Experior Controller Unit 3036/6036 User`s Manual
Contents
1. can change these settings through buttons on the controller s front panel Detail procedure see below It is not necessarily the bigger number of the force grade to have bigger force The suggested way to use it is allocate every force grade to a machining part turning the force level to best fit to the part Note the workpiece material will have an impact on the actual clamping force The idea settings for any specific workpiece part should be determined via experimentation This optimized force can then be recalled easily by selecting this particular force grade gt Utilizing Buttons in the Front Panel of the Controller Press or button to select force grades gt Utilizing the CNC PLC input terminals Send a code through FO F3 terminals Code to send F3 F2 F1 FO Force Grade Selected 1111 1 1110 2 1101 3 1100 4 1011 5 1010 6 1001 7 1000 8 0111 9 0110 10 0101 11 0100 12 0011 13 0010 14 0001 15 0000 16 2 Magnetize In Operation Mode gt Utilizing Buttons in the Front Panel of the Controller Keep pushing ACT button for 3 seconds Page 8 3 4 Experior Controller Unit 3036 6036 User s Manual gt Utilizing the CNC PLC input terminals Send a signal through ON OFF terminals Code to send ON OFF Function 10 Magnetize the chuck Demagnetize In Operation Mode lt Description If the chuc2. AC 110V 400V 50Hz 60Hz E Output Control unit 3036 0V 360V 30A Control unit 6036 0V 360V 60A E Maximum magnetize time 1s E Short circuit protection delay time 10us E Caution Although shot circuit protection is built into the controller Addition protection must still applied between the input AC Power Line and the controller 30A Fuse for 3036 60A Fuse for 6036 or appropriate circuit breaker protection Function lt Experior controller unit 3036 6036 has 2 working modes the Operation Mode and the Setting Mode When power is on it is in Operation Mode by default Operation Mode is for normal operation like Magnetize Demagnetize Selecting Force Grade When utilizing the Controller in the Operations Mode the controller may be operated via the CNC PLC input terminals or by utilizing the buttons on the front panel of the controller itself Setting Mode is used to change the original factory settings for the controller If the installer or end users needs to change features like the force level adjustment for each force grade or desires to auto calibration the internal sensors and so on They can do it by push the buttons on the front panel of the Control Unit itself A Configuration of input and output signal Definition of input and output voltage level Respect to signal GND lt 1V 0 6V 24V 1 Page 4 Experior Controller Unit 3036 6036 User s
3. Experior International Ltd 299 FuTe Zhong Road Building 49 F3 Section 3 Tel 86 21 5046 1958 Wai Gao Qiao Free Trade Zone Fax 86 21 5046 1959 Shanghai CHINA 200131 Experior International Electro Permanent Magnetic Chuck Controller User s Manual Model Numbers 3036 amp 6036 Experior Controller Unit 3036 6036 User s Manual Page 1 Experior Controller Unit 3036 6036 User s Manual Introduction EXPERIOR CONTROL UNIT 3036 amp 6036 is a new advancement in EP Chuck controllers integrating Solid State Power Control technology and Micro Controller technology and is ideally suited for modern Grinding Machines due to its high compatibility with CNC and PLC controlled system It is designed to be Plug and play When the end user wired up and power on for the first time It will be calibrated automatically and ready to run It has factory set to provide users 16 levels of force control The new advancement in EP controller technology enables the controller to auto adapter to any Brand of EP Chuck as well as any workpieces to provide better magnetize demagnetize quality Structure The outer shell of EXPERIOR CONTROL UNIT 3036 amp 6036 is made of injection molded ABS UL94 HB It can be installed either using 35mm DIN Rail or screws Input terminals Power Input and CNC PLC Signal Input are located in the upper side of the controller Output terminals are in the lower side In the upper half of the
