marposs E20N User manual

Manual code No. D2200004UB
Installation Manual
E
20N
GRINDER ACOUSTIC CONTROLLER

2E20NInstallation Manual
This product is in conformity with the EMC requirements as for the directives:
2004/108/CE
This product is intended to operate in industrial locations; it is not intended for connections
to a public mains network but is intended to be connected to a power network supplied from
a high or medium voltage transformer.
This product is in conformity with the “Electrical Safety” requirements as for the directive
73/23/CEE
Electrical safety
The equipment has been manufactured in conformity with EN 61010-1 specifications.
Manufacturer: Marposs S.p.A.
Address: Via Saliceto 13, Bentivoglio (BO) Italia
www.marposs.com
Manual Code: D2200004UB
Issue: September 1995
Edition: (04) January 2006
Iussed by: Marposs S.p.A. , Via Saliceto 13, Bentivoglio (BO) Italia
MARPOSS S.p.A. does not take on the obligation of notifying possible further
changes to the product.
The descriptions reported in this book do not authorize any tampering by non-
authorized personnel.
The warranty on the equipments will decay if such tamperings are found.
© Copyright Marposs S.p.A. 2006
D2200004UB_04.doc (Save Date 20/01/06 15.13)

3
About the Directive 2002/95/EC “RoHS” regulating the presence of certain
hazardous substances in electrical and electronic equipment.
The Member States of the European Community are in the process of completing
the national reception and enforcement of the Directive 2002/95/EC regulating the
presence of certain hazardous substances in electrical and electronic equipment.
The Directive explicitly excludes from its scope of application finished products
such as those manufactured and sold by Marposs. It is still indeed a widely debated
matter whether the complete removal of the regulated substances could affect the
reliability of the product.
Marposs shares in the social responsibility of continuously supporting every form
of innovation that reduces or minimizes any risk of adverse impact on human health
and the environment.
Marposs is therefore voluntarily pursuing the progressive removal of the regulated
substances from our products. Marposs will do so with the clear understanding that
any improvement achieved on the protection of health and the environment should
not come as a compromise for the quality and reliability of our products.
Marposs will put the greatest consideration in any initiative that our Customers
undertake with the purpose of reducing the environmental risk. Our commitment is the
support of their effort developing products that be of the highest quality and reliability.

4E20NInstallation Manual
Preface
The instructions refer to all possible configurations of the MARPOSS E20N so only
the parts relevant to the specific application must be considered.
The code number of the MARPOSS E20N electronic amplifier is indicated on the label
on the back.
The configuration of your MARPOSS E20N amplifier may be determined, on the basis
of the code number, by consulting capter 2.1, "Codification plan" on page 11.
Warning
All servicing or special maintenance operations must be carried out by
authorized personnel.

5
List of documentation
1. Specifications and general warnings.............................................................. 9
1.1 Premise....................................................................................................... 9
1.2 Final test and warranty................................................................................ 9
1.3 Definition of safety notices .......................................................................... 9
1.4 Customer to provide:................................................................................. 10
2. Description of Marposs E20N system ........................................................... 11
2.1 Codification plan........................................................................................ 11
2.2 Dimensions of the electronic unit .............................................................. 13
2.3 Applications............................................................................................... 15
2.3.1 GAP control....................................................................................... 15
2.3.2 CRASH control.................................................................................. 15
2.4 Configuration of the system....................................................................... 16
2.4.1 E20N with one GAP channel............................................................. 17
2.4.2 E20N with one CRASH channel........................................................ 17
2.4.3 E20N with two GAP channels in switching ........................................ 17
2.4.4 E20N with one GAP channel + one CRASH channel........................ 17
2.5 Microphones compatibility......................................................................... 17
3. Connections to the electronic unit ................................................................ 18
3.1 General connections (rear view) ............................................................... 18
3.2 Connection to the machine logic ............................................................... 20
3.2.1 Input signals ...................................................................................... 20
3.2.2 Output commands............................................................................. 21
3.2.3 Connection diagram for 1 GAP Channel ........................................... 23
3.2.4 Connection diagram for 1 CRASH Channel ...................................... 24
3.2.5 Connection diagram for two switching GAP channels ....................... 25
3.2.6 Connection diagram for one GAP channel + one CRASH channel ... 26
3.2.7 GAP control cycle.............................................................................. 27
3.2.8 CRASH control cycle......................................................................... 28
3.3 Connection to EGC - Analog output function............................................. 30
4. Installation of the microphone....................................................................... 31
4.1 Fixed microphone...................................................................................... 32
4.2 Microphone with contactless transmission ................................................ 33
5. Use and programming.................................................................................... 34

