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Chapter 5 Commissioning ………………………………………………………………………….. 26

5.2 Procedure ………………………………………………………………………………………… 26

5.2.2 Action commissioning ……………………………………………………………………………… 27

5.2.3 Precision commissioning …………………………………………………………………………. 27

5.2.4 Counting commissioning …………………………………………………………………………. 28

5.2.5 Retreat commissioning ……………………………………………………………………………. 28

Chapter 6 Maintenance ……………………………………………………………………………….. 29

6.2 Routine inspection …………………………………………………………………………….. 29

6.3 Periodic inspection ……………………………………………………………………………. 30

Chapter 7 Appendix ……………………………………………………………………………………. 32

7.2 Grounding design ……………………………………………………………………………… 32

7.3 Protective measures ………………………………………………………………………….. 34

E21 Installation Manual

Estun E21 Controller Manual

Preface

This manual describes operation of E21 numerical control device and is meant for operators who are instructed for operation of the device. Operator shall read through this manual and know operation requirements before using this device.

Copy right is preserved by ESTUN. It is not allowed to add or delete part or all of the manual content without ESTUN’s consent. Do not use part or all of manual content for the third party’s design.
E21 device provides complete software control and has no mechanical protection device for operator or the tool machine. Therefore, in case of malfunction, machine tool must provide protection device for operator and external part of the machine tool. ESTUN is not responsible for any direct or indirect losses caused by normal or abnormal operation of the device.

ESTUN preserves the right to modifying this manual in the event of function adding or print error.

1.1 Product introduction

This product is equipped with press brake machine dedicated numerical control device which is applicable to various users. On the basis of ensuring work precision, the cost of numerical control bending machine is reduced significantly.

Features of this product are listed below:

 Positioning control of back gauge.

 Intelligent positioning control.

 Unilateral and bidirectional positioning which eliminates spindle clearance effectively.

 Retract functions.

 Automatic reference searching.

 One-key parameter backup and restore.

 Fast position indexing.

 40 programs storage space, each program has 25 steps.

 Power-off protection.

1.2 Operation panel

Operation panel is shown in Figure 1-1.

Functions of panel keys are described in Table 1-1.

Table 1-1 Description of key functions

Key	Function description
	Delete key: delete all data in input area on left bottom of displayer.
	Enter key: confirm the input content. If no content is input, the key has the similar function to direction key .
	Start key: automatic start-up, top left corner of the key is operation indicator LED. When operation is started, this indicator LED is on.
	Stop key: stop operation, top left corner of the key is Stop indicator LED. When initialize normal start-up and no operation, this indicator LED is on.
	Left direction key: page forward, cursor remove
	Right direction key: page backward, cursor remove
	Down direction key: select parameter downward
	Function switch: switch over different function pages
	Symbolic key: user input symbol, or start diagnosis
	Numeric key: when setting parameter, input value
	Decimal point key: when set up parameter, input decimal point.
	Manual movement key: in case of manual adjustment, make adjustment object move in forward direction at low speed.
	Manual movement key: in case of manual adjustment, make adjustment object move in backward direction at low speed
	High speed selection key: in case of manual adjustment, press this key and press simultaneously, make adjustment object move in increasing direction at high speed, then press , make adjustment object move in decreasing direction at high speed.

1.3 Displayer

E21 numerical control device adopts 160*160 dot matrix LCD displayer. The display area is shown in Figure 1-2.

 Title bar: display relevant information of current page, such as its name, etc.

 Parameter display area: display parameter name, parameter value and system information.

 Status bar: display area of input information and prompt message, etc.

The paraphrases of shortening on this page are as shown in Table 1-2.

Table 1-2 The paraphrases of shortening

Part2 — Operation Instruction

2.1 Basic operation procedure

Basic switch over and operation procedure of the device is shown in Figure 2-1.

2.2 Programming

The device has two programming methods, which are single-step programming and multi-step programming. User can set up programming according to actual demand.

2.2.1 Single-step programming

Caution: When the parameter X or Y displays ******** on the page, please do not enter the RUN page or Manual page, unless you have reset the teach function of X-axis or Y-axis.

Single-step programming is generally used for processing single step to finish work piece processing. When controller is power on, it will automatically enter single-step program page.

Operation steps

Step 1 After starting up, the device will enter setting up page of single-step program automatically, as shown in Figure 2-2.

Step 2 Press , select parameter which needs to be set up, press numerical key to input program value, press to complete input.

[Note] Parameter can only be set when Stop indicator is on.

Setting range of singe step parameter is shown in Table 2-1.

Step 3 Press , system will execute according to this program, as shown in Figure 2-3.

• Operation example

On single-step program page, program bending depth to 100.0mm, back gauge position to
80.00mm, retract distance to 50mm, concession waiting time to 2s, holding time to 3s, work
piece to 10.
Operation steps are shown in Table 2-2.

Table 2-2 Operation steps of single step example

Operation steps	Operation
Step1	Press , select “XP” parameter.
Step2	Input 80.00 by numerical key.
Step3	Press , confirm setting of this parameter.
Step4	Press , select “YP” parameter.
Step5	Input 100.0 by numerical key.
Step6	Press , confirm set up of this parameter.
Step9	Press , select “DX” parameter, “DLY” parameter, “HT” parameter, “PP” parameter respectively.
Step10	Set up parameter to 50mm, 2s, 3s, 10, 0 by numerical key.
Step11	Press , system execute according to this program.

2.2.2 Multi-step programming

Caution: When the parameter X or Y displays ******** on the page, please do not enter the RUN page, unless you have reset the teach function of X-axis or Y-axis.

Multi-step program is used for processing single work piece of different processing steps, realize consecutive implementation of multi-steps, and improve processing efficiency.

Operation step

Step 1 Power on, the device displays the single-step parameter page automatically.
Step 2 Press , switch to program manage page, as shown in Figure 2-4.

Step 3 Press , select program serial number, or input program number directly, such as input “1”.

Step 4 Press , enter multi-step program setting page, as shown in Figure 2-5.

Step 5 Press , select multi-step programming parameter which requires set up, input
setting up value, press , and the set up takes effect.
Step 6 In completion of set up, press , enter step parameter set page, as shown in Figure 2-6.

Step 7 Press , select step parameter that needs to be set up, input program value, press , and the setup takes effect.
Step 8 Press to switch over between steps. If the current step is the first step, press to enter the last page of step parameter setting; if the current step is the last one, press to enter the first page of step parameter setting.

Multi-step parameter setting range is shown in Table 2-3.

Table 2-3 Multi-step parameter setting range

Step 9 Press , system will operate according to this program, as shown in Figure 2-7.

• Operation example

[Background] One work piece requires processing 50 as shown below;

 First bend: 50mm;

 Second bend: 100mm;

 Third bend: the other direction 300mm;
[Analysis] according to work piece and technological conditions of machine tool:

 First bend: X axis position is 50.0mm; Y axis position is 85.00mm, concession 50mm