Service Training Electronic Roland 300

Main drive
5

5 Main Drive ..........................................................................3

5.1 Main Drive Control Principle............................................................ 3
5.2 Overview – Current Converter......................................................... 5
Four-quadrant behavior ...................................................................... 6
5.3 Compendium of installed 4Q Drives ............................................... 7
5.4 Ansteuerung Hauptantrieb R300... Fehler! Textmarke nicht definiert.
5.5 Siemens 6 RA 22............................................................................. 11
Overview Connection ....................................................................... 12
Overview of the different main drive activation systems ................... 14
Parameter setting ............................................................................. 16
Parameter setting ............................................................................. 17
Speed allignment.............................................................................. 18
Diagnosis, error search .................................................................... 19
5.6 Baumüller BKF 12........................................................................... 21
Overview connection ........................................................................ 21
Overview of the different main drive activation systems ................... 23
Parameter setting ............................................................................. 24
Speed allignment.............................................................................. 26
Diagnosis, error search .................................................................... 27
5.7 Instructions for start-up ................................................................. 28
5.8 Main motor ...................................................................................... 29
Checking and maintenance .............................................................. 29
5.9 Brake Main Motor ........................................................................... 31
Maintenance ..................................................................................... 35
Air gap determination (see Fig.: 1 & 3) ............................................. 35
Checking and/or adjusting the microswitch (see Fig. 2) ................... 36
5.10 Signal Sensor Main Motor.............................................................. 37
Series overview of signal sensors main motor.................................. 37
Tacho generator / Speed transmitter ................................................ 37
Incremental encoder......................................................................... 38

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Main drive
5
5 Main Drive

5.1 Main Drive Control Principle

Safety guards
Run commands Emergency Stop
Stop-Halt-Safe

Hardware safety circuit

K1 / K2
SPS

UWR
Interface monitoroing

RTR

Angle
Interface

encoder

Interface board
Tacho
Rectifier

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Main drive
5

5.2 Overview – Current Converter

Grid-
connection

Power
supply Current converter

Field supply
Digital Controller Temperature monitoring
Nominal value
Speed feedback
Speed controller
Current feedback
Current controller Thyristor-
Start ramp
Controller enable
module
Impulse release
Phase rotation direction
Release Main contactor
Display functions

Tacho Motor

External wiring
MAN Roland

A fully regulated current converter (G000) is used to control the DC-main motor (M000). So as to
enable driving and braking in both torque directions a four-quadrant operation current converter is
used.

In the employed fully digitized current converters a processor is responsible for the control and
regulation.
The required rev value arrives in digital form via a serial interface from the real time computer.
The actual rev value is indicated as an analog / digital value by a tachometer generator /
incremental sensor.
The following operations may be performed via the integrated keyboard with display on the current
converter:
• change settings
• display operation statuses
• read out error memory

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5 Main drive

Four-quadrant behavior

Operation in all four quadrants,

driving and braking when changing speed and moment direction

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-
Rev-torque diagram

In braking operation the converter works in inverted rectifier mode (alternating-current converter)
The motor converts the remaining kinetic energy of the machine into electrical energy (generator
operation). The spent direct current is fed back into the grid as alternate current by the converter. Æ
electric regenerative braking!
The braking operation requires a connection to the mains. In case of a power cut and machine
standstill the mechanical halting brake is used.

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Main drive
5

5.3 Compendium of installed 4Q Drives

R300 R900
Baumüller - BKF12 from Series 320
rating DC 70/200/250A
input voltage.
3AC 400 (+15% / – 20%)
field supply
2AC 400 (+15% / – 20%)
frequency
45 to 65
Simoreg - 6RA22 to Series 319
rating DC 90/200/250A
input voltage.
3AC 400 (+15% / – 20%)
field supply
2AC 400 (+15% / – 20%)
frequency
45 to 65

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5 Main drive

5.4 R300 Main Drive Run release functions

 Relay contact -A343 -K2 has to be closed (Stop-secure-circuit)
 Relay contact -A343 -K1 has to be closed (Emergency-Stop-circuit)
 UWR- Relays on -A566-board (-K2, -K4, -K5) has to be closed
 RTR-Relay (-K2 on -A454-board) got to be closed
Î High signal at PIN 19

) Run-command pressed the first time:

 310 to 313: Auxiliary contactor –K252 activated via output -A354/14 Byte. Bit 19.3
Main contactor is activated
Machine run signal sounds
Feedback signal from the signal generator is sent to the Input -A354/3 Byte. Bit

 AS of 314: machine run signal

Feedback signal from the signal generator is sent to the Input -A354/3 Byte 1.0
Auxiliary contactor –K014 activated via Output -A354/14 Byte. Bit 19.3
Main contactor activated

) Run-command pressed for the second time:

 RTR-relay (-K1 on -A454-board) activated

Î High signal at PIN 17

 [BKF12] K1 / [K3] and K2 / [K1] on main drive activated; deactivated only when machine speed is „0“
 K2 [K1] (main drive) closes bypass via +Ax -A343 K1 and K2 (necessary for 4-quadrant-run)
 K1 / [K3] (main drive) closes the circuit to -K022
 UWR-Relay on -A566-board (-K3) is activated
 -K022 is activated
 With -K022 (contactor break release) micro switch -S804 is closed
 High-signal on PIN 18

 Release Main drive

 Input -A354/3 Byte 2.0 (break control) activated

0 While pressing a Stop-Secure-Button the UWR starts a counter (400ms);

if the machine speed doesn’t slow down during this period of time, all UWR contacts would
be opened.