6E20NInstallation Manual
5.1 Front Panel ............................................................................................... 35
5.2 GAP control programming......................................................................... 36
5.2.1 Stable and repetitive background noise ............................................ 37
5.2.2 Variable and oscillating background noise ........................................ 38
5.2.3 EGC Function - Analog Output.......................................................... 39
5.3 CRASH control programming.................................................................... 40
5.3.1 Programming procedure.................................................................... 40
6. Internal Programming..................................................................................... 41
6.1 Selection of the type of microphone .......................................................... 42
6.2 Selection of the frequency range............................................................... 43
6.2.1 Definition of the frequency range ...................................................... 43
6.3 Alarms programming................................................................................. 45
7. Troubleshooting and Maintenance................................................................ 46
7.1 Alarm conditions........................................................................................ 46
7.2 Replacement of the protection fuse........................................................... 47
7.3 Microphones protection fuses ................................................................... 48
7.3.1 Substituting microphone fuses .......................................................... 48
7.3.2 Resetting operation with resettable fuses.......................................... 49
8. Technical Data................................................................................................. 50
8.1 Electrical power supply.............................................................................. 50
8.2 Operation characteristics .......................................................................... 50
8.3 Environment characteristics ...................................................................... 50

7
List of drawing
Figure 1. Overall dimensions of E20N with rack 19” assembly ................................. 13
Figure 2. Overall dimensions of E20N with stand alone case (IP54)......................... 13
Figure 3. Overall dimensions of E20N with remote panel ......................................... 14
Figure 4. Connections to the electronic unit (rear view) ............................................ 18
Figure 5. Connection diagram for 1 GAP Channel.................................................... 23
Figure 6. Connection diagram for 1 CRASH Channel ............................................... 24
Figure 7. Connection diagram for two switching GAP channels................................ 25
Figure 8. Connection diagram for 1 GAP channel + 1 CRASH channel.................... 26
Figure 9. Time chart of the signals for GAP control cycle ......................................... 27
Figure 10. Time chart of the signals for CRASH control cycle .................................. 28
Figure 11. Connection to EGC - Analog output function ........................................... 30
Figure 12. Installation of fixed microphone................................................................ 32
Figure 13. Installation of microphone with contactless transmission ......................... 33
Figure 14. E20N internal programming ..................................................................... 41
Figure 15. Replacement of the protection fuse ......................................................... 47
Figure 16. Replacement of the microphone protection fuses .................................... 48
Figure 17. Sheet for amplifier with resettable fuses .................................................. 49

Specifications and general warnings 9
1. SPECIFICATIONS AND GENERAL WARNINGS
1.1 Premise
This instruction manual supplies all the specific information necessary to know and
correctly use your MARPOSS equipment.
The descriptions reported in this manual are aimed to the following personnel:
•MARPOSS personnel or Customer's personnel who has to install the equipment;
•Customer's technicians who directly operate the MARPOSS equipment;
•Customer's technicians who are responsible of the maintenance of the production
line where the MARPOSS equipment is installed.
All rights are reserved. This manual is intended for Customer's internal use
only. Any other use is forbidden.
1.2 Final test and warranty
The defects of the materials are covered by the warranty with the following limitations:
•DURATION OF THE WARRANTY: the warranty covers all repairs made within
the agreed terms
•OBJECT OF THE WARRANTY: the warranty is applied to the product and to its
parts marked with serial number or other identification number by MARPOSS.
The above mentioned warranty has to be considered valid, unless of different
agreements between MARPOSS and the Customer.
1.3 Definition of safety notices
There are two types of notices: Warning and Attention
Warning
This note indicates the possibility to damage the electronic unit and other
devices connected to it, or the possibility to loose data.
Attention
This note indicates dangerous conditions for the operator/technician.