4. Manual B Connection 1 Input Terminals Three green input terminals are located in the upper side of the controller __ aom X5 X6 x1 Fe FS R ie ON OFF GND N G R X5 FO F3 input terminals for clamping force selection gt F3 X5 4 gt Bit3 gt F2 X5 3 gt Bit2 gt FI X5 2 gt Bitl gt F0 X5 1 gt Bit0 X6 ON amp OFF terminals for magnetize demagnetize gt ON X6 1 gt Input signal for magnetize 24V respect to GND gt 1 OV respect to GND gt 0 gt OFF X6 2 gt Input signal for demagnetize gt GND X6 3 gt Signal Ground Reference Page 5 Experior Controller Unit 3036 6036 User s Manual X1 N L1 L2 PE Connecting to AC power wire lt gt For connect to 3 phase power source AC380V AC400V gt N X1 1 gt Neutral line gt LI X1 2 gt Live line 1 gt L2 X1 3 gt Live line 2 gt PE X1 4 gt Earth AC380V 400V connecting plan 50 60 Hz Force Selection N L1 L2 PE x5 X6 x1 FO F1 F2 F3 ON OFF GND N L41 L2 PE m a 41 lt gt For connect to 1 phase power source AC 110V AC220V gt N X1 1 L2 X1 3 gt Neutral Line gt LI X1 2 gt Live Line gt PE X1 4 gt Earth AC110V 220V connecting plan 50 60 Hz Force Selection N L1 L2 PE x5 FO F1 F2 F3 x6 ON OFF GND x1 N L41 L2 PE Page 6 Experior Controller Unit 3036 6036 User s Manual O
5. front panel you will find a 2 decimal display and four LED light for status while in the lower half there are three buttons The controller s internal parameters and settings can be changed by push these buttons in different combinations Input Terminals Front Panel Output Terminals Page 2 Experior Controller Unit 3036 6036 User s Manual IV Safety Advice A Although Experior controller unit 3036 6036 was designed with internal safety protection there is still a risk of accidents in the event that it is used incorrectly Like use the controller for other purposes than those stipulated The controller s PE port in the Power Input Terminal must connect securely with the earthed conductor Any interruption in the earth conductor either inside or outside the appliance is dangerous and not permitted Fuse or circuit breaker protection must be applied between the input AC Power Line and the controller 30A Fuse for 3036 60A Fuse for 6036 or appropriate circuit breaker protection The unit is not allowed to be used outdoors while unprotected and should never contact with water During the magnetize demagnetize process big amount of current will flow through the EP chuck s internal coils Therefore big force and big voltage may be appears on the chuck Addition precaution is needed Page 3 Experior Controller Unit 3036 6036 User s Manual Electrical Ratings E Input Single Phase
6. k is magnetized by CNC PLC signal it can be demagnetized only by CNC PLC signal too The Button will not function at this time To the contrary if the button is used to magnetize the chuck then both button and CNC PLC signal can demagnetize the chuck gt Utilizing Buttons in the Front Panel of the Controller Keep pushing ACT button for 3 seconds when chuck was magnetized by the controller s front panel buttons gt Utilizing the CNC PLC input terminals Send a signal through ON OFF terminals Code to send ON OFF Function 0l Demagnetize the chuck Entering Setting Mode From Operation Mode gt Press and button at same time Page 9 5 Experior Controller Unit 3036 6036 User s Manual Back to Operation Mode and save changes From Setting Mode gt Press ACT button Change the force level in each force grade In Setting Mode lt Each force grade can have a force level between 1 and 99 of Maximum Force It represents 2 100 of the clamping force By entering Setting Mode the force level of current selected force grade will be displayed on the 2 Decimal Display in the front panel It can then changed by or button 1 In Operation Mode select the force grade to change 2 Enter the Setting Mode by press and at same time 3 Use or button to change the force level for c
