st100, st200 - Series
st100, st200 - Series
ST100
ITALIANO
ENGLISH
ST200
FRANÇAIS
DEUTSCH
ESPAÑOL
Manuale uso e manutenzione
Instruction and maintenance manual
Manuel d’utilisation et d’entretien
Betriebs- und Wartungsanleitung
Manual de uso y mantenimiento
ENGLISH
1.11 Limitations...................................................34
10 ANALYSIS OF RESIDUAL RISKS.......52
1.12 Improper or non permitted use...................35
1.13 Nameplate data...........................................35
11 MAINTENANCE......................................52
2 TRANSPORTATION AND 11.1 Premise ......................................................52
11.2 Maintenance safety instructions.................52
HANDLING...............................................36
11.3 Weekly maintenance...................................53
2.1 Receipt........................................................36
11.4 Monthly maintenance .................................53
2.2 Handling......................................................36
11.5 Maintenance to be carried out every
2.3 Transportation.............................................36
six months...................................................53
2.4 Storage . .....................................................36
11.6 Extraordinary maintenance.........................53
11.7 Information on extraordinary reparation
3 DESCRIPTION OF THE SYSTEM. .....37 and maintenance.........................................53
3.1 Description of the controllers......................37
3.2 Model ST100X.............................................37
12 TROUBLESHOOTING AND
3.3 Model ST200X.............................................38
3.4 Control push-buttons for st controllers ....39 CORRECTIVE ACTIONS. .....................54
7 PLC............................................................46
Edition: 07-12
Replaces: 03-09
Instruction and maintenance manual 31
1 GENERAL NOTES & 1.1 Overview of the company
Thank you for purchasing one of the many products TECNOMAGNETE started its activities in 1972 as
manufactured by TECNOMAGNETE S.p.A. manufacturer of permanent-electro magnetic sys-
tems designed to ensure power, flexibility and maxi-
This manual is designed to help you become familiar mum safety. Its state-of-the-art technologies and the
with your new product and must therefore be care- patents developed over the years have enabled the
fully read and followed. company to become a leading supplier in several
For further information on the system, you can con- international markets.
tact TECNOMAGNETE’s technical support at any The permanent-electro magnetic systems manufac-
time. tured by TECNOMAGNETE are able to produce all
the magnetic force required both to clamp and lift
The descriptions and illustrations provided in this work pieces, thus eliminating the need of using elec-
ENGLISH
A copy of this manual must always be made availa- All information related to safety is highlighted in bold.
ble to the operators responsible for the installation, All warnings that draw the attention of operators on
operation and maintenance of the controller in order operations that may be hazardous in terms of safety
to allow them to carry out all the required operations or health or that may cause physical injuries, if the
in compliance with the instructions provided in the applicable instructions are not followed, are high-
manual. lighted in red and marked with the following sym-
bol:
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. All warnings related to operations that have to be
ENGLISH
The manual forms integral part of the controller. carried out by skilled and qualified personnel are
Therefore, all reproduction and divulgation rights re- highlighted in bold and marked with the following
lated to the manual or its exhibits are reserved. symbol:
It is severely forbidden to remove parts, tear pages Some operations, as stated in this manual, can only
or alter this manual. be performed by qualified and skilled personnel. The
qualification level is described by means of the fol-
The manual should always be carefully preserved so lowing standard definitions:
that it is not damaged. • Qualified personnel is personnel with specific
technical knowledge and/or the experience nec-
Always protect the manual from excessive humidity
essary to avoid potential risks originating from
and heat and store it in a location where it can be
power supply (engineers and technicians).
easily accessed by operators in case of need.