0 Switch over of current limit -A352/13 Byte. Bit 0.7 ; „0“ during forward movement; „1“ during
reverse movement (only with main drive Siemens 6RA22 „Simoreg“)

0 Current limit: 150% of the nominal anchor current is allowed during accelerating;
100% during breaking

0 Temperature control on the main drive app. 80°C with a message on central consol monitor

8 C95A 6424 39 - 11. Feb. 2004

 -24V -24V -K1 => Relaiskontakt Hardwareschleife,
Stromgrenzenumschaltung
[RTR]
NOT-AUS, +Ax-A343
Power Output -K2 => Relaiskontakt Hardwareschleife,
-A352/13 [SPS-Anl.]
Stop-Halt-Sicher, +Ax-A343
Byte.Bit 0.7 RTR => Hardwarekontakte des RTR,
-S804 +Ax-A454
ÜWR => Hardwarekontakte des ÜWR,
Microschalter
mech. Bremse +Ax-A566
-K050 => Schütz: Stromrichter, Hauptantrieb
+A*-A343
K2 K1 (UWR)
-K252 => Hilfsschütz für -K050 (Hauptschütz)
Not
Bei R300 -K014
230VAC SHS
AUS K050

-K021 => Schütz: Bremse Hauptantrieb

Main drive

UWR UWR +A*-A566

-K022 => Schütz: Bremse lösen
K4 K5 (UWR Relais)

Schütz für
Schütz für
Hauptantrieb

Bremse lösen
Power Output -24V RTR RTR +A*-A454
-A354/14 [SPS-Allg.] K1 K2 (Zusatzverteiler BD)
Byte.Bit 19.2 19.3 RTR

X1 16 17 19 Adapterplatine A386 20 18 X1

RS485
X1 16 21 22 25 17 19 20 18

SINEC L1 Protokoll
Schnittstelle zu UWR

GND
X300
B5 [X303]
8
9-pol. SUB-D
U001 B2 [X1] B3 [X11] Schnittstelle zu RTR
Q014 1 3 5 A1
MRO

P24
+18V bis +30V/max.150mA
ungeregelte Spg.Versorg.
(+AC1C)
SIMOREG 6RA22

Stop-Halt-Sicher Funktion
Schnellhalt
Funktion
X200

Reglerfreigabe
B4 [X203]
Schnittstellenkarte
Relais K2
Hauptschütz ON A2 F454
64
K1 Temperaturüberw.
Betriebsbereit

3
(+AC1D)

P24
X1
1
X1 4 6 7 8 X1 1 3 6 7 Tachosignal zum UWR
2 4 6
B5
6 5 X3

1 3 5 K050
Tachosignal von Motor
-K252 15000D/h = 3000 1/min. =180VDC

2 4 6

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+A*-A566 K2
+A*-A566
(UWR Relais)
A1 (UWR Relais)

+A*-A343
-A354/02
(Sicherheitskarte)
K050 K2 K1 K3
A2 Input
-A354/03
Byte.Bit 3.3 2.7 2.0 2.4

A2 A2
K252 K022
Rückmeldung Schütz
Bremse lösen
Endschalter:
Bremse, Hauptantrieb
Rückmeldung:
Hauptschütz

Temp.überwachung
Stromrichter

A1 A1
Antriebsteuerung SIMOREG 6RA22.VSD / MRuef
0V 0V
Service Training Electronic

9
Roland 300
 -24V -24V

10
Stromgrenzenumschaltung
-K1 => Relaiskontakt Hardwareschleife,
[RTR] NOT-AUS, +Ax-A343
Power Output -K2 => Relaiskontakt Hardwareschleife,

5
R300: -A352/13 [SPS-Anl.] Stop-Halt-Sicher, +Ax-A343
Byte.Bit 0.7
230VAC bis Serie 329 RTR => Hardwarekontakte des RTR,
-S804 +Ax-A454
24VAC ab Serie 330
Microschalter
ÜWR => Hardwarekontakte des ÜWR,
R700: mech. Bremse +Ax-A566
400VAC bis Serie 736
+A*-A343 -K050 => Schütz: Stromrichter, Hauptantrieb
(mit Trafo -T005)
K2 K1 (UWR) -K252 => Hilfsschütz für -K050 (Hauptschütz)
24VAC ab Serie 737
SHS Not Bei R300 -K014
Service Training Electronic

AUS K050
-K021 => Schütz: Bremse Hauptantrieb
-K022 => Schütz: Bremse lösen
Main drive

UWR UWR +A*-A566

K4 K5 (UWR Relais)

Schütz für
Schütz für
Hauptantrieb

Bremse lösen
Power Output -24V RTR RTR +A*-A454
-A354/14 [SPS-Allg.] (Zusatzverteiler BD)
K1 K2
Roland 300

Byte.Bit 19.2 19.3 RTR

16 17 19 X1 20 Adapterplatine A386 18 X1
X1 20 21 22 25 9 24 18

RS485
Schnittstelle zu UWR

X601

GND
mit USS-Protokoll
9-pol. SUB-D
Schnittstelle zu RTR

+24V/100mA
nicht stabilisiert
X602
Q014 1 3 5 G000

X15
X15
Inkrementalgebersignal

3.9493
X9

Stop-Halt-Sicher Funktion
Schnellhalt
Funktion
Reglerfreigabe
BKF 12 an UWR
64 X8 und X9
Relais K1
sind elektrisch parallelgeschaltet