7. ng e seconds then ON LED 5 light on Demagnetize Keep Demagnetize The clamping alternated pushing force grade flashing ON ACT for 3 selected light off after seconds demagnetized A Number 5 between 01 to z 99 Will be Bae ane Pa nad After antee to displayed Setting atthe Setting mode special represents the 1 No display functions can be to 99 of the Mode same time realized charging current set into the selected force grade Button BCD amp Function Description LED Status 5 Operation Display aE the Press ACT Back to Normal The clamping Setting Mode and save any force grade No display Button once Mode changes selected Adjusting the For the selected force r aes aa Poe the force in the force level of Press or grade selected any keg force grade No display the selected force level 1 99 can selected to the force grade be set largest force N Auto Calibrate the T internal current sensor p auto detect the Counting down va ae Push and frequency of the AC from 5 when 0 Calibration ACT at power source After displayed it No display z same time the auto Calibration means calibrating a process the controller finished will return to Normal Mode co ae Display total Display how Te 24 rier Push and Magnetize Demagnetiz many times the ACT at e cycles After the controller No dis
8. play magnetized s ome F same time display it will turn to magnetized and and i Normal Mode demagnetized demagnetized Page 11 Experior Controller Unit 3036 6036 User s Manual E Troubleshooting Problem Cause Solution Magnetize Demagnetize procedure take very long time to finish But chuck is working fine gt 5 seconds for magnetize Internal current sensor need recalibrate Take a recalibration procedure Magnetize Demagnetize procedure take very long time to finish The chuck is not working too gt 5 seconds for magnetize AC Power Line frequency is not sensed correctly Take a recalibration procedure Demagnetize quality is not good Internal sensor need recalibrate Take a recalibration procedure Error LED is on Shoot circuit between Chuck coils or between coils and Earth Find and solved shoot circuit problem Turn off the power and restart the controller Page 12
9. urrent force grade 4 Press ACT button to save the change and return to Operation Mode Calibrate internal sensor lt Experior control unit 3036 6036 has several internal sensors It will be calibrated automatically when the first time the controller been powered up But if customer found the magnetize demagnetize function doesn t work well Some time the internal sensors need to be recalibrated It can be done by this procedure 1 Enter the Setting Mode by press and at same time 2 Press and ACT button together to activate the recalibration procedure 3 2 Decimal Display will flash from 5 down to 0 to finish the recalibration procedure 4 A number 77 78 for 50Hz 92 93 for 60Hz will be flashed to indicate the AC power frequency 5 After this the recalibration procedure is finished The control unit will back to Operation Mode automatically Page 10 Experior Controller Unit 3036 6036 User s Manual D Instruction of Button Operations on the Front Panel of the Controller lt Button 3 Function Description BCD Display LED Status s Operation Force grade Press or 16 different force The clamping No change Selection button grades can be selected force grade selected Magnetize Keep Magnetize The clamping LED Flashing pushing force grade followed by zZ ACT for 3 selected LED Flashi
10. utput Terminals Three green output terminals are located in the lower side of the controller a x2 x3 X4 PE QUT3 OUT2 OUTI OUTO 24V ON OFF ERR GND X2 EARTH gt Connect to a EP Chuck gt P K2 2 gt EP Chuck gt 7 X2 3 gt EP Chuck gt PE X2 1 gt EP Chuck PE X3 Out0 Out3 gt Output signal for selected force grade gt Out3 X3 1 gt Bit3 gt Out2 X3 2 gt Bit2 gt Out X3 3 gt Bitl gt Out0 X3 4 gt BitO X4 24V ON OFF ERR GND gt 24V X4 1 Connect to external 24V supply power for output signal gt ON OFF X4 2 1 magnetized 0 not magnetized gt ERR X4 3 1 in the event of error message 0 no problem gt GND X4 4 Signal Reference Ground Connect to Output Output Error Chuck Force Step On Off Signal x3 X4 OUT3 OUT2 OUT1 OUTO 24V ON OFF ERR GND 24 Page 7 Experior Controller Unit 3036 6036 User s Manual General Operation 1 Select Force Grade In Operations Mode lt Concept of force grade Experior controller unit 3036 6030 has 16 force grades preset for customer use It is an easy way to choose between clamping forces By factory default 1 16 force grade has been setup as 16 different force levels from smallest force in Grade 1 gradually increased to maximum force in Grade 16 But the end user
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