• Trained staff is personnel that operates following
the instructions and/or under the supervision of
1.4 Conventions qualified personnel, who is responsible for verify-
ing that they are not exposed to potential hazards
To simplify consultation, the manual has been divid- resulting from the contact with power (personnel
ed into the following hierarchical order so that each responsible for operation and maintenance). This
phase is described in detail: personnel must have the following qualifications:
1. All personnel must be trained and authorized to
1 Section 1 of the manual. disconnect the machine from the power supply, to
connect it to the grounding system and to mark
1.1 Chapter 1 of Section 1 of the manual.
circuits and equipment following standard safety
1.1.1 Paragraph 1 of Chapter 1 of Section 1 of procedures.
the manual.
2. All personnel must have been specifically trained
1.1.1.1 Subparagraph 1 of paragraph 1 of Chap- to follow correct maintenance procedures and
ter 1 of Section 1 of the manual. use the protective equipment in accordance with
standard safety procedures.
Some chapters and/or sections contain bulleted lists • Before using the unit, users shall always have to
to allow operators to follow the operation described verify with authorized personnel that:
step by step.
1. All personnel has received a copy, has read and
Parts that require specific attention are highlighted understood the content of the instruction manu-
with symbols. al.
2. All personnel has agreed to follow the instructions
provided.
Instruction and maintenance manual 33
All operators are therefore expected to follow the
1.7 Trained personal instructions below and to thoroughly comply with
the safety procedures concerning the installation
• OPERATORS: workers who, after receiving the and use of the equipment applicable in the coun-
necessary instructions, have been authorized by try in which the unit is used.
the owner to operate the controller and the equip-
All ordinary and extraordinary maintenance op-
ment connected to it. Workers with this qualifica-
erations shall have to be carried only after the
tion must be thoroughly familiar with the content
unit has been disconnected from the power sup-
of this manual.
ply.
• ELECTRIC MAINTENANCE TECHNICIAN (ref.
Before connecting the power cable, it is essential
EN60204 paragraph 3.45): this qualification is as-
to verify that the line voltage complies with the
signed to all personnel specifically trained to per-
one shown on the nameplate of the controller.
form operation on electric components, which in-
clude connections, adjustments, maintenance
ENGLISH
The personnel referred to in the paragraph above In the event of emergency, it is always advisable
must always wear suitable protective clothing to follow the procedures outlined in the operation
and use the protection means generally required and maintenance manual of the machine on
to operate the tool machine on which the Tec- which the controller is installed.
nomagnete module and controller are installed.
In the event of fire, always use the extinguishing
In particular, personnel shall always have to wear means provided being careful not to use water to
industrial shoes along with ear protection, hel- extinguish fires on electric parts.
mets and goggles, if required.
All personnel should refrain from wearing loose 1.11 Limitations
clothing that could get tangled with moving com-
ponents.
1.9 General safety precautions 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.
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.
ENGLISH
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.
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.
2.4 Storage
ENGLISH
• ST100F (milling) 135
• ST100R (grinding)
• ST200F (milling)
• ST200R (grinding)
50
75
3.2 Model ST100X
Rear
The controller does not have a socket for the con- power of the chuck.
nection to the power supply. The controller has an
ON–OFF (0-1) switch, thus to adequately protect it It is also possible to order a compact version for
against short circuits, it is necessary to install a suit- ST200-QE electric cabinets with supporting terminal
able protection system upstream from the controller. board, to power the controller and magnetic chuck,
It is generally advisable to use a magneto thermal with interface connector and push-button panel.
switch (curve C) with an In value compliant with the
rating specified on the magnetic chuck nameplate
that will be connected to the controller.
275
33
1
85
ENGLISH
PUSH-BUTTON PANEL
• Demagnetization DEMAG,
A ➜ FULL-MAG button
• Enabling ENABLE.
B ➜ ENABLE button
The ENABLE button is used together with the mag- C ➜ DEMAG button
netization and demagnetization button, depending
D ➜ MAG led
on the cycle that needs to be performed.
E ➜ Cycle led
There are also 4 indicator lights placed next to the
F ➜ DEMAG led
FULL-MAG and DEMAG buttons and the CYCLE
and ALARM symbols. G ➜ Alarm status led
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.
System status MAG Led DEMAG Led Cycle Led Alarm Led
• Demagnetization DEMAG,
• Enabling ENABLE.