Zusatzbaugruppe
Hauptschütz ON
K3 F454 15-pol. SUB-D
X8

Betriebsbereit Temperaturüberw.
X1 4 6 X1 39 41 X1 31 32
2 4 6
X1/A2
1 3
6 5 Inkrementalgebersignal
von Motor
1 3 5 K050
-K252
2 4 6

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+A*-A566 K2
+A*-A566
(UWR Relais)
A1 (UWR Relais)

+A*-A343
-A354/02
(Sicherheitskarte)
K050 K2 K1 K3
A2 Input
-A354/03
Byte.Bit 3.3 2.7 2.0 2.4

A2 A2
K252 K022
Rückmeldung Schütz
Bremse lösen
Endschalter:
Bremse, Hauptantrieb
Rückmeldung:
Hauptschütz

Temp.überwachung
Stromrichter

A1 A1
Antriebsteuerung BAUMUELLER BKF12.VSD / MRuef
0V 0V
 Service Training Electronic Roland 300

Main drive
5
5.5 Siemens 6 RA 22

2 3

1. Firmware-Prom
2. Connecting terminals
3. Display with keypad
4. Potentiometer R1 - R4

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Overview Connection
Interface card Z1011 on R700 SIMORG current converter to Series 715

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

• W1: pin bridge “top“,
from HW9 (bus end resistor R15 off) • 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 SIMORG)
(CST = Chip select)
• TTY/RS232: no significance!
Significance of 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“:
glowing DPR is being processed
off no telegram on neither
interface, basic error of device
• LED D4(SINEC)“3“:
off no significance, since LED D3, D4, D5 blinking together:
interface RS232 not active
illegal switch position of S1/S4, S3/S2 and SW1
• LED D5(DUST)“4“:
on interface RTR receiving
valid telegrams
off no interface traffic
blinking reception error (fatal error)

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Main drive
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Interface card R700 SIMORG- current converter from Series 716

Jumper J1 in position ”on“ Significance of the rotation 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 –24Vconverted to +5V on interface
card (U1)

During data transfer LED D3 und LED D4 display the following:

D3 D4
! blinks 1x/sec.
OFF
OFF
blinks 4x/sec.
communication with SIMOREG is o.k.
communication with Leitstand is o.k.
blinks 4x/sec. OFF no data exchange with SIMOREG
OFF ON no or missing communication with Leitstand
During the start-up phase the interface CPU starts an internal selftest for RAM, DPR and
EPROM:
D3 D4
! ON
ON
OFF
blinks 4x/sec.
Reset
RAM error
blinks 4x/sec. ON DPR error
OFF ON EPROM error

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 14
5
-24V -24V -24V -24V
current limit selection
[RTR]
6 5 6 +A*-A566
5
K2 K4 K5 (UWR Relais) Power Output
K3 5 6 5
6

contactor
X82 3 1 X82 8

brake release
-A352/13 [SPS-Anl.] -XB14.A354 3
X1 3 X1 6 X1 5 X1 4 X1 9 X1 8 X1 7 X1 10 Byte.Bit 0.7
Output Power Output
-F452 -F453 -S804 -A354/10 [SPS-Allg.] -A354/11 [SPS-Allg.]
T> T> Byte.Bit 13.1 Byte.Bit 16.2
8
X8 6 X8 5 X8 4 X8 9 X8 8 X8 7 X8 10 microswitch
M000 brake
7 7
Service Training Electronic

K1 X82 4 2 X82 9
2 3
K2 +A*-A343
(UWR)

-XB15.A352
Emergency 8 SHS 8 44

-XB12.A354
-XB15.A354
stop
K050
Main drive

X6 18 X6 17 X6 16 X6 21 X6 20 X6 19 X6 22

X4 21 X4 20 X4 19 X4 22 43 X35 2
X4 16

+A*-A345 +A*-A345
(SPS) 0V
(SPS)
R300 from S317
X37 4 X11 3 X11 4 X11 2 X11 1 X31 2 X29 12

X2 1 X2 3
-X4.A375 13 12

Contactor
Contactor
main drive

brake release
+A*-A375
Roland 300

3 2 +A*-A454
230VAC Power Output -24V 12 14 mountingplate
K1 K2 distributor board
-A354/14
2 3 BD A2
Byte.Bit 19.2 19.3
K021 K021
X2 2 X2 4
11
4 A1
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 Protokoll
Interface to UWR

GND
X300
B5 [X303]
8

9-pol. SUB-D
U001 Interface to RTR

B2 [X1] B3 [X11]
A1

M RO

P24
+18V to +30V/max.150mA
nonstabilizedvoltage
(+AC1C)
SIMOREG 6RA22

normal stop
quick stop
X200

impulserelease
interface board
B4 [X203]
Relais K2
main contractor A2 K1 F454
on ready for temperature 64
operation monito
(+AC1D)

P24
X1
1 3
X1 4 6 7 8 X1 1 3 6 7
Tacho signal to UWR B5
6 5 X3
Q014 1 3 5 13

K050
14 Tacho signal from motor
X37 3 X11 8 X11 5 X5 2 X3 14 16 15 11
15000D/h = 3000 1/min. =180VDC

17
+A*-A345 (SPS)

18

C95A 6424 39 - 11. Feb. 2004

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
1 3 5 X4 15 X4 14

X6 15 14

-A354/02
-XB3.A354

(safety board)
-K014
1
2 4 6 Input
K2
2
-A354/03
-X300.A375 1 2
Overview of the different main drive activation systems

