PARAFIN to load the determined value
in to the current converter.
To do so use PARAFIN to load the
appropriate parameter set and call submenu
Speed Alignment in menu General. Enter
the determined parameter value in all four
data sets! Use Download to load the
parameters in to the current converter.
• Set key parameter 104 to 17 (keyboard release)
• Set P001 communication source
(can be changed by keyboard only)
to `*.3`. (control via interface board )
After completing all the above activities, switch off machine (shut off the system) and boot it again
! after a waiting period of about 30 sec..
(see also: Protecting Parameters against Overwriting)

Main drive
Diagnosis, error search
Allocation of the parameter sets

• The parameter sets are valid only for the indicated motor-current converter combination since
they contain motor type and current converter specific data.
(nameplate drive / motor or techn. documentation)
• Accidental use of data set that does not belong to the motor-current converter combination can
! lead to damage or the destruction the motor.
• It is not allowed to use a different parameter set than that specified for the given motor type and
current converter!
• For motor and current converter data see cover sheet of the document Application of the
Parameter Set or the head of the parameter list [(*.TXT, ASCII text file) or menu:
GENERAL - EDIT HEAD (V1.10: GENERAL – EDIT HEAD) of the PARAFIN program] executed.
Checking the parameter set
1. Use main (Ax) switch to switch on machine
2. Press Stop-Halt-Safe key on the machine
and SAVE.
3. If the 7-segment display on the current
converter is dark: press key '↓' for 1s . When
released the display is active.
4. Select and check parameter P129. The
following bits of the 7-segment display must P129 loaded / programmed data set
glow (when the machine is at standstill).
5. If this is not the case use parameter set
attached to the press to program the current data set programmed: DS1 DS2 DS3 DS4
converter
(see Chapter 11 Diagnosis / PARAFIN)
6. Checking the different parameters:
To check the settings of the different
parameters by hand interrogate current
converter (e.g.: data set 1 [during operation Data set active: DS0 DS1 DS2 DS3 DS4
(loaded)
or standstill P020, P024, P025) and compare
with PARAFIN parameter list *.TXT (e.g.
P010, DS 1: No.: 10.0).
7. If this is not the case use parameter set
attached to the press to program the current
converter
(see Chap. 11 Diagnosis / PARAFIN)
Display of all regulation parameters
P106 Display of all regulation parameters (inputs) P107 Display of all relay functions
Controller enable X1:23 Fast stop X1:24 K1 (Controller ready) K3: release brake
Main contactor ON X1:22 Impuse release X1:25
Main contactor ON K4: temp. monitoring
Terminals X1/A2: 4, 6
Interface
Main contactor ON
Controller enable Fast stop X1:24

Main drive
4.7 Instructions to putting into operation
i Control functions of the current converter

Note: You will need the following to check the control functions of the current converter:
• An assistant to activate the machine run commands
• Voltmeter
• Two-pole voltage tester
• Clamp-on ammeter DC
• Measurement lines with two testing points (2 sets) and pick-up terminal (one)
Checking the power connection
! Activate the run command so that the main contactor pulls and so that there is voltage on 1U, 1V,
1W.
1. Check voltages on the connections (1U, 1V, 1W, 2U, 2W, 3U, 3W).
2. Check rotating field on the anchor terminals: right rotating field
3. Check phase allocation:
Phase equality between 1U, 2U, 3U or between 1W, 2W; 3W must be available. There may be
no voltage between the connections when the phases are equal. Check using a voltage tester
(not high resistance measuring device) to avoid measuring errors. Voltage between 1U, 2U, 3U =
0V; 1W, 2W, 3W = 0V.
Checking the firmware and jumper connections
1. Checking basic devices of the software version:
The EPROM of the basic device board of the current converter must have the software version
i indicated in the commissioning instructions from Baumüller. It is also possible to interrogate the
display of the current converter via parameter P003 or by PARAFIN in menu COMMUNICATION
– CHECK VERSION (V1.10: KOMMUNIKATION - VERSIONSAB-FRAGE).
2. Checking the interface boards of the software version:
The EPROM of the interface board (3.9493) must have the software version indicated in the
commissioning instructions from Baumüller.
3. Checking the plugged jumper connections on the board of the basic device and on the interface
board:
For configuration please see Baumüller commissioning instructions.
Function check
The points listed below are included in the function check. The points are then described in detail.
Correct motor/current converter combination installed?
Current converter loaded with parameters fitting to the machine?
Rev speed adjustment made?
Belt tension correctly adjusted?
Plugged jumpers and DIP switches on basic device board and interface board o.k.?
'Emergency off function’ o.k.?
'Stop-Safe’ function' o.k.?
Run command procedure o.k.?
RTR communication with main drive o.k.?
Communication source P001 correct (P001=3.3)?
Voltage supply for control terminals (adapter board) o.k.?
Pulse release available?
Brake activation (R700, R702/R702L/R703, R300)
'Regulator release terminal’ function o.k.?
Nominal value setting (P050) o.k.?
Error message: Blocking protection responded?
Error message: Drive not rotating while brake released?
Error message: Wrong rev speed when jogging at reduced speed?
Notes:
Main drive
4.8 Main motor

