TECNOMAGNETE ST100 Series Instructions for use
Sistema elettronico di controllo per piani magnetici
Electronic control system for magnetic chucks
Système électronique de commande pour des plateaux magnétiques
Elektronisches Steuersystem für Magnetplatten
Sistema electrónico de control para planos magnéticos
Manuale uso e manutenzione
Instruction and maintenance manual
Manuel d’utilisation et d’entretien
Betriebs- und Wartungsanleitung
Manual de uso y mantenimiento
Nr. 50 100 7816
ITALIANO
ENGLISHFRANÇAISDEUTSCHESPAÑOL
ST100
ST200
31
Instruction and maintenance manual
ENGLISH
INDEX
1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
1.11
1.12
1.13
2
2.1
2.2
2.3
2.4
3
3.1
3.2
3.3
3.4
4
4.1
4.2
4.3
5
5.1
5.2
6
6.1
6.2
6.3
7
Page
GENERAL NOTES .................................32
Overview of the company...........................32
Importance of the manual ..........................33
Storing the manual .....................................33
Conventions ...............................................33
Denition of symbols .................................33
Personnel responsible for operations ........33
Trained personal .........................................34
Individual protection means .......................34
General safety precautions.........................34
Behavior during emergency situations ......34
Limitations ..................................................34
Improper or non permitted use ..................35
Nameplate data ..........................................35
TRANSPORTATION AND
HANDLING ..............................................36
Receipt .......................................................36
Handling .....................................................36
Transportation ............................................36
Storage ......................................................36
DESCRIPTION OF THE SYSTEM ......37
Description of the controllers .....................37
Model ST100X ............................................37
Model ST200X ............................................38
Control push-buttons for ST controllers ....39
INSTALLATION ......................................43
General .......................................................43
Connecting ST100 controllers to the
power supply .............................................44
Connecting ST200 controllers to the
power supply ..............................................44
ENABLING ..............................................45
ST100 .........................................................45
ST200 .........................................................45
OPTIONAL COMPONENTS ...............46
Starting the ST100 controller .....................46
Push-button panels of models ST100
and ST200 ..................................................46
QE version ..................................................46
PLC ...........................................................46
8
8.1
8.2
8.3
8.4
9
9.1
9.2
10
11
11.1
11.2
11.3
11.4
11.5
11.6
11.7
12
13
13.1
13.2
14
14.1
14.2
15
Page
CONNECTION TO
TECNOMAGNETE MODULE .............48
Installation of miller ST100 .........................48
Installation of grinder ST100 ......................48
Installation of miller ST200 .........................49
Installation of grinder ST200 ......................50
ORDINARY USE .....................................51
ST100 .........................................................51
ST200 ........................................................51
ANALYSIS OF RESIDUAL RISKS ......52
MAINTENANCE .....................................52
Premise ......................................................52
Maintenance safety instructions.................52
Weekly maintenance ..................................53
Monthly maintenance ................................53
Maintenance to be carried out every
six months ..................................................53
Extraordinary maintenance.........................53
Information on extraordinary reparation
and maintenance ........................................53
TROUBLESHOOTING AND
CORRECTIVE ACTIONS ......................54
DECOMMISSIONING AND
DISPOSAL ...............................................54
Decommissioning ......................................54
Dismantling ................................................54
WARRANTY AND TECHNICAL
SUPPORT ................................................55
Warranty terms and conditions ..................55
Invalidity of warranty ..................................55
TECHNICAL SUPPORT SERVICE ....56
DELARATION OF
CONFORMITY .......................................57
Edition: 07-12
Replaces: 03-09
32 Instruction and maintenance manual
ENGLISH
1 GENERAL NOTES &
Thank you for purchasing one of the many products
manufactured by TECNOMAGNETE S.p.A.
This manual is designed to help you become familiar
with your new product and must therefore be care-
fully read and followed.
For further information on the system, you can con-
tact TECNOMAGNETE’s technical support at any
time.
The descriptions and illustrations provided in this
manual are for reference only.
While conrming the general characteristics
of the controllers described in the manual,
TECNOMAGNETE S.p.A. reserves the right, at its
discretion, to change at any time some of the char-
acteristics in order to improve the product or due to
manufacturing and commercial reasons. The neces-
sary updates, if required, shall be supplied as attach-
ments.
This manual is property of TECNOMAGNETE S.p.A.
and cannot be copied in whole or in part or made
available to third parties without the written authori-
zation of the manufacturer. Should the products be
amended and/or updated, upon authorization of
TECNOMAGNETE S.p.A., the manufacturer shall
integrate the existing manual by providing the text
explaining the use of the modied/integrated com-
ponent along with a description of potential residual
risks.