Byte.Bit 3.3 2.3 2.4 2.7 2.6 2.5 2.0

1
+A*-A375 temperature monitoring

X8
(Montageplatte)
K1

+A*-A343 (UWR)

3
2

A1 A2 A2
K050 -K050 => Main contactor K014 K022

handshakecontactor
brake release
Reserve
handshake
main contactor
current rectifier
main drive:
warning
125°C
shut off
140°C
microswitch
brake release

A2 -K014 => Auxiliary contactor for K050 A1 A1

-K021 => brake release from SPS drive control R300_S317-.VSD / MRuef
0V 0V
-K022 => brake release from main drive
 Service Training Electronic Roland 300

Main drive
5
Operation keypad and display

The display of the Siemens Simoreg 6RA24

current converter consists of a 3-digit 7-segment
display (H1-H3). On the left, next to the 7-
segment display, are the selection keys ”Higher“
(S2) and ”Lower“ (S3), symbolized by arrows in
each direction. To the left of those is the
selection button (S1).

Fig.: Display Simoreg

Selection button Significance of the potentiometers R1-R4

i • Switching among parameter numbers,
parameter value and index number
• Acceleration of the adjustment procedure
started by the Higher or Lower key.
• Acknowledgement of an error message
• R1 rough adjustment (Tacho)
• R2 fine adjustment (Tacho)
• R3 n-actual (!! May not be changed !!)
• R4 I-actual (!!May not be changed!!)

Higher or Lower key

• Selecting a different parameter number.
• Selecting a different parameter value.
• Selecting a different index number.
• Stopping a selected function via parameter
P051.

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Adjustment of the load resistors of the field current measurement

The current converter is to be adjusted by removing load resistors so that motor field design current
(IFN) is greater than 50% of the field design current of the current converter (IFN)!

P076
Original current Load resistors I FN
Motor × 100%
converter that are to be removed 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

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Parameter setting
The SIMOREG 6RA22 current converter must
be loaded with machine specific parameters. Personal
Computer
The following tools installed for this purpose:
•
9pol 1:1-cable RS232/485
PARAFIN, installed on a notebook and converter

• adjustment hardware (converter/lines)

necessary. 9pol 1:1-cable

B2 B3 interface module

Siemens 6RA22

See that only the valid set of parameters

i is loaded!!
[currently on diskette]
First, however, save [Upload] the “old“ set of
parameters if available!
Not only does the electrical connection to the
converter have to be correct, but also the
setting of the communication parameters and
the setting of the interface modules.
The relevant communication parameters of the
6RA22 are:

Since only few parameter deviate from the initial value, it is possible to make the changes by hand
i (see also Checklist, Point 5 in part Diagnosis, error detection)

Parameter number Parameter value Description

P051 --20 Release setting
P097 019 Operation mode of the serial interface
Caution!
! It is absolutely necessary to observe the
sequence of the parameters

The two employed interface modules, i.e. MAN-Roland (communication computer Siemens main
drive A0734) and Z1011 (Siemens original), contain also some encoding switches that define
different parameters of the interface.
The switches must be set as follows:

MAN-Roland module 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)

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Speed allignment
• On the real time computer, on the memory
extension card in Slot 9 Position 5, it is
necessary to set the DIP switch.
Now, in the 7-segment display, appear the
100s (top display) and 10s (bottom display) which
indicate the number of revolutions.
The display of the actual value on the
Leitstand and the trend display (+BA3A) on 0
EF 12
D 3
the DW 1 are rounded off to 100 sheets/h. C 4
B 5
A 6
9 87

• R1 Rough adjustment:
(adjust R1 only during machine standstill)

! Potentiometer pointer to position “15.30 hours“

• Start the machine at an idle speed of 3000 ’Idle rev speed’ is determined on the
LEITSTAND in menu
[sheets/h]. (nominal speed)
Pr / Machine – Idle run“
• R2 Fine adjustment:
Compare actual rev value on the trend
display (+BA3A) with the required value Adjustment should be checked and/or corrected
(Leitstand). at rev speeds of
The exact actual rev value is determined on ( 8000 [sheets/h] & 13000 [sheets/h] ).
the RTR RAM card. (10s)
CAUTION:
If necessary use R2 for speed allignment. !! the values become smaller when the potis
rotate to the right !!
If the adjustment range of R2 is insufficient,
stop the machine, turn R1 clockwise as
necessary and repeat adjustment procedure.

RTR RAM card Pos.5 shows the 100s and 10s Adjustment tolerance max. +/- 20 sheets/h
i range of the actual rev value.

The following functions are impossible if the basic rev is below or above 3000 sheets/h:
! • feeder clutch
• autom. production “ON“
“ON“

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Main drive
5
Diagnosis, error search
Problem:
• No machine run possible
or
• Error message on the Leitstand :
“SPS: HA: brake does not release“
Check following voltages: CAUTION!
! 1. armature voltage
Field current is switched off when the motor is at
standstill.
2. field voltage
3. field current

Check list:
1. non-stabilized voltage between terminals 16
and 21 on +AC1C (approx.25V)?