10 E20NInstallation Manual
1.4 Customer to provide:
The Customer must provide the following connections:
•power supply according to the data reported on the equipment plate;
•connection to the machine logic according to the indications of chapter 3.2, on
page 20.

Description of Marposs E20N system 11
2. DESCRIPTION OF MARPOSS E20N SYSTEM
2.1 Codification plan
Below there is a list of the possible configurations and the corresponding coding plan
of the MARPOSS E20N:
Code number: 8 3 0 2 8 x y z v w
"x" TYPE OF STRUCTURE
With rack assembly A
Blindbox for remote panel (4)B
With stand alone case C
Without case, without panel D
"y" FUNCTIONAL CHARACTERISTICS
1 GAP channel 0
2 GAP switching channels with 1 microphone 1
2 GAP switching channels with 2 microphones 2
2 simultaneou channel (GAP + CRASH) with 1 microphone 3
2 simultaneous channels (GAP + CRASH) with 2 microphones 4
1 CRASH channel 5
1 GAP channel + analogue output 6
2 GAP switching channel with 1 microphone+ analogue output 7
2 GAP switching channels with 2 microphones+ analogue output 8
"z" SPECIAL OPTIONS
No optional features (self-locked commands) 0
Non-self-locked command for Channel 1 1
Non-self-locked command for Channel 2 2
Non-self-locked commands for Channel 1 and Channel 2 3
EGC function (Ext Gain Control) with self-locked commands 5
EGC function + non-self-locked command for Channel 1 6
EGC function + non-self-locked command for Channel 2 7
EGC function + non-self-locked commands for Channel 1 and Channel 2 8
"v" TYPE OF INPUTS
24 VDC Source/Sink / 24VAC 4
"w" NETWORK POWER SUPPLY
200-240 VAC (IEC) 2
100-120 VAC (IEC) 3

12 E20NInstallation Manual
(4)
Remote Panel Codice
1 GAP channel 6303411245
2 GAP channels 6303411205
1 GAP channel +1 CRASH channel 6303411225
1 CRASH channel (not available with EGC) 6303411265
Cable Lengh Cable Lengh
6734516039 3 m 6734516040 6 m
6734516041 10 m 6734516062 15 m
6734516049 20 m 6734516071 30 m

Description of Marposs E20N system 13
2.2 Dimensions of the electronic unit
Figure 1. Overall dimensions of E20N with rack 19” assembly
Figure 2. Overall dimensions of E20N with stand alone case (IP54)

14 E20NInstallation Manual
Blind box: Fixing with brackets
Remote panel assembly
Terminal (M4) for the connection to the center of ground terminal.
Cable Length Cable Length
6734516039 3 m 6734516040 6 m
6734516041 10 m 6734516062 15 m
6734516049 20 m 6734516071 30 m
Figure 3. Overall dimensions of E20N with remote panel

Description of Marposs E20N system 15
2.3 Applications
The MARPOSS E20N detects, by means of a piezoelectric transducer (microphone),
the ultrasonic energy generated by the contact of the grinding wheel with the
workpiece or another part of the grinder
2.3.1 GAP control
The following applications are possible:
•Check of the contact between wheel and workpiece.
The definition of a noise threshold makes it possible to detect the contact
between wheel and workpiece to switch from approach speed to feed rate.
•Check of wheel position.
The definition of a noise threshold makes it possible to detect the position of the
wheel with respect of a known reference.
•Check of continuity of dressing.
The detection of the ultrasonic emissions during the wheel dressing makes it
possible to optimize the dressing cycle. The dressing cycle can be considered
completed when the ultrasonic emission is continuous and not interrupted.
2.3.2 CRASH control
The definition of an appropriate noise threshold makes it possible to detect accidental
collisions of the grinding wheel.