Shunt-wound electric motors made by the
Bamüller company are used on MRO presses.
Characteristic features of DC shunt-wound

electric motor:
• Voltage is proportional to rev speed

• Current is proportional to torque
• Revolutions can be regulated to 0 min-1
• A load can be held when the holding brake is
open.(four Q-drive)
• Four-quadrant operation with brakes as
generators is possible
German English
Section of a DC motor
Fremdlüfter ventilator
Stator stator
Rotor rotor
Kommutator commutator
Kohlebürsten carbon brushes
The main field of a DC machine is generated by
i the field coils.
See that the shunt-wound field coil connection lines are not disconnected when under voltage.
! The field current is measured indirectly (current display).
Inspection and maintenance

• Brush holder setting and the position of the
marks always on the collector side
• Carbon brushes, rest length
• Commutator running surface See maintenance instructions of the motor
• Carbon brush change and trimming of the manufacturer
carbon brushes
Trimming the carbon brushes
If the rotor of a machine turns roughly it is
necessary to trim the brushes of each bolt by
holding in the hand emery cloth and moving it
backwards and forwards under the brushes.

Main drive
4.9 Brake main motor

Putting into operation and maintenance instructions for swing-pressure disk brake,
type SB 50 ,SB 100 ,SB 200 (see under TA EMO 00004 & 00005 by co. Baumüller)
from series 739: SB360 replaced type DSB320/SB200 (see under TA BMK 00016 made by co. Baumüller)
1. Design and function ( see Fig. 1 )
• The pot-shaped magnet ( Pos.1 ) with casted magnet coil is rigidly connected by two bolts (Pos.
9) with the flank ( Pos.2 )
• When braking, the anchor disk (Pos.3) is pressed by several pressure springs ( Pos.4 )
against the brake disk ( Pos.5 ) and the flank ( Pos.2 ).
• The brake disk ( Pos.5 ) is connected with the shaft via a follower ( Pos.6 ) .
• When releasing the brake, the excited pot-shaped magnet ( Pos.l ) pulls the anchor disk ( Pos.3 )
against the spring force of the pressure springs ( Pos.4 ). The brake disk can thus move freely
and the braking effect is cancelled.
2. Assembly
• The spring pressure brakes are mounted as an independent system directly to the machine parts
( e.g. electro-motors ).
• Mounting: Insert the adjusting spring ( Pos.7 ) into the shaft, slide the follower ( Pos.6 ) on to the
slightly greased shaft and secure it against axial shift by a safety ring ( Pos.8 ).
• Mount the complete disk brake on to the follower ( Pos.6 ) and that on to the centring wheel of
the given machine part and secure with six bolts ( Pos.11 ).
• Tacho-generators or pulse generators, etc., can be mounted to these brakes via an extended
shaft and intermediate flank.( see also Fig.: 3 to 5 )

Main drive
List of parts:
Pos. 1. Complete pot-shaped magnet
Pos. 2. Flank
Pos. 3. Anchor disk
Pos. 4. Pressure spring
Pos. 5. Brake disk
Pos. 6. Follower
Pos. 7. Adjustment spring
Pos. 8. Safety ring
Pos. 10. Terminal box
Pos. 11. Setting screw
Pos. 15. Terminal bar
Pos. 16. Insulation plate
Pos. 17. Sealing
Pos. 18. Hand ventilation bolt with middle position spring
Pos. 19. O-Ring
Pos. 20. Manual air lever
Pos. 21. Micro-switch
Pos. 22. Pressure spring for micro-switch
Pos. 23. Closing cap
Pos. 24. Thread
Pos. 25. Damping bolt