1.1 Overview of the company
TECNOMAGNETE started its activities in 1972 as
manufacturer of permanent-electro magnetic sys-
tems designed to ensure power, exibility and maxi-
mum safety. Its state-of-the-art technologies and the
patents developed over the years have enabled the
company to become a leading supplier in several
international markets.
The permanent-electro magnetic systems manufac-
tured by TECNOMAGNETE are able to produce all
the magnetic force required both to clamp and lift
work pieces, thus eliminating the need of using elec-
tric power during machining.
Its main elds of activity include:
CLAMPING SECTION FOR LIFTING
•
MTE permanent-electro lifters designed to ena-
ble the handling of ferrous loads of any shape and
dimension.
•
BAT-GRIP permanent-electro lifters with incor-
porated battery.
•
MaxX manual lifters.
WORK HOLDING LINE
•
QUADSYSTEM chucks for millers and machining
centers of all sizes.
•
TFP0 and TFP1 for high precision grinding.
•
RADIAL-POLE chucks for nishing or roughing
operations on boring mills.
•
QUAD-RAIL modules to clamp rails of varying
lengths.
•
MDS chucks for EDM machines.
STAMPING and MOLDING LINE
•
QUAD-PRESS systems to clamp molds.
TECNOMAGNETE has installed approximately
50,000 units in over twenty years, thanks mainly to
its wide-ranging offer, its exibility to meet custom-
ers’ requirements and its efcient post-sales serv-
ice.
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Instruction and maintenance manual
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1.2 Importance of the manual
A copy of this manual must always be made availa-
ble to the operators responsible for the installation,
operation and maintenance of the controller in order
to allow them to carry out all the required operations
in compliance with the instructions provided in the
manual.
A full compliance with the instructions provided in
this manual is an essential requirement to be able to
correctly use the equipment and ensure the safety of
operators and other people.
The manual forms integral part of the controller.
Therefore, all reproduction and divulgation rights re-
lated to the manual or its exhibits are reserved.
The manual must always be transferred to the new
owner of the machine if the latter is sold.
1.3 Storing the manual
It is severely forbidden to remove parts, tear pages
or alter this manual.
The manual should always be carefully preserved so
that it is not damaged.
Always protect the manual from excessive humidity
and heat and store it in a location where it can be
easily accessed by operators in case of need.
1.4 Conventions
To simplify consultation, the manual has been divid-
ed into the following hierarchical order so that each
phase is described in detail:
1 Section 1 of the manual.
1.1 Chapter 1 of Section 1 of the manual.
1.1.1 Paragraph 1 of Chapter 1 of Section 1 of
the manual.
1.1.1.1 Subparagraph 1 of paragraph 1 of Chap-
ter 1 of Section 1 of the manual.
Some chapters and/or sections contain bulleted lists
to allow operators to follow the operation described
step by step.
Parts that require specic attention are highlighted
with symbols.
1.5 Definition of symbols
All information related to safety is highlighted in bold.
All warnings that draw the attention of operators on
operations that may be hazardous in terms of safety
or health or that may cause physical injuries, if the
applicable instructions are not followed, are high-
lighted in red and marked with the following sym-
bol:
All warnings related to operations that have to be
carried out by skilled and qualied personnel are
highlighted in bold and marked with the following
symbol:
1.6 Personnel responsible for operations
Some operations, as stated in this manual, can only
be performed by qualied and skilled personnel. The
qualication level is described by means of the fol-
lowing standard denitions:
•
Qualied personnel is personnel with specic
technical knowledge and/or the experience nec-
essary to avoid potential risks originating from
power supply (engineers and technicians).
•
Trained staff is personnel that operates following
the instructions and/or under the supervision of
qualied personnel, who is responsible for verify-
ing that they are not exposed to potential hazards
resulting from the contact with power (personnel
responsible for operation and maintenance). This
personnel must have the following qualications:
1. All personnel must be trained and authorized to
disconnect the machine from the power supply, to
connect it to the grounding system and to mark
circuits and equipment following standard safety
procedures.
2. All personnel must have been specically trained
to follow correct maintenance procedures and
use the protective equipment in accordance with
standard safety procedures.
•
Before using the unit, users shall always have to
verify with authorized personnel that:
1. All personnel has received a copy, has read and
understood the content of the instruction manu-
al.
2. All personnel has agreed to follow the instructions
provided.
34 Instruction and maintenance manual
ENGLISH
1.7 Trained personal
•
OPERATORS: workers who, after receiving the
necessary instructions, have been authorized by
the owner to operate the controller and the equip-
ment connected to it. Workers with this qualica-
tion must be thoroughly familiar with the content
of this manual.
•
ELECTRIC MAINTENANCE TECHNICIAN (ref.