2. If Par. 00 = 8: approx. 25V between

terminals 19 and 21? (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 switches terminal 17 just before the

machine starts!
19 20 K1 K2

4. Operation statuses (Par. 00) (Operation statuses 01 to 04 are checked each time when the machine is started!)

08: not ready for operation, i.e. terminal 19 =“0“ (EMERGENCY-OFF activated)
07: ready for operation, i.e. terminal 19 = ”1“ (no EMERGENCY-OFF activated)
06: not in use
05: not in use
04: field current supply not o.k.(F14); P76 o.k.?, R52 auf +AC1D removed?
03: current supply 1U-1V-1W (right rotating field) not o.k. (F04)?
02: mains conditions
- mains frequency outside 45...65Hz(F03)
- mains voltage outside the tolerance of +/- 20%
-with weak mains: P51=99 and L33=xx1 or xx2 or xx3 set,
to minimize mains problems;
L33=022 is a recommendation for the operation of
diesel generators!
01: no regulator release?
-voltage between terminal 18 and 21 o.k.?
-check micro-switch –S804 `brake release`
-hardware K1 on +AC1D for activation
-relay –K022 ` brake release ` check.

5. Check the SIMOREG parameter (according to list 039C696938) or read values from diskette
`Parameter main drive`, file `7xx.LST` (Overall list of parameters) or file` 7xx.ADI`(list of
parameter differences)).

! To change a parameter it is necessary set P51 =

20.

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Main drive
5

5.6 Baumüller BKF 12

Overview connection

X8 X9 X602 X601

1. For pin description see next page

2. Firmware-Prom interface card
3. Firmware-Prom drive
4. Display with keypad
5. Control circuit connecting terminals

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22 C95A 6424 39 - 11. Feb. 2004

 6 5 6 +A*-A566 -24V -24V -24V -24V
5 current limit selection
K2 K4 K5 (UWRRelais)
K3 6 5 [RTR]
6 5

X1 3 X1 6 X1 5 X1 4 X1 9 X1 8 X1 7 X1 10 Power Output

contactor
X8 6 X8 5 X8 4 X8 9 X8 8 X8 7 X8 10 -A352/13 [SPS-Anl.] X82 3 1 X82 8

brake release
-XB14.A354 3
Byte.Bit 0.7

R300 from S320

K1 Output Power Output
7 K2 7
-F452 -F453 -S804 -A354/10 [SPS-Allg.] -A354/11 [SPS-Allg.]
+A*-A343
T> T> Byte.Bit 13.1 Byte.Bit 16.2
quick normal (UWR) 8
8 Microswitch
8
stop stop main motor
M000 brake

X6 18 X6 17 X6 16 X6 21 X6 20 X6 22
2 3
X6 19 X82 4 2 X82 9
Main drive

X4 21 X4 20 X4 19 X4 22

-XB15.A352
X4 16 44

-XB12.A354
-XB15.A354
+A*-A345
(SPS) K050
X37 4 X11 3 X11 4 X11 2 X11 1
43 X35 2
X2 1 X2 3
0V +A*-A345
(SPS) 0V
3 3
up to S. 329 +A*-A454 2
K1 K2 X31 2 X12 12 1
(ZusatzverteilerBD)
230VAC 2 2

-X4.A375 13 12

contactor
from S. 330

main contactor

release brake
X2 2 X2 4
+A*-A375
24VAC Power Output 12 14 (Montageplatte)
-A354/14 [SPS-Allg.]
A2
Byte.Bit 19.2 19.3
K021 1 up to Series 330
K021
11
2 from Series 331 A1
3 4
16 17 19 X1 20 Add-on board A386 18 X1

-XB16.A354
X1 20 21 22 25 9 24 18

RS485
Interface to UWR

Protokoll
X601

with USS-

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

+24V/100 mA
nonstabilized
X602

BKF 12

X15
X15
Relais K1 Incrementalencoder
-24V
3.9493
X9

main contactor ON

quick stop
controller enable

normal stop
signal to UWR
X8 und X9
Adapter board

64
K3 are parallel connected
ready for F454
15-pol. SUB-D

Temperature
X8

operation
monitoring
X1 4 6 X1 39 41 X1 31 32

X1/A2
Overview of the different main drive activation systems

1 3

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6 5 X3 Incrementalencoder
Q014 1 3 5
13
signal from motor
K050
14
X37 3 X11 8 X11 5 X5 2 X3 14 16 15 11

17
+A*-A345 (SPS)

18
2 4 6

X4
X11 12 X8 20 12 13 16 15 14 9
X11 9 X11 10

+A*-A345
(SPS)
20 12 13 16 15 14 9
1 3 5
X4 15 X4 14

X6 15 14

-A354/02
-XB3.A354

-K014 (safety board)

1
2 4 6 Input

(UWR)
K2
-A354/03
2
-X300.A375 1 2 Byte.Bit 3.3 2.3 2.4 2.7 2.6 2.5 2.0
1
+A*-A375 Temperature monitoring

X8
(Montageplatte) K1

+A*-A343

3
2
Service Training Electronic

A1 A2 A2
K050 -K050 => Main contactor K022
K014
current rectifier
Main mo tor
Warning
125 °C
Shut off
140 °C

Reserve
Feedback
main contactor

Feedback contactor
brake release
Micro switch
main motor brake

A2
-K014 => Auxiliary contaktor for K050
A1 A1
-K021 => Contactor brake main drive
5

0V 0V
-K022 => Contactor brake release

23
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5 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(red) modulation limit
H16(red) current limit
H17(yellow) moment direction 2
H18(green) moment direction 1
H19(yellow) rev number n=0(P078)
H20(green) regulation release
H21(red) regulation lock
H22(red) error or message
(display of P159)

There are three selection keys below the 7-

segment display: Mode (M)
Higher(©), lower(ª)
Activate keyboard/display by pressing keys
”higher“ or ”lower“ for about 1 sec.
Parameter setting
Preparation:
Parameter setting takes place via MRO software ”PARAFIN V.2.41“
On this Baumüller drive communication takes place via the service interface on the front disk which
is designed as a normal RS232 interface. A connection requires a simple 9pol 1:1-cable and the
adapter3 from 9pole to 25 pole DSub.