Main drive

Main drive
3. Connection and putting into operation
!! SAFETY NOTE !!
Caution! The braking effect is cancelled when the voltage is connected to the brake!
• Compare the available voltage with the data on the rating plate.
Remove terminal box ( Pos.10 ) and connect brake according to the circuit diagram cast onto the
bottom of the terminal box.
• The brake must be earthed in the terminal box, if it is to be connected to a machine part that is
not yet earthed.
(Earthing bolt M4x10 DIN 84 –galvanised + safety washer S4Zn)
• Before putting the machine into operation and when the brake is ventilated (electrically and
mechanically) check, if the brake disk moves freely when the rotor is rotating.
4. Rating plate

Main drive
Maintenance
!! SAFETY NOTE !!
Caution!
Before starting the maintenance work move system to zero position so that the brake is not
under load.
Disconnect machine completely from the mains.
The effect of the brake is cancelled when voltage is connected to the brake as well as during
its disassembly.
Air gap determination (see Fig. 1 & 3)

• Dismantle brake from machine part (motor)
• Place assembled brake on to pot-shaped magnet (Pos.1), (Caution! Secure setting screw of
the micro-switch against braking off) so that the flange side faces up.
• Earth the brake using the earthing bolt in the terminal box.
• Connect brake electrically and ventilate.
• (Anchor disk releases the brake disk) The air gap is measured by a slip gauge inserted
between the friction surface of the flank and the brake disk.
• The table below indicates the matching rated moment, rated air gap and the max. allowed
operation air gap of the different brake design sizes.
Brake design size SB50 SB100 SB200 SB360
Rated moment [Nm] 50 ≤ 33 100 ≤ 66 200 ≤ 140 320 ≤ 250
Rated air gap [Nm] 0.35 0.35 0.4 0.4 0.4 0.4 0.35 0.35
max. allowed
operation air gap 0.75 1.1 0.85 1.4 0.75 1.1 0.8 1.1
[mm]

Main drive
Checking or setting the micro-switch (s. Fig. 2)
!! SAFETY NOTE !!
Caution! The braking effect is cancelled when the voltage is connected to the brake!
• Connect continuous testing device to the micro-switch terminals

• Release locking nut (Pos.13)
• Loosen setting screw (Pos.12) by 2-3 revolutions
• Ventilate brake electrically and leave it ventilated.
• Turn setting screw (Pos.12) by exactly 60° (±10°) = 1/6 revolution and lock in this position by the
locking nut (Pos.13) lightly (=2Nm).
• Secure locking nut by safety varnish in the position (Pos.14) indicated in Fig 2.
• Testing: if the micro-switch is activated during electrical and mechanical ventilation.

Main drive
4.10 Signal Sensor Main Motor

Series overview of the signal sensor main motor
R700
Angle sensor from series 721
1024 steps
Type Stegmann or
Heidenhain
0 37U 4065 44 X
rev sensor to series 720

GHT-612/46
0 37M 3926 44 X
Tacho-generator / rev sensor

Technical specifications:
BAUMUELLER GHT 612/46
Fuse type: IP 44;
Insulation category: B
Construction form: B 14;
60 V / 1000 min-1
Voltage fluctuation: -0 +10%
I = max. 10 mA;
N = max. 4000 min-1
With integrated socket type: MKE 300
All important information regarding maintenance and putting into operation is included in the
instruction manual for the maintenance and putting into operation of tacho-generators type GHTS
and GHT
Additional notes:
• Tacho-runout, CAUTION!
The tacho- and collector shaft (glued) must Greater tacho-runout, differences can be
have a true rotation of <0.02mm. The corrected at co. Baumüller.
oscillation of the tacho-signal would
otherwise be too high and the signal useless
for rev speed regulation -> drive vibrates
(increased wear of carbon brushes)
• Imbalance / Vibrations: here to excessive
values cause a useless tacho-signal. -> drive
vibrates
• Bad ambient conditions, observe fuse type

Main drive
Incremental sensor / Angle sensor

Techn. specifications:
DG 60L XSR
MADE BY.: STEGMANN
Item no.: 5W4XC2F00F00
Max. output frequency:

–RS 422 300(600 at > 5000 lines)kHz
Max. operation speed:

with shaft washer 6,000 min-1
Operation voltage range

at – RS 422 4…6V
Working temperature range: 0 … +85 °C
Operation temperature range: -20 … +85 °C Operation current without load
at 5 V 120 mA
DG 60L C10
MADE BY.: STEGMANN
as DG 60L XSR 1024 I
but housing treated (blue)
no shaft washer !!
Max. operation speed:

without shaft washer 10,000 min-1
ROD 426.0010 ( RADIAL )

MADE BY: HEIDENHAIN
Max. scanning frequency: max. 300 kHz
Mechan. permitted rev: max. 12000 min-1
Max. working temperature: 100 °C

Min. working temperature:
Permanent flank socket or cable: -40 °C
Movable cable: -10 °C
Voltage supply: 5 V ± 10 %
Max. current consumption (without load) 150 mA


E7E04 MainDrive 01

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E7E04 MainDrive 01

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Main drive

Product Training Electronics – ROLAND 700 4

© MAN Roland Druckmaschinen AG C 95A 6428 39 - 02.10.2006 4-1

4-2 C95A 6428 39 - 02.10.2006 © MAN Roland Druckmaschinen AG

4.1 Overview current converter

Hardware safety circuit

y Feldregler y Drehzahlregelung y Ankerspannung

© MAN Roland Druckmaschinen AG C 95A 6428 39 - 02.10.2006 4-3

4.2 Main drive control concept

Hardware-Sicherkreis -safety circuit

4-4 C95A 6428 39 - 02.10.2006 © MAN Roland Druckmaschinen AG

Operation in all four quadrants,

In braking operation the converter works as an inverse rectifier.

© MAN Roland Druckmaschinen AG C 95A 6428 39 - 02.10.2006 4-5

4.3 Overview of series with 4Q drives

4-6 C95A 6428 39 - 02.10.2006 © MAN Roland Druckmaschinen AG

4.4 Activation of the main drive R700

) Pres run command key

) Press run command key for the second time

0 When Stop-Safe key is pressed, UWR opens a time window (400ms);

© MAN Roland Druckmaschinen AG C 95A 6428 39 - 02.10.2006 4-7

-24V -24V -K1 => Relay contact hardware loop,

Power Output -K2 => Relay contact hardware loop,

-K021 => Contactor: main drive brake

16 17 19 Adapter board A386 20 18 X1

U001 Interafce to RTR

C95A 6428 39 - 02.10.2006

1 3 5 K050 Tacho signal from motor

- for certified service technicians only -

Power Output -K2 => Relay contact hardware loop,

© MAN Roland Druckmaschinen AG

- for certified service technicians only -

-K021 => Contactor: main drive brake

16 17 19 X1 20 Adapter board A386 18 X1

C 95A 6428 39 - 02.10.2006

BKF 12 X8 and X9 signal

Stop safety function

Antriebsteuerung BAUMUELLER BKF12.VSD

4-10 C95A 6428 39 - 02.10.2006 © MAN Roland Druckmaschinen AG

Significance of the jumpers Significance of the rotating switches S1-S4

Significance of the LED D2 – LED D5 DIP switch position SW1

© MAN Roland Druckmaschinen AG C 95A 6428 39 - 02.10.2006 4-11

Interface board on R700 SIMORG current converter from series 716

Jumper J1 in position ”on“ Significance of the rotating switches S1-S3

• S1(data transfer speed): =0

LED D1: Voltage supply (+5V)

LED D3 and LED D4 display the following during data transfer:

4-12 C95A 6428 39 - 02.10.2006 © MAN Roland Druckmaschinen AG

© MAN Roland Druckmaschinen AG

- for certified service technicians only -

C 95A 6428 39 - 02.10.2006

U001 Interface to RTR

(+AC1D) operation Monitoring

Tacho signal to UWR B5

A2 -K252 => Aux. contactor for -K050 (main cont.) A1 A1

Current limit selection

U001 Interface to RTR

C95A 6428 39 - 02.10.2006

Tacho signal to UWR B5

A2 -K252 => Aux. contactor for -K050 (main cont.) A1 A1

- for certified service technicians only -

Keypad and display operation

The display of the Siemens Simoreg 6RA22