EN60204 paragraph 3.45): this qualication is as-
signed to all personnel specically trained to per-
form operation on electric components, which in-
clude connections, adjustments, maintenance
and/or reparations, and to personnel who is qual-
ied to perform operations inside electric cubicles
and boards. This qualication implies having a
perfect knowledge and full familiarity with the
content of this manual.
1.8 Individual protection means
The personnel referred to in the paragraph above
must always wear suitable protective clothing
and use the protection means generally required
to operate the tool machine on which the Tec-
nomagnete module and controller are installed.
In particular, personnel shall always have to wear
industrial shoes along with ear protection, hel-
mets and goggles, if required.
All personnel should refrain from wearing loose
clothing that could get tangled with moving com-
ponents.
1.9 General safety precautions
The instructions and recommendations provided
below comply with current safety regulations and
imply the obligation of complying with applicable
provisions.
TECNOMAGNETE S.p.A. shall not be responsible
for damages caused to people or equipment
originating from the failure to follow applicable
safety provisions and to comply with the instruc-
tions given below.
All operators are therefore expected to follow the
instructions below and to thoroughly comply with
the safety procedures concerning the installation
and use of the equipment applicable in the coun-
try in which the unit is used.
All ordinary and extraordinary maintenance op-
erations shall have to be carried only after the
unit has been disconnected from the power sup-
ply.
Before connecting the power cable, it is essential
to verify that the line voltage complies with the
one shown on the nameplate of the controller.
All transportation, installation, ordinary and ex-
traordinary maintenance operations performed
on the controller must be carried out only by per-
sonnel with the qualifications stated in Chapter
1.6 and 1.7.
1.10 Behavior during emergency
situations
In the event of emergency, it is always advisable
to follow the procedures outlined in the operation
and maintenance manual of the machine on
which the controller is installed.
In the event of fire, always use the extinguishing
means provided being careful not to use water to
extinguish fires on electric parts.
1.11 Limitations
The unit can be used only for the applications
specified in operating instructions and only in
combination with the equipment and compo-
nents recommended by TECNOMAGNETE S.p.A.
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Instruction and maintenance manual
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1.12 Improper or non permitted use
The controller is not designed and has not been
manufactured to be used in explosive environ-
ments.
An improper use may:
•
Cause injuries to personnel.
•
Damage the controller or any other equipment
connected to it.
•
Affect the reliability and performance of the
controller.
In particular, it is essential to adhere to the fol-
lowing instructions:
•
Always use suitable working parameters.
•
Carry out the required maintenance in accord-
ance with the instructions provided.
•
Use suitable equipment.
•
Comply with all the instructions provided.
•
Fix the unit onto a stable surface.
•
Contact TECNOMAGNETE S.p.A. in case of
doubt to determine whether a specific opera-
tion is permitted.
1.13 Nameplate data
The controller is tted with an identication label in
compliance with current laws.
ATTENTION
The nameplate should never be removed even if
the unit is resold.
If the nameplate is damaged or has been
removed, it is necessary to contact
TECNOMAGNETE S.p.A. to order a duplicate.
Always quote the model printed on the
nameplate in all communications with
TECNOMAGNETE S.p.A.
Failure to comply with the above instructions
shall entitle TECNOMAGNETE S.p.A. to disclaim
any responsibility for injuries to personnel and
damage to equipment, making the user fully re-
sponsible before competent authorities.
36 Instruction and maintenance manual
ENGLISH
2 TRANSPORTATION AND
HANDLING
The unit is shipped in a cardboard box, covered with
a plastic sheet and enveloped by polyurethane foam
to protect it from damage in the event of impacts or
accidents.
2.1 Receipt
All units are carefully inspected before shipping.
Upon receipt, customers should verify that the
packaging and the material inside it has not
been damaged (unless otherwise instructed by
TECNOMAGNETE S.p.A.) in order to ensure that the
unit has not been damaged during transport and that
the material supplied complies with order specica-
tions. Visible transport damages should be immedi-
ately reported to TECNOMAGNETE S.p.A. and the
forwarding agent.
ATTENTION
All damages and anomalies must be reported within
ten days from receiving the goods.
2.2 Handling
Weight of model ST100: 0,4 kg.
Weight of model ST200: 2,0 kg.
Always keep the original packaging so that it can
be used to transport the unit if needed.
2.3 Transportation
The unit should always be transported within the fol-
lowing environmental limits: temperature ranging
from –10°C to +55°C, with temperature increase up
to 70°C for a maximum of 24 hours.
If the unit requires the use of specic transportation
means (by sea or air), special provisions shall have to
be adopted in order to protect it from damages
caused by potential impacts. The box should also
contain hygroscopic salts to protect the unit from
atmospheric agents.
2.4 Storage
The unit should always be throughly cleaned and
adequately protected when stored for long periods
of time.