Baumüller
BKF12

P123
Personal adapter 3
Computer

RS232

9pol 1:1-cable

Connect the PC with the current converter and 9pol DSUB 25pol DSUB

!
socket plug
start the software. Observe please point
2.4) Using PARAFIN with 1 8
Windows 3.1x/9x/NT 4.0 2 3
3 2
in the PARAFIN documentation.
4 20
5 7
6 6
7 4
8 5
9 22

1:1-cable BKF12
Adapter pin assignment for BKF12 (Adapter 3)

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Main drive
5

1. Version Check
see instructions for ”Parafin V2.41“

2. Activation of the converter Caution!

set P104 to 17hex (keyboard release) This activation must be conducted for every
P001 to *.1, download and upload.
(see Manual BKF12)

3. UPLOAD This is for safety reasons. The old parameter set

i Always first upload and then save data.
(see Parafin instructions)
is still available.
(possibly in order to compare / for MRO)

4. Download parameters CAUTION!

(Security download) The loaded parameters are compared with the
The execution of the download is described original ones during a security download.
in detail in the PARAFIN operation
instructions attached to each PARAFIN
program. The main drive parameter set
attached to the given machine is to be used.

5. Switch off machine

(via main switch)
-wait for about 30s
-switch on again.
Compare parameters
6. Locking the converter CAUTION!
! After the transfer of the parameters it is
necessary to set the communication source
This step may not be forgotten, otherwise the
converter cannot be used in the machine!
back to >*.3< (P001), so as to enable again
control via the interface card. For that it is
necessary to proceed according to the
instruction described above.

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Speed allignment
• On the real time computer set DIP switch on
the memory extension card in slot 9 to
position 5.
Now the rev speed appears in the 100s
(upper display) and 10s digits (lower display) of
the 7-segment display.
The actual value display on the Leitstand
and on the trend display (+BA3A) on DW 1 are 0
EF 12
D 3
rounded off to 100 sheets/h. C 4
B 5
A 6
9 87

• Start the machine at an idle speed rev The presetting of idle speed rev number is done
on the LEITSTAND in menu
number of 3000 [sheets/h].
”Pr / Machine – Idle run“

•
i •
Set key parameter 104 to the value of 17
(keyboard input)
Compare actual rev value on the trend
The adjustment is to be checked and/or
display (+BA3A) with the nominal rev value corrected at speeds of (8000 [sheets/h] &
(Leitstand). 13000 [sheets /h] ).
The exact actual rev value is determined on The max. deviation of the actual rev value
the RTR RAM card (10s). (RTR): ±20 sheets/h at given rev value.
• The maximal value for P142 is:
! P142 = 3150
• If a higher value is determined, it is
necessary to check the 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
into the current converter.
In addition use also PARAFIN to load the
parameter set appropriate for the press and
call it up in menu General and submenu
Speed Alignment. The determined
parameter value is to be entered in all four
data sets! Use Download to load the
parameters into the current converter.
• Set key parameter 104 to the value of 17
(keyboard release)
• Set P001 communication source
(can be changed by keyboard only)
to `*.3`. (control via interface)

After completing all the steps described above, switch off the machine (download the system) and
! switch it on again after 30 sec..
(see also: Protecting parameters against overwriting)

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5
Diagnosis, error search

Distribution 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.
(identification plate drive / motor or techn. documentation)
• Accidental use of a data set that does not belong to the given motor current converter
! combination may lead to damage or destruction of the motor.
• It is not allowed to use a parameter set for a different motor type and current converter than
indicated!
• The motor and current converter data are included in the base sheet attached to the Application
of the Parameter Set or included in the header of the list of parameters [(*.TXT, ASCII text file) or
in menu:
GENERAL - EDIT HEAD (V1.10: GENERAL – EDIT HEADER) of the PARAFIN program].
Checking the parameter set
1. Use main switch (Ax) to switch on machine
2. Activate 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. The
display becomes active after the key is
released.
4. Select and check parameter P129. The P129 loaded / programed data set
following bits of the 7-segment display must
glow (on an idle machine).
5. If this is not the case, then program the Programed data set: DS1 DS2 DS3 DS4
current converter using the parameter set
attached to the machine.
(see Chap. 11 Diagnosis / PARAFIN)
6. Checking different parameters:
To check different parameters by hand
interrogate them on the current converter Data set active: DS0 DS1 DS2 DS3 DS4
(loaded)
(e.g.: data set 1 [during operation or
standstill] P020, P024, P025) and compare
with the PARAFIN parameter list *.TXT (e.g.
P010, DS 1: No.: 10.0).
7. If this is not the case, then program the
current converter using the parameter set
attached to the machine.
(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 Quick stop K1 (Controller ready) K3: release brake