The magnetization buttons MAG-1L, MAG-2L and
FULL-MAG enable to select three different levels of
magnetization.
G B H
The ENABLE button is used together with the mag-
netization and demagnetization buttons, depending PUSH-BUTTON PANEL
on the cycle that needs to be performed.
A ➜ FULL-MAG button
There are also 4 indicator lights placed next to the
FULL-MAG and DEMAG buttons and the CYCLE B ➜ ENABLE button
and ALARM symbols. C ➜ DEMAG button
These indicator lights provide information on the sta- D ➜ FULL-MAG led (fixed) of MAG led for partial
tus of the controller. When the controller is started, magnetization (flashing)
the corresponding LED indicator switches on.
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
ENGLISH
• Demagnetization DEMAG,
• Enabling ENABLE. C E
System status MAG Led DEMAG Led Cycle Led Alarm Led
Full magnetization
Permanently on Off Off Off
Level 8
Demag Off Permanently on Off Off
Partial magnetization
On flashing Off Off Off
Levels 1-7
Cycle Off Off Permanently on Off
PUSH-BUTTON PANEL
The status LEDs are off when the corresponding
magnetic chuck is in DEMAG mode, are on (though A ➜ CH1 selection button
not flashing) in FULL-MAG mode and flashing when B ➜ CH2 selection button
the partial magnetization mode is selected. C ➜ CH3 selection button
The cycle LEDs shall be on (though not flashing)
D ➜ CH4 selection button
when a cycle is in progress and off when no cycle is
in progress. E ➜ FULL-MAG Led (fixed) of MAG Led for partial
Alarm LEDs are on (though not flashing) during all magnetization (flashing), discharge 1
alarm conditions, except for communication alarms. F ➜ FULL-MAG Led (fixed) of MAG Led for partial
magnetization (flashing), discharge 2
G ➜ FULL-MAG Led (fixed) of MAG Led for partial
magnetization (flashing), discharge 3
H ➜ FULL-MAG Led (fixed) of MAG Led for partial
magnetization (flashing), 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
ENGLISH
responsible for damages originating from the failure ST200 controllers are designed to operate with
to connect the unit to an appropriate grounding sys- supply voltages of 200V - 480V at 50/60 Hz and
tem. can therefore be used, after validation, to enable
Users shall have to make sure that the unit is pro- Tecnomagnete modules with different voltage
tected with a differential magnetothermal switch specifications. To use different voltages, install a
suitable to withstand the rated current used by the transformer with a rating compliant to that of the
system. It is therefore necessary to install a suitable magnetic chuck or contact TECNOMAGNETE S.p.A.
protection with magnetothermal switch (curve C) for assistance.
with a In value compliant with nameplate data.
TECNOMAGNETE systems are permanent-electro ATTENTION
systems, which means that they need to be powered All cables supplied must have a bending radius with
only during the short cycle phases. This configura- a diameter <10mm and a tension of >15N/mm2. In-
tion is designed to ensure maximum safety in the stallation must always be performed by qualified
event of power failure. technicians in accordance with current law require-
TECNOMAGNETE controllers use the power supply ments.
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 qualified personnel
only.
Instruction and maintenance manual 43
4.2.4 Electric specifications
4.2 Connecting ST100 controllers to the
power supply The fuses of model ST100 model are 12.5A lagged
fuses with a length of 20 mm and a diameter of 5 mm
4.2.1 Connecting the controller to the power (20 x 5 mm).
supply
The controller must be supplied with a single-phase 4.3 Connecting ST200 controllers to the
voltage. The multi-pole cable supplied with the con- power supply
troller has three leads suitable for the purpose.
The controller cannot be powered from the three- 4.3.1 Connecting the controller to the power
phase + neutral distribution network that supplies supply
the tool machine used. If the voltage required for the
controller is not available, install a power transformer The controller must be supplied with a single-phase
with a rating suited for the magnetic chuck. voltage. The supplied multi-pole cable has three
ENGLISH
leads suitable for the purpose, two for the phase and
neutral terminals (or phase) and one for the earth
Single-phase power supply (yellow/green).