Disconnect the controller from the magnetic chuck
and from the power supply.
It is generally advisable to cover the unit with a wa-
terproof bag and store it in dry and safe place.
The temperature of the storage area should range
between 0°C (32°F) and 55°C (131°F).
Relativy humidity should be between 30% and 90%,
non condensing.
The atmosphere should be clean, free from acids,
corrosive gases, salts, etc
When restarting the machine, always follow the in-
structions provided in Chapter 4.
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Instruction and maintenance manual
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3 DESCRIPTION
OF THE SYSTEM
3.1 Description of the controllers
ST is an innovative electronic controller for
networked chucks designed for milling and grin-
ding operations.
The sections that follow provide information on the
size and the basic characteristics of the available
models:
•
ST100F (milling)
•
ST100R (grinding)
•
ST200F (milling)
•
ST200R (grinding)
3.2 Model ST100X
The rated operating voltage is 230V.
The control push-button panel is integrated in to the
controller.
The control electronics are situated under the control
push-button panel and enclosed in a plastic hou-
sing.
To simplify installation and facilitate the reading of
the push-button panel, it is also possible to install
the controller on a workbench or mount it on the wall
by simply rotating the control panel.
The plastic material of the housing ensures a high
level of insulation and the utmost safety during use.
The rear part of the controller has a block with a male
pin (designed to be connected to the power cable),
an ON–OFF (0-1) switch and a fuse-holder with two
12.5A protection fuses (type 5x20 mm). Two or more
cable ties for the output of the discharge cables of
the chucks to be magnetized may be present next to
these components.
The maximum useful current that ows into the
ST100X controller is approximately 12.5A; the cur-
rent supplied to the module is impulsive with a cycle
time around a few hundreds of milliseconds (app. 1
second per discharge).
ST100X controllers are suitable to control small
chucks with a single phase voltage of 230V and a
maximum absorption of rated current of 3kW.
For different rated voltages, use a transformer with a
suitable transformation ratio and a rating suitable to
handle the maximum power of the chuck or at any
rate a maximum power of 4kVA. For example, if the
available voltage is 400V, a transformer with a
400/230 transformation ratio is required.
ATTENTION! Control units can be moved only
when controls are not powered.
135
135
40
50
75
135
40
MAIN PARTS
A ➜ Main switch
B ➜ Push-button panel
C ➜ Discharge cable output
D ➜ Start contact
E ➜ Power supply input
Fuse-holder Main Power supply
switch input
Rear
38 Instruction and maintenance manual
ENGLISH
3.3 Model ST200X
The rated operating voltage of this controller varies
according to the type of magnetic chuck to which it
is connected.
The control push-button is external, but can also be
integrated into the controller.
The control electronics are enclosed in a metal hous-
ing. The metal material of the housing is grounded in
order to guarantee maximum safety during the ena-
bling cycles.
It is important to verify that the grounding system is
always in good working order.
The controller does not have a socket for the con-
nection to the power supply. The controller has an
ON–OFF (0-1) switch, thus to adequately protect it
against short circuits, it is necessary to install a suit-
able protection system upstream from the controller.
It is generally advisable to use a magneto thermal
switch (curve C) with an In value compliant with the
rating specied on the magnetic chuck nameplate
that will be connected to the controller.
The maximum power of controller ST200X is ap-
proximately 25kW per discharge if the single phase
power supply is 400V, 15kW for power supplies of
230V and 30kW for power supplies of 480V. The ab-
sorbed current is impulsive with a cycle time around
a few hundreds of milliseconds (approximately 1
second per discharge).
ST200X controllers are suitable to power single
chucks or chucks that are part of large magnetic
banks
When using chucks with a different rated voltage,
install a transformer with a suitable transformation
ratio and a rated power that matches the maximum
power of the chuck.
It is also possible to order a compact version for
ST200-QE electric cabinets with supporting terminal
board, to power the controller and magnetic chuck,
with interface connector and push-button panel.
275
331
85
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Instruction and maintenance manual
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3.4 Control push-buttons for ST
controllers
ST controllers can be connected to the push-button
panels described below.
3.4.1 ST100 (basic version),
ST200 (basic version)
This push-button panel is the base model used to
control milling chucks.
It is tted with the following three-buttons:
•
Magnetization FULL-MAG,
•
Demagnetization DEMAG,
•
Enabling ENABLE.
The ENABLE button is used together with the mag-
netization and demagnetization button, depending
on the cycle that needs to be performed.
There are also 4 indicator lights placed next to the
FULL-MAG and DEMAG buttons and the CYCLE
and ALARM symbols.
These indicator lights provide information on the sta-
tus of the controller. When the controller is started,
the corresponding LED indicator switches on.
If a cycle is active, the only LED that is on is the one
related to the cycle, while all the others are off.