Main contactor ON K4: temp. monitoring

X1/A2: 4, 6
Terminals
Interface

Main contactor ON

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5.7 Instructions for start-up

i Control functions of the current converter

Note: To check the control functions of the current converter you need:
• an assistant to activate the machine run commands
• Voltmeter
• 2-pole voltage tester
• DC current display
Measuring lines with testing points (2 pieces) and caliper terminal (1 piece)
Function check
Function check includes the following points. The points are described in detail below.
† Is the motor/current converter combination correct ?
† Does the parameter set of the current converter match that of the machine ?
† Was speed allignment completed ?
† Is the belt tension correct ?
† Are the plugged jumpers and the DIP switches in the basic device board and interface card o.k.?
† 'Emergency off' function o.k.?
† 'Stop-Safe' function o.k.?
† Run command sequence o.k.?
† Communication of the RTR with main drive o.k.?
† Is communication source P001 correct (P001=3.3)?
† Is the voltage supply for the control terminals (adapter board ) o.k.?
† Is impulse release signal available ?
† Brake activation (R700, R702/R702L/R703, R300)
† Is the controller enable signal o.k.?
† Is the required value setting (P050) o.k.?
† Error message: blocking protection active?
† Error message: drive does not rotate although brake is released ?
† Error message: Wrong speed during jogging at reduced speed ?
Checking the output connection
! Activate run command so that the main contactor pulls and voltage on 1U, 1V, 1W is available.
1. Check voltage on the connections (1U, 1V, 1W, 2U, 2W, 3U, 3W).
2. Check rotation field on the armature terminals: right rotation field
3. Check phase assignment:
There must be phase equality among 1U, 2U, 3U and among 1W, 2W; 3W. With identical phase
there may not be a voltage between the connections. This is to be checked by a voltage tester
(not an high-resistance measuring device), otherwise there is a danger of measuring errors.
Voltage among 1U, 2U, 3U = 0V; 1W, 2W, 3W = 0V.
Checking the firmware and the jumper connections
1. Check of the software version of the basic device:

i
The EPROM of the basic device board of the current converter must contain the software version
indicated in the Baumüller commissioning instructions. Other possibilities include interrogation on
the display of the current converter via parameter P003 or using PARAFIN in menu
COMMUNICATION – CHECK VERSION (V1.10: KOMMUNIKATION - VERSIONSAB-FRAGE).
2. Check of interface card software version:
The EPROM of the interface card (3.9493) must contain the software version indicated in the
Baumüller commissioning instructions.
3. Check of plugged jumpers on the basic device board of the interface card:
For configuration please see Baumüller commissioning instructions.

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Main drive
5

5.8 Main motor

On MRO printing presses DC motors with
separate excitation made by Baumüller are
used.

Features of this motor type :

• Voltage is proportional to rev speed

• Current is proportional to torque
• Rev speed can be regulated from 0 to
maximum
• When the mechanical brake is opened it can
hold a load.(four-Q drive)
• Four quadrant operation with motor acting as
generators to decelerate is possible.
Cross section through a DC motor

i The main field of the DC motor is generated by

the field coil.

It is important to see that the exciting coil connection lines are not disconnected while under voltage.
! Field current is measured indirectly (current clamp).

Checking and maintenance

• Brush holder adjustment and position of the
marks always on the collector side
• Carbon brushes, residual length See maintenance instructions of the motor
• Commutator contact surface manufacturer
• Carbon brush change and trimming
(grinding) the carbon brushes
Trimming the carbon brushes
On machines with a roughly running rotor it is
necessary to trim the brushes of each bolt by
hand using a lubrication gel that is moved
backwards and forwards under the brushes.

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Diese Seite bleibt aus technischen Gründen frei.

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Main drive
5

5.9 Brake Main Motor

Commissioning and maintenance instructions
for the spring-loaded disk brake type SB 50 ,SB 100 ,SB 200 (R700 / R300)
(see TA EMO 00004 & 00005 made by Baumüller)
from series 739 SB360 replaces type DSB320/SB200
(see TA BMK 00016 made by Baumüller)

1. Design and function ( see Fig.: 1 )

• The pot-shaped magnet ( Pos.1 ) with a cast integral magnet coil is rigidly connected to the
flange (Pos.2 ) by bolts ( Pos.9 ).
• When braking, the armature disk ( Pos.3 ) is pushed by several pressure springs ( Pos.4 )
against the brake disk ( Pos.5 ) and the flange ( Pos.2 ).
• The brake disk ( Pos.5 ) is connected to the shaft by a follower ( Pos.6 ).
• When ventilating, the excited pot-shaped magnet ( Pos. 1 ) pulls the armature disk ( Pos.3 )
against the spring force of the pressure springs ( Pos.4 ). The brake disk can thus move freely
and braking effect is eliminated.

2. Assembly

• The spring loaded brakes can be directly mounted on machine parts as independent systems
(e.g. motors).

• Mounting: Insert fitting springs ( Pos.7 ) in the shaft, push the follower (Pos.6 ) on to the greased
shaft and secure it against axial movement using a safety ring ( Pos.8 ).
• Place the complete disk brake on to the follower ( Pos.6 ), then position the centering edge on
the machine part and fix it using six bolts ( Pos.11 ).
• If an intermediate flange and an extended shaft are used, tachometer generators or impulse
sensors etc. can be attached to these brakes. ( see also Fig’s.: 3 to 5 )

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List of parts:
Pos. 1. complete pot-shaped magnet
Pos. 2. flange
Pos. 3. armature disk
Pos. 4. pressure springs
Pos. 5. brake disk
Pos. 6. follower
Pos. 7. fitting springs
Pos. 8. safety ring
Pos. 10. terminal box
Pos. 11. setting screw
Pos. 15. terminal strip
Pos. 16. insulation board
Pos. 17. sealing
Pos. 18. manual ventilation bolt with spring for middle position
Pos. 19. O-ring
Pos. 20. manual ventilation lever
Pos. 21. micro-switch
Pos. 22. pressure springs for micro-switch
Pos. 23. closing cap
Pos. 24. threaded connection
Pos. 25. damping bolt

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3. Connection and commissioning

!! SAFETY NOTE !!
Caution! No braking effect when under voltage!

