Montronix PulseNG Kit User manual

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Operating Manual
PulseNG Kit
Montronix GmbH Telephone: [phone] OPI-PulseNGKit-en-141106
Benzstr. 7 Fax: [phone] Version: 2.01
D-71720 Oberstenfeld E-Mail: [email protected]
Germany Internet: www.montronix.de Page 1 of 31
Certied CE
Operating Manual
PulseNG Kit

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Table of contents
Introduction���������������������������������������������������������������������������������������������������������������5
Product Certication.................................................................................................5
Copyright and Operating Instructions��������������������������������������������������������������������6
Safety Instructions ���������������������������������������������������������������������������������������������������7
Organizational Measures .........................................................................................7
Personnel .................................................................................................................8
Operation .................................................................................................................8
Special Risks............................................................................................................8
IBU-NG �����������������������������������������������������������������������������������������������������������������������9
Dimensions ..............................................................................................................9
Please observe..................................................................................................9
Connections ...........................................................................................................10
Communication Ports.............................................................................................11
LAN.....................................................................................................................11
USB ....................................................................................................................11
Serial interface....................................................................................................11
Diagnosis and LED signals ....................................................................................12
Sensor Connection.................................................................................................12
PulseNG .................................................................................................................12
Dimensions ............................................................................................................12
Mounting������������������������������������������������������������������������������������������������������������������13
Torque values.........................................................................................................13
Cable......................................................................................................................14
Power Supply .........................................................................................................14
Software PulseNG-hmi �������������������������������������������������������������������������������������������15
Installation ..............................................................................................................15
Software version ....................................................................................................15
Using the software .................................................................................................15
PulseNG-hmi main window������������������������������������������������������������������������������������16
Reset alarms ..........................................................................................................16
Teach......................................................................................................................16
Settings ..................................................................................................................17
Filter data view....................................................................................................17

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Raw data view ....................................................................................................17
Statistics .............................................................................................................17
Save limits..............................................................................................................18
Event Log ...............................................................................................................18
Text EL................................................................................................................18
Graphics EL ........................................................................................................19
Previous ..........................................................................................................19
Next .................................................................................................................19
Load le...........................................................................................................19
Save le...........................................................................................................19
DSP .................................................................................................................20
Text EL full view / Text EL partial view....................................................................20
Export csv le ..................................................................................................20
Cong.....................................................................................................................21
Global (Global settings) ......................................................................................21
Plot......................................................................................................................22
Sensor axes........................................................................................................22
Machine axes......................................................................................................22
Machine interface ...............................................................................................23
Help........................................................................................................................23
Operating Manual ...............................................................................................23
About ..................................................................................................................23
About Qt..............................................................................................................24
Scenario .................................................................................................................24
Scenario #...........................................................................................................25
Scenario name....................................................................................................25
Teach count ........................................................................................................25
Teach time ..........................................................................................................25
Limit 1-3 ..............................................................................................................25
Load le ..............................................................................................................26
Save le ..............................................................................................................26
Select sensor .........................................................................................................27
Add .....................................................................................................................27

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Description: .....................................................................................................27
IP address: ......................................................................................................27
Server port:......................................................................................................27
Delete .................................................................................................................27
Edit......................................................................................................................27
Service ...................................................................................................................28
Software update..................................................................................................28
Firmware update.................................................................................................28
Default ................................................................................................................28
Login / Logout ........................................................................................................28
Statistics / Raw data...............................................................................................28
Contact ��������������������������������������������������������������������������������������������������������������������29

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Introduction
The PulseNG Kit serves as permanently installed diagnostic tool for machines and
machining centers.
In principle, the PulseNG Kit consists of the PulseNG sensor and the interface
IBU-NG. For further details, please refer to the technical specications as listed in our
“BDS-PulseNGKit-en“.
The software provided as user interface for the PulseNG monitoring system is titled
PulseNG-hmi.
PulseNG-hmi runs under Microsoft Windows XP®, Windows 7 and Windows 8.
PulseNG-hmi provides process visualization for the different scenarios and serves to
check and set individual parameters and limits.
Valid up to PulseNG version 0.3.0 Build $Rev: 150$ R and Firmware version 013.
Product Certication
„This veries that PulseNG-hmi can be installed on and operated with SINUMERIK
840D sl with SINUMERIK Operate 4.5 SP3 on PCU 50 with Windows 7.“

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Copyright and Operating Instructions
In order to ensure safe and reliable operations of production facilities, only trained
and qualied professionals may install, maintain, and operate the system. Improper
installation, maintenance, or operation can lead to damages to the machine(s) and
even bodily harm.
You must always observe the following safety instructions. However, they do not
replace the safety instructions and warnings contained in the operating manuals of the
production machines or any accessories thereof.
This manual is based on the information available at the time of writing and believed
to be correct. The manual does not claim to cover all possible details or variations
in hardware, software, installation, or operation of the system. Changes and
improvements will be made to the system as conditions warrant. Montronix GmbH
assumes no liability with respects to the information contained in this manual.
No part of this publication may be reproduced, transmitted, translated, or forwarded
to a third party in any form or by any means without written permission of Montronix
GmbH. This is also true for any forwarding or copying of excerpts and includes all
forms of digital forwarding and its use for training purposes.
Copyright © Montronix GmbH, 2014. All rights reserved.Copyright for this operating
manual rests exclusively with
Montronix GmbH
Benzstrasse 7
71720 Oberstenfeld Germany