At the end of the cycle, the only visual indication that
is on is the one related to the new system status.
G
DEF
A C
B
PUSH-BUTTON PANEL
A
➜ FULL-MAG button
B
➜ ENABLE button
C
➜ DEMAG button
D
➜ MAG led
E
➜ Cycle led
F
➜ DEMAG led
G
➜ Alarm status led
System status MAG Led DEMAG Led Cycle Led Alarm Led
Full-Mag Permanently on Off Off Off
Demag Off Permanently on Off Off
Cycle Off Off Permanently on Off
Current alarm Off Off Off Permanently on
Communication
alarm
*
Off Off Off On ashing
*
For version ST200 only
40 Instruction and maintenance manual
ENGLISH
3.4.2 ST100 (version with 2 levels),
ST200 (version with 2 levels)
To be able to use different levels of magnetization, it
is possible to replace the push-button panel de-
scribed above with a 2-level model that enables to
control milling and grinding chucks.
This push-button panel has the following ve but-
tons:
•
Magnetization FULL-MAG,
•
Partial magnetization MAG-1L
•
Partial magnetization MAG-2L
•
Demagnetization DEMAG,
•
Enabling ENABLE.
The magnetization buttons MAG-1L, MAG-2L and
FULL-MAG enable to select three different levels of
magnetization.
The ENABLE button is used together with the mag-
netization and demagnetization buttons, depending
on the cycle that needs to be performed.
There are also 4 indicator lights placed next to the
FULL-MAG and DEMAG buttons and the CYCLE
and ALARM symbols.
These indicator lights provide information on the sta-
tus of the controller. When the controller is started,
the corresponding LED indicator switches on.
If a cycle is active, the only LED that is on is the one
related to the cycle, while all the others are off.
At the end of the cycle, the only visual indication that
is on is the one related to the new system status.
FULL-MAG and DEMAG indicator lights are always
on; MAG-1L and MAG-2L ash only during partial
magnetization cycles.
GH
DEF
AC
B
PUSH-BUTTON PANEL
A
➜ FULL-MAG button
B
➜ ENABLE button
C
➜ DEMAG button
D
➜ FULL-MAG led (xed) of MAG led for partial
magnetization (ashing)
E
➜ Cycle Led
F
➜ DEMAG Led
G
➜ 2nd level MAG button
H
➜ Alarm status Led
I
➜ 2nd level MAG button
System status MAG Led DEMAG Led Cycle Led Alarm Led
Full-Mag Permanently on Off Off Off
Demag Off Permanently on Off Off
Mag Level 1 On ashing Off Off Off
Mag Level 2 On ashing Off Off Off
Cycle Off Off Permanently on Off
Current alarm Off Off Off Permanently on
Communication
alarm
*
Off Off Off On ashing
*
For version ST200 only
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3.4.3 ST200 (model with 7 levels)
To be able to use several levels of magnetization, it is
possible to replace the basic push-button panel with
a 7-level model that enables to control milling and
grinding chucks.
This push-button panel has the following ve but-
tons:
•
Magnetization MAG,
•
Increase of magnetization
level +
•
Reduction of magnetization
level –
•
Demagnetization DEMAG,
•
Enabling ENABLE.
The ENABLE button is used together with the mag-
netization and demagnetization buttons, depending
on the cycle that needs to be performed.
There are also ve indicator lights placed next to the
full FULL-MAG, DEMAG, + and – buttons and the
CYCLE and ALARM buttons.
These indicator lights are used to provide informa-
tion on the status of the system, which is automati-
cally reset to the last operating cycle.
Once the start sequence has been successfully
completed, the indicator light corresponding to the
total/partial magnetization or demagnetization
switches on, depending on the option selected. A
failure in the start sequence switches on the central
alarm indicator light.
If a cycle is active, the only LED that is on is the one
related to the cycle, while all the others are off.
The FULL-MAG and DEMAG indicator lights are al-
ways on and ash during partial magnetization cy-
cles only.
J
G
I
H
D
E
F
A
C
B
PUSH-BUTTON PANEL
A
➜ MAG button
B
➜ ENABLE button
C
➜ DEMAG button
D
➜ Button +
E
➜ Button -
6
➜ FULL-MAG Led (xed) of MAG Led for
partial magnetization (ashing)
G
➜ Cycle Led
H
➜ DEMAG Led
I
➜ Alarm status Led
J
➜ Level selection LED (levels from 1 to 7) and
FULL-MAG 8
System status MAG Led DEMAG Led Cycle Led Alarm Led
Full magnetization
Level 8 Permanently on Off Off Off
Demag Off Permanently on Off Off
Partial magnetization
Levels 1-7 On ashing Off Off Off
Cycle Off Off Permanently on Off
Current alarm Off Off Off Permanently on
Communication
alarm
*
Off Off Off On ashing
*
For version ST200 only
42 Instruction and maintenance manual
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3.4.4 ST200 CH-ENABLE
This push-button panel can be used when you need
to select different discharge levels for the magnetic
chucks, i.e. enable or disable the desired discharge.