• Compare available voltage with data on the rating plate.

Remove terminal box ( Pos.10 ) and connect brake according to the circuit diagram integrated in
the floor of the terminal box.

• If the brake is mounted on a machine part that has not yet been grounded, it must be grounded
in the terminal box.
(Grounding bolt M4x10 DIN 84 -gal. zinc coated + safety disk S4Zn)

• Before commissioning check whether the brake disk moves freely when the follower is rotated
while the brake is being ventilated (electrically or mechanically).

4. Rating plate

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Main drive
5
Maintenance
!! SAFETY NOTE!!
Caution!
Move system before the beginning of maintenance work to zero position so that the brake is
not under load.
Disconnect machine completely from the mains.
The braking effect is cancelled when connecting voltage to the brake as well as during
disassembly.

Air gap determination (see Fig.: 1 & 3)

• Dismantle brake from machine part (motor).
• Place assembled brake on the pot-shaped magnet (Pos.1), (!Caution! Protect setting screw
of the micro-switch against breakage), so that the flange side faces up.
• Ground brake using the grounding bolt in terminal box.
• Connect brake electrically and ventilate.
• (Armature disk release brake disk) To measure air gap insert slip gauge between the flange
contact surface and the brake disk.
• See table for rated air gap value as well as the max. permissible operation air gap assigned
to 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. permissible
operation air gap 0.75 1.1 0.85 1.4 0.75 1.1 0.8 1.1
[mm]

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Checking and/or adjusting the microswitch (see Fig. 2)

!! SAFETY NOTE!!
Caution! No braking effect when voltage is connected to the brake!

• Connect ohm meter or continuity checker to the micro switch terminal points.
• Loosen locking nut (Pos.13).
• Loosen setting screw (Pos.12) by turning it 2-3 times
• Ventilate and leave brake ventilation open.
• Turn in setting screw until micro switch is actuated
• Turn in setting screw (Pos.12) by exactly 60° (±10°) = 1/6 revolution turn further and lock (=2Nm)
in this position using a locking nut (Pos.13).
• Secure locking nut with safety varnish in the position shown on Fig. 2 (Pos.14).
• Test whether electrical and mechanical operation of the brake the micro switch reacts.

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Main drive
5

5.10 Signal Sensor Main Motor

Series overview of signal sensors main motor

R300
Angle encoder from series 320
1024 steps
Type Stegmann or Heidenhain

0 37U 4065 44 X

Tacho generator Up to series 319

GHT-612/46
0 37M 3926 44 X

Tacho generator / Speed transmitter

Technical data:
BAUMUELLER GHT 612/46
protection type: IP 44;
insulation class: B
construction form: B 14;
60 V / 1000 min-1
voltage oscillation: -0 +10%
I = max.10 mA;
N = max. 4000 min-1
with integrated socket type: MKE 300

For all important information related to maintenance and commissioning see Commissioning and
Maintenance Instructions for Tachometer Generators of the GHTS and GHT types
Moreover please observe the following points:
• Tacho-concentricity, CAUTION!
Tacho- and collector shaft (glued) must have a Bigger differences in tacho- concentricity can be
true rotation of <0.02mm otherwise the corrected by the Baumüller company.
voltage swing of the tacho-signal is too big
and the signal is useless for speed regulation
-> drive swings.
(higher carbon brush wear)
• Imbalance / Vibrations, also here, too high
values produce a useles tacho-signal -> drive
swings
• Bad ambient conditions, observe protection
class

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Incremental encoder
Technical data:
DG 60L XSR
PRODUCED BY: STEGMANN
Item no.: 5W4XC2F00F00

Max. output frequency:

–RS 422 300kHz

Max. operation speed:

with sealing ring 6.000 min-1

Allowed shaft load Operation voltage range

– Radial DG 60 L X.. 20 N at RS 422 4…6V
– Axial DG 60 L X.. 10 N
Operation current without load
at 5 V 120 mA

Working temperature range: 0 … +85 °C Signal line

Operation temperature range: -20 … +85 °C (Voltage supply is potential free to housing,
shield is housing potential)
– diameter 8 mm
– min. bending radius 40 mm
DG 60L C10
PRODUCED BY: STEGMANN
as DG 60L XSR 1024 I
however, housing finished (blue)
no shaft sealing ring !!

Max. operation speed:

without sealing ring 10.000 min-1

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ROD 426.0010 ( RADIAL )
PRODUCED BY: HEIDENHAIN
Max. scanning frequency: max. 300 kHz

Mechan. allowed speed: max. 12000 min-

1

Shaft load:
n < 6000 min-1: axial 40 N / radial 60 N at end of
shaft
n > 6000 min-1: axial 10 N / radial 20 N at end of
shaft Voltage supply: 5 V ± 10 %

Max. working temperature: 100 °C Max. current consumption (without load) 150 mA
Min. working temperature: -40°C

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Notes:

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