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Safety Instructions
Installation and service of the PulseNG sensor must only be performed by
trained professionals! Improper installation of the equipment may lead to
malfunction, equipment damage and could even cause bodily harm�
All safety instructions issued by the machine manufacturer must be observed�
When installing sensors, please make sure to secure suspended axes to
prevent them from falling!
• In addition to the operating manual, the user must observe the universally
accepted, legally and otherwise binding regulations governing accident prevention
and environmental protection, and must instruct others herein.
• The operating manual must be permanently available for reference at the location
of the system.
The operating manual must be read by any and all persons in charge of the following
tasks at the machine/machining center:
• All machine operations, including set-up, trouble-shooting during processing,
(preventive) maintenance, disposal of production waste, supplies, and additives
• maintenance (servicing, inspections, repairs) and/or
• transport
In addition to the operating manual, the operator is required to observe all accident
prevention regulations specic to the country and location where the system has been
installed, as well as generally recognized rules for safe and professional operations.
Organizational Measures
• Heed all safety and caution signs at the machining plant and building!
• Upon noticing changes to a machine‘s safety equipment or to its operations,
the machine/plant must be immediately stopped and any malfunction be
communicated to the person / authority in charge!

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Personnel
• Use only trained and instructed personnel. Clearly delineate each staff member’s
responsibilities for operation, set-up, maintenance, and repairs!
• Make sure that operations on the machine are performed only by personnel
properly assigned to it!
• Work on electrical plants may only be performed by licensed electricians or trained
personnel supervised and instructed by a licensed electrician according to the
rules and regulations of the electrical trade.
Operation
• Safety must always be your rst priority!
• Operate the plant/machine only with all safety equipment in place and operating
properly, including but not limited to: removable protection devices, emergency
shut-offs, sound-proong devices, exhaust equipment, etc.!
• Power-up and shut-down cycles and their associated control checks must be
performed according to the machine’s operating manual and maintenance
instructions. This includes all activities concerning general operations, production
changes, tool and set-up changes of the machine or its safety-related equipment
as well as inspections, servicing and repairs!
• Avoid endangering any persons when powering up the machine!
Should it become necessary to remove safety equipment when setting up, servicing,
or repairing machinery, you must reinstall and test all such equipment immediately
after nishing your work.
Special Risks
• When performing inspection, servicing, and repair work on plant or machine parts,
you may be obligated to switch them to zero potential. Check the potential rst,
then ground and short-circuit the parts before insulating neighboring parts that are
still under current!
• The electrical parts of a machine must be tested and inspected regularly. Defects
such as loose connections or burnt cables must be repaired immediately.
• Should it become necessary to perform work on parts with live wiring, a second
technician must be present and ready to activate the main shut-off in case of an
emergency. Close off the work area with red and white tape and a warning sign.
Use only insulated tools!

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IBU-NG
Dimensions
Height Width Depth
120 mm 42 mm 120 mm
Table 1: IBU-NG dimensions
• robust aluminum housing, with DIN rail attachment according to EN 50022
Please observe
Installation of the IBU-NG may require wiring
operations in a high-voltage area� In order to
avoid accidents due to electrical current
(serious bodily injury or even death), only
qualied professionals may perform the
installation!
Labeling Function
PE Ground
0 V GND voltage supply
24 V +24 V voltage supply
IN5 Reset, delete errors
IN4 Monitor Active
IN3 Bit 3 (Value 4) of scenario number
IN2 Bit 2 (Value 2) of scenario number
IN1 Bit 1 (Value 1) of scenario number
OUT5 Ready
OUT4 Machine emergency stop
OUT3 Limit 3 triggered
OUT2 Limit 2 triggered
OUT1 Limit 1 triggered
STAT LED for IBU-NG status
SENS LED for sensor status
Table 2: IBU-NG labeling Figure 1: IBU-NG front
OUT1
OUT2
OUT3
OUT4
OUT5
IN1
IN2
IN3
IN4
IN5
24 V
0 V
PE
STAT
SENS
IBU-NG
USB
LAN
2
4
6
8
10
12
14
16
18
20
1
3
5
7
9
11
13
15
17
19
24V
0V
PE
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Connections
G1
-WZ.1
MONTR
- B2
1
SENSOR
IN5
IN4
IN3
IN2
IN1
OUT5
OUT4
OUT3
OUT2
OUT1
SENSOR
IBU-NG
9pol
SPECTRA
SPECTRA
-X1
-X2
19
17
15
13
11
9
7
5
3
1
3
2
1
PE
0 V DC
24 V DC
20
18
16
14
12
10
8
6
4
2
ETHERNET
USB
+24 V +24 V
OUT1 OUT2 OUT3 OUT4
OUT5
IN1 IN2 IN3 IN4 IN5
0 V
L24
M24
Ax. x
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Clip 9
24 V DC LIMIT 1 LIMIT 2 LIMIT 3
Emergency cutout
Operative Scenario Bit 1 Scenario Bit 2 Scenario Bit 3 MONITOR ACTIVE CONTROL. ON ERROR RESET 0 V DC Supply 24 V DC Supply 0 V DC PE
Figure 2: IBU-NG wiring diagram
Labeling Voltage Terminal Terminal PLC Outputs/Inputs
IN5 0 V 19 20 O Reset, delete errors
IN4 0 V 17 18 O Monitoring ON
IN3 0 V 15 16 O Bit 3 of scenario number
IN2 0 V 13 14 O Bit 2 of scenario number
IN1 0 V 11 12 O Bit 1 of scenario number
Out5 +24 V 910 I Ready
Out4 +24 V 7 8 I Terminal HW machine emergency stop
Out3 +24 V 56I Limit 3 triggered
Out2 +24 V 34I Limit 2 triggered
Out1 +24 V 12I Limit 1 triggered
Table 3: IBU-NG labeling of wiring diagram