The push-button panel can be used in combination
with a push-button and LED to manage selections.
It has four buttons that enable to select/deselect the
desired discharge channel. The status of the channel
is shown by the corresponding LED.
After you have selected the discharge sequence,
you can also specify which discharges have to be
carried out with a full or partial magnetization and/or
select them with the appropriate buttons (CH1, CH2,
CH3 and CH4).
The status LEDs are off when the corresponding
magnetic chuck is in DEMAG mode, are on (though
not ashing) in FULL-MAG mode and ashing when
the partial magnetization mode is selected.
The cycle LEDs shall be on (though not ashing)
when a cycle is in progress and off when no cycle is
in progress.
Alarm LEDs are on (though not ashing) during all
alarm conditions, except for communication alarms.
M
I
JN
D
H
EF
AB
C
L
G
K
PUSH-BUTTON PANEL
A
➜ CH1 selection button
B
➜ CH2 selection button
C
➜ CH3 selection button
D
➜ CH4 selection button
E
➜ FULL-MAG Led (xed) of MAG Led for partial
magnetization (ashing), discharge 1
F
➜ FULL-MAG Led (xed) of MAG Led for partial
magnetization (ashing), discharge 2
G
➜ FULL-MAG Led (xed) of MAG Led for partial
magnetization (ashing), discharge 3
H
➜ FULL-MAG Led (xed) of MAG Led for partial
magnetization (ashing), discharge 4
I
➜ Cycle Led
J
➜ Alarm status Led
K
➜ CH1 selection Led
L
➜ CH2 selection Led
M
➜ CH3 selection Led
N
➜ CH4 selection Led
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Instruction and maintenance manual
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4 INSTALLATION
4.1 General
Electric safety can be guaranteed only if the electric
system is correctly connected to a grounding sys-
tem in good working order, as foreseen by current
laws concerning electric safety. Therefore, it is es-
sential to always verify this safety requirements be-
fore starting the unit and have the distribution sys-
tem carefully inspected by qualied personnel in
case of doubt. TECNOMAGNETE S.p.A. shall not be
responsible for damages originating from the failure
to connect the unit to an appropriate grounding sys-
tem.
Users shall have to make sure that the unit is pro-
tected with a differential magnetothermal switch
suitable to withstand the rated current used by the
system. It is therefore necessary to install a suitable
protection with magnetothermal switch (curve C)
with a In value compliant with nameplate data.
TECNOMAGNETE systems are permanent-electro
systems, which means that they need to be powered
only during the short cycle phases. This congura-
tion is designed to ensure maximum safety in the
event of power failure.
TECNOMAGNETE controllers use the power supply
by means of a sophisticated partializing process,
which means that they can be operated only when
the machine is idle and that they require a rated cur-
rent that is normally lower than the one required to
operate the machine on which the magnetic system
being controlled is installed.
ATTENTION
Do not perform repeated MAGNETIZATION/DE-
MAGNETIZATION CYCLES
TECNOMAGNETE systems are constituted by per-
manent magnets and use electric power only to en-
able/disable the area being machined. Therefore,
they can be regarded “COLD” magnetic clamping
systems.
The repetition of MAGNETIZATION/DEMAGNETI-
ZAZION cycles at very close intervals may increase
the temperature of the magnetic chuck, especially
when using controllers with DEMAG NUFLUX cycle.
It is therefore advisable to run cycles only when nec-
essary.
The connection of the magnetic chuck to the power
supply must be carried out by qualied personnel
only.
Check the supply voltage and frequency.
The electrical supply to the controller must be sin-
gle-phase 230V/400V/480V (phase + neutral) or two-
phase (phase + phase).
ATTENTION
ST100 controllers are designed to operate with sup-
ply voltages of 230V 50/60 Hz and cannot therefore
be used for Tecnomagnete modules with lower or
higher ratings. To use different voltages, install a
transformer with a suitable rating (not above 4 kVA)
or contact TECNOMAGNETE S.p.A. for assistance.
ATTENTION
ST200 controllers are designed to operate with
supply voltages of 200V - 480V at 50/60 Hz and
can therefore be used, after validation, to enable
TECNOMAGNETE modules with different voltage
specications. To use different voltages, install a
transformer with a rating compliant to that of the
magnetic chuck or contact TECNOMAGNETE S.p.A.
for assistance.
ATTENTION
All cables supplied must have a bending radius with
a diameter <10mm and a tension of >15N/mm2. In-
stallation must always be performed by qualied
technicians in accordance with current law require-
ments.