The controller cannot be powered from the three-
F
phase + neutral distribution network that supplies
N the tool machine used. If the voltage required for the
PE controller is not available, install a power transformer
with a rating suited for the magnetic chuck.
BLACK
BROWN
Single-phase power supply
YELLOW/GREEN
F
N
PE
4.3.3 Selecting the correct dimensions for dis- The ST200 controller has an enabling device fitted
ENGLISH
charge cables on connector DB9 situated on the rear of the control-
ler (PINS 8 and 9).
The discharge cable fitted on ST200 comprises four The technical specifications for the contact are:
leads suitable for the purpose, has a standard length
of six meters and is dimensioned to prevent over- • Voltage 30V, current 1A
heating and the loss of power on the chuck in ordi- • Voltage 110V, current 0.3A
nary operating conditions.
It is always advisable to use an auxiliary relay.
Ordinary operating conditions are intended as ena-
Before using other models of start systems, contact
bling/disabling cycles occurring at an interval above
TECNOMAGNETE S.p.A. for assistance.
1 minute.
When at least one of the magnetic chucks controlled
Before using longer cables, always make sure that
by ST200 is in magnetization mode, the enabling
the cable section used guarantees a voltage drop
contact is closed. PINS 6 and 7 can be connected to
below 1%.
the power of the tool machine and used to run the
enabling cycles through the controller: the controller
4.3.4 Electric specifications
can only run the cycles when PINS 6 and 7 are clo-
All ST200 controllers are available as single and two- sed. Connect the safety catch to the operating ma-
phase models; the maximum installed power for chine on which the TECNOMAGNETE module is in-
each cycle is 25 kVA (cosϕ=0.9) for two-phase 400V stalled.
plants, 15kVA for 230V plants and 32 kVA for 480V
plants. DB9 PIN connector
To optimally protect the installation, it is necessary to
install a suitable magnetothermal switch (curve C) 5 4 3 2 1
with an In value compliant with the rating specified 9 8 7 6
on the nameplate.
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
ST100 models can be fitted with an optional external Model ST200 has a PLC interface that is constituted
start button, connected with means of a male/female by an external housing that has to be connected to
connector. the controller by means of the DB9 connector. The
interface is constituted by a DB37 pin connector de-
When the magnetic chuck is controlled by the ST100 signed to be interfaced with the control system and
controller, it is magnetized, which means that the used to receive the magnetization/demagnetization
controller enabling contact is closed enabling controls, to increase and reduce the mag-
The technical specifications for the contact are: netization levels and to provide indications on the
ENGLISH
6.3 QE version
37 20
ENGLISH
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
Magnetic
module
ENGLISH
Connector
Discharge cable
Controller
Power supply
Magnetic
module
Cable tie
Discharge cable
Controller
Power supply
ENGLISH
Magnetic chucks
Magnetic chuck
Magnetic chucks
Magnetic chuck
Magnetic chucks
Magnetic chucks
ENGLISH
4) Verify that the LEDs on the push-button panel
turn on.
5) Press the demagnetization button (DEMAG).
Note: for ST100 (base) and ST100 (version with
2 levels) simultaneously press buttons ENABLE WARNING
and DEMAG. Do not place the discharge connector near or in
6) Verify that the LED above the DEMAG button the presence of liquids, flammable material or
turns on. any other hazardous material.
7) Press the magnetization button (MAG).
Note: for ST100 (base) and ST100 (version with
2 levels) simultaneously press buttons ENABLE
and FULL-MAG.
8) Verify that the LED above the MAG button
switches on.
9) Verify that the module is magnetized.
10) Start working remembering to close the con-
nector and check the status of the chuck after
every magnetization/demagnetization cycle.