16 E20NInstallation Manual
2.4 Configuration of the system
1 GAP channel 1 CRASH channel
1 GAP channel + 1 CRASH channel 2 GAP switching channels

Description of Marposs E20N system 17
2.4.1 E20N with one GAP channel
The E20N is connected to one microphone for GAP control.
Machine connection diagram in Figure 5, on page 23.
2.4.2 E20N with one CRASH channel
The E20N is connected to one microphone for CRASH control.
Machine connection diagram in Figure 6, on page 24.
2.4.3 E20N with two GAP channels in switching
The E20N is connected to one or two microphones for GAP control with two
independent and switching channels.
In case of applications with two microphones, each channel is connected to a given
microphone.
Only one channel at a time is active.
When the E20N is switched on, channel 1 is automatically Inserted.
Machine connection diagram in Figure 7, on page 25.
2.4.4 E20N with one GAP channel + one CRASH channel
The E20N is connected to one or two microphones for gap and crash control:
•Channel 1 for GAP control
•Channel 2 for CRASH control
In case of applications with two microphones, each channel is connected to a given
microphone.
Both channels are active at the same time
Machine connection diagram in Figure 8, on page 26.
2.5 Microphones compatibility
The E20N can be connected to different types of microphones (see 6.1, on page 42):
wide range microphone
•traditional type (3424802152) with contactless transmission (3424802000+
3424802014)
•"old" type microphone (34130011XX)
Warning
The E20N is factory programmed for wide range microphones
(3424802xxx).

18 E20NInstallation Manual
3. CONNECTIONS TO THE ELECTRONIC UNIT
3.1 General connections (rear view)
Figure 4. Connections to the electronic unit (rear view)
W1 10-pole Veam connector for the connection of the microphone 1.
Microphone relevant to channel 1 (and channel 2 for systems with only one
microphone).
W2 10-pole Veam connector for the connection of the microphone 2 (relevant
to channel 2). In the systems with one microphone this connector is
not present.
J1 15-pole Cannon connector for the connection to the machine logic.
J2 5-pole Lumberg connector for the connection of EGC function / analog I/O.
In the systems without this function, the connector is not present.
H1 Hirshman connector (2 poles + ground) for the connection to the power
network.

Connections to the electronic unit 19
T1 Identification plate with code and serial number of the electronic unit.
T2 Plate for the electrical characteristics of the equipment.
Terminal ( M4) for ground connection.
Warning
The ground connection of the system and of the machine tool must be
common.

20 E20NInstallation Manual
3.2 Connection to the machine logic
The connection to the machine logic is performed through a 15-pole cannon
connector (reference J1 in Figure 4 on page 18).
Warning
In the following connection diagrams, the relay outputs are represented in
rest position.
When the E20N is switched on (in case of CRASH) or when the "GAP
start cycle" signal is given (in case of GAP), the relevant relay is
energized and the state of the contacts is inverted
3.2.1 Input signals
Inputs power supply: 24V DC/AC
The 24VDC connection can be either SOURCE or SINK type.
The following connection diagrams show the different types of connection for the input
signals.
Description of the input signals
The following is a general description of all the input signals; to determine the signals
of your E20N, please see the relevant connection diagram.
pin 10 Start cycle
Normally-open contact for START CYCLE signal.
When the contact is closed, the start cycle is given
pin 3 Selection 1/2
Normally-open contact for SELECTION OF CHANNEL 1/CHANNEL 2
•Contact open = channel 1 (CH1)
•Contact closed = channel 2 (CH2)
The selection of channel 1 or channel 2 must be given at the START
CYCLE signal.
For a correct operation, the channels must not be switched during the
Gap cycle.
CRASH enable
Normally-open contact for CRASH enable.
When the contact is closed, the CRASH control is enabled.