44 Instruction and maintenance manual
ENGLISH
4.2 Connecting ST100 controllers to the
power supply
4.2.1 Connecting the controller to the power
supply
The controller must be supplied with a single-phase
voltage. The multi-pole cable supplied with the con-
troller has three leads suitable for the purpose.
The controller cannot be powered from the three-
phase + neutral distribution network that supplies
the tool machine used. If the voltage required for the
controller is not available, install a power transformer
with a rating suited for the magnetic chuck.
F
N
PE
BLACK
BROWN
YELLOW/GREEN
Single-phase power supply
4.2.2 Power cable
TECNOMAGNETE supplies a suitable multi-pole
power cable with a standard length of two meters,
which prevents overheating problems and a voltage
drop within the rating of the TECNOMAGNETE mod-
ule, if used in ordinary operating conditions.
Before using longer cables, always make sure that
the cable section used guarantees a voltage drop
below 1%.
Ordinary operating conditions are intended as inter-
mittent working cycles, with intervals of at least one
minute between two enabling cycles.
4.2.3 Selecting the correct dimensions for dis
charge cables
The discharge cable tted on ST100 comprises suit-
able leads, has a standard length of three meters
and is dimensioned to prevent overheating and the
loss of power on the chuck in ordinary operating
conditions.
Ordinary operating conditions are intended as ena-
bling/disabling cycles occurring at an interval above
1 minute.
Before using longer cables, always make sure that
the cable section used guarantees a voltage drop
below 1%.
4.2.4 Electric specifications
The fuses of model ST100 model are 12.5A lagged
fuses with a length of 20 mm and a diameter of 5 mm
(20 x 5 mm).
4.3 Connecting ST200 controllers to the
power supply
4.3.1 Connecting the controller to the power
supply
The controller must be supplied with a single-phase
voltage. The supplied multi-pole cable has three
leads suitable for the purpose, two for the phase and
neutral terminals (or phase) and one for the earth
(yellow/green).
The controller cannot be powered from the three-
phase + neutral distribution network that supplies
the tool machine used. If the voltage required for the
controller is not available, install a power transformer
with a rating suited for the magnetic chuck.
F
N
PE
BLACK
BROWN
YELLOW/GREEN
R
S
T
PE
BLACK
BROWN
YELLOW/GREEN
Single-phase power supply
Three-phase power supply
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Instruction and maintenance manual
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4.3.2 Power cable
TECNOMAGNETE supplies a suitable multi-pole
power cable with a standard length of four meters,
which prevents overheating problems and a voltage
drop within the rating of the TECNOMAGNETE mod-
ule, if used in ordinary operating conditions.
Before using longer cables, always make sure that
the cable section used guarantees a voltage drop
below 1%.
Ordinary operating conditions are intended as inter-
mittent working cycles, with intervals of at least one
minute between two enabling cycles.
4.3.3 Selecting the correct dimensions for dis-
charge cables
The discharge cable tted on ST200 comprises four
leads suitable for the purpose, has a standard length
of six meters and is dimensioned to prevent over-
heating and the loss of power on the chuck in ordi-
nary operating conditions.
Ordinary operating conditions are intended as ena-
bling/disabling cycles occurring at an interval above
1 minute.
Before using longer cables, always make sure that
the cable section used guarantees a voltage drop
below 1%.
4.3.4 Electric specifications
All ST200 controllers are available as single and two-
phase models; the maximum installed power for
each cycle is 25 kVA (cosϕ=0.9) for two-phase 400V
plants, 15kVA for 230V plants and 32 kVA for 480V
plants.
To optimally protect the installation, it is necessary to
install a suitable magnetothermal switch (curve C)
with an In value compliant with the rating specied
on the nameplate.
5 ENABLING
5.1 ST100
ST100 controllers are not tted with a specic ena-
bling device, which may however be ordered as op-
tional (see Chapter 6.1).
5.2 ST200
The ST200 controller has an enabling device tted
on connector DB9 situated on the rear of the control-
ler (PINS 8 and 9).
The technical specications for the contact are:
•
Voltage 30V, current 1A
•
Voltage 110V, current 0.3A
It is always advisable to use an auxiliary relay.
Before using other models of start systems, contact
TECNOMAGNETE S.p.A. for assistance.
When at least one of the magnetic chucks controlled
by ST200 is in magnetization mode, the enabling
contact is closed. PINS 6 and 7 can be connected to
the power of the tool machine and used to run the
enabling cycles through the controller: the controller
can only run the cycles when PINS 6 and 7 are clo-
sed. Connect the safety catch to the operating ma-
chine on which the TECNOMAGNETE module is in-
stalled.