9.2 ST200
ENGLISH
qualified and skilled personnel only, include:
• Visual inspection of the terminal boards, the mag-
netic chucks and the controllers;
• Visual inspection of the cables and plugs.
The LEDs No voltage Verify that Demolition and disposal operations should be car-
do not turn voltage is ried out in compliance with appropriate regulations
on when the present. in order to protect the health of workers and the en-
switch is vironment. In particular all separation, recycling and
pressed. disposal operations must be compliant with the pro-
visions stated in the national or regional laws con-
The controller Disconnected Inspect the cerning the disposal of solid industrial and toxic and
performs the discharge connections. dangerous waste. Said provisions apply in particular
required cycle, cable to:
but does not • Sleeves, flexible ducts and plastic or non metal
magnetize the parts must be disposed of as special waste.
chuck. • Electric components such as switches, transform-
ers, sockets, etc. must be disassembled so that
they can be reused, if in good conditions, or in-
spected and recycled.
TECHNICAL SUPPORT The warranty shall not apply in the following cases:
• If the customer fails to make the payments at due
14.1 Warranty terms and conditions time or fulfill contractual obligations
• If unauthorized reparations or alterations are
TECNOMAGNETE products are guaranteed for 36 made
months from the date of manufacture except where • If the serial number has been tampered with or
otherwise indicated in writing. Said warranty covers deleted
all defects of materials and workmanship. Faulty
• If the damage originates from improper opera-
parts shall be replaced or repaired by the manufac-
tions or use; for example improper maintenance,
turer in his workshops.
impacts and other causes that cannot be attrib-
ENGLISH
All material to be repaired must be sent CARRIAGE uted to ordinary operating conditions
PAID. • If the controller has been disassembled, tampered
with or repaired without the written authorization
After reparation, the controller shall be sent
of TECNOMAGNETE S.p.A.
CARRIAGE FORWARD to the customer.
The warranty does not cover expenses relating to All controversies originating from this warranty
our engineers visiting the installation site nor ma- shall be settled by the Court of Milan.
chine dismantling. If on-site assistance is required,
labor cost shall be invoiced at current prices, along For help or further information, contact our technical
with transfer and travel expenses. services department at the following address:
TECNOMAGNETE SPA
Via Nerviano 31
20020 – LAINATE (MI) ITALY
Modelli/Models
“ST 100 / 200”
SONO STATE UTILIZZATE LE SEGUENTI NORME E THE GROUP ALSO CONFORMS WITH THE
SPECIFICHE TECNICHE: FOLLOWING STANDARDS AND TECHNICAL
SPECIFICATIONS:
....................................
SIGNATURE AND STAMP OF AUTHORIZED PERSON
14.01.2005
• IT • SE • CN
TECNOMAGNETE S.p.A. TECNOMAGNETE AB TECNOMAGNETE Shanghai R.O.
20020 Lainate (MI) Gustafsvagen 16 Pudong Lujiazui Dong road 161,
Via Nerviano 31 633 46 Eskilstuna Room 2110 - PC: 200120
Tel. +39 02.937.591 Tel. +46 016 132 200 Tel. +86 21 68882110
Fax +39 02.935.708.57 Fax +46 016 132 210 Fax + 86 21 58822110
[email protected]
www.tecnomagnete.com
• FR • US • SG
TECNOMAGNETE S.A.R.L. TECNOMAGNETE Inc. TECNOMAGNETE Singapore R.O.
52 avenue Saint-Exupéry 6655 Allar Drive, 101 Thomson Road 26 - 02 United Square
01200 Bellegarde-sur-Valserine Sterling Hts, MI 48312 Singapore 307591
Tel. +33.450.560.600 Tel. +1 586 276 6001 Tel: +65 6354 1300
Fax +33.450.560.610 Fax +1 586 276 6003 Fax +65 6354 0250
• DE • JP
TECNOMAGNETE GmbH TECNOMAGNETE Y.K. Ltd.
Ohmstraße 4, D - 63225 Langen Omodaka Building 1F
09CONTR01