DB9 PIN connector
5 4 3 2 1
9 8 7 6
ENABLE ENABLE
MACHINE CONTROLLER
pin n° 1 ➜ B1
pin n° 2 ➜ A2
pin n° 3 ➜ Vdc
pin n° 4 ➜ Gnd
pin n° 5 ➜ Alarm
pin n° 6 ➜ COM ENABLE Controller
pin n° 7 ➜ ENABLE Controller
pin n° 8 ➜ COM ENABLE machine
pin n° 9 ➜ ENABLE machine
When possible, it is advisable to use both types of
contacts.
46 Instruction and maintenance manual
ENGLISH
6 OPTIONALS
6.1 Starting the ST100 controller
ST100 models can be tted with an optional external
start button, connected with means of a male/female
connector.
When the magnetic chuck is controlled by the ST100
controller, it is magnetized, which means that the
controller enabling contact is closed
The technical specications for the contact are:
•
30V voltage, 1A current
•
110V voltage, 0.3A current
It is generally advisable to use an auxiliary relay.
Before using other models of start systems, contact
TECNOMAGNETE S.p.A. for assistance.
6.2 Push-button panels of models ST100
and ST200
ST100 controllers can be tted with an optional two-
level push-button panel for milling and grinding
chucks.
Model ST200 can instead be tted with an optional
2-level push-button panel for milling and grinding
operations and with a 7-level push-button panel.
It is also possible to remotely connect all models of
push-button panels (basic, 2-level, 7-level).
6.3 QE version
On models QE it is possible to use an optional exter-
nal teleruptor with a power rating compliant to the
one printed on the nameplate of the connected mag-
netic chuck. Said teleruptor must be installed in ac-
cordance with the instructions provided on the elec-
tric wiring diagram supplied with the equipment.
This device ensures a more efcient control of the
electric commands through the machine.
7 PLC
Model ST100 is not tted with a PLC interface that
can be used for control purposes.
Model ST200 has a PLC interface that is constituted
by an external housing that has to be connected to
the controller by means of the DB9 connector. The
interface is constituted by a DB37 pin connector de-
signed to be interfaced with the control system and
used to receive the magnetization/demagnetization
enabling controls, to increase and reduce the mag-
netization levels and to provide indications on the
machine status.
The function of available contacts is described be-
low.
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Instruction and maintenance manual
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19 1
37 20
Pin Name Direction Description
1 SW Mag Magnetization button
2 SW Demag Demagnetization button
3 SW Level + Button that increases the magnetization level
4 SW Level - Button that decreases the magnetization level
5 Abilit PLC Enabling input for PLC management
6 Input Enable Input-Enable input
7 nc Not connected
8 nc Not connected
9 nc Not connected
10 Level 1 1st level magnetization output
11 Level 2 2nd level magnetization output
12 Level 3 3rd level magnetization output
12 Level 4 4th level magnetization output
14 Level 5 5th level magnetization output
15 Level 6 6th level magnetization output
16 Level 7 7th level magnetization output
17 Level 8 8th level magnetization output
18 COM Normally open common contact Out-Abilit
19 NO2 Normally open contact Out-Abilit
20 Wait Output, cycle in progress
21 Alarm Alarm output
22 Ld3 Not used
23 Ld5 Not used
24 Out2 Not used
25 Out1 Not used
26 nc Not connected
27 nc Not connected
28 Vext Common contact for buttons Mag, Demag, Level+, Level-
29 Vext Insulated 24Vdc (power supply provided by customer)
30 Vext Insulated 24Vdc (power supply provided by customer)
31 Rif Common contact for output statuses
32 Rif Insulated 0V (reference to customer power supply)
33 Rif Insulated 0V (reference to customer power supply)
34 Mag Magnetization status output
35 Demag Demagnetization status output
36 COM Normally open common contact Out-Abilit
37 NO2 Normally open contact Out-Abilit
48 Instruction and maintenance manual
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8 CONNECTION TO THE
TECNOMAGNETE MODULE
8.1 Installation of miller ST100
8.2 Installation of grinder ST100
Magnetic
module
Connector
Discharge cable
Controller
Power supply
Cable tie
Power supply
Controller
Discharge cable
Magnetic
module
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Instruction and maintenance manual
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8.3 Installation of miller ST200
Power supply
Push-button panel
CH ENABLE push-button panel
Enabling
Discharge
Discharge
PLC interface
ON/OFF
4 PIN connector
7 PIN connector
Junction box
Controller
ST200
Controller
ST200
Controller
ST200
Controller
ST200
Installation of Installation of
1 chuck 3 chucks
Magnetic chucks
Magnetic chuck
Installation of Installation of
2 chucks 4 chucks
Magnetic chucks
Magnetic chucks
This manual suits for next models
4
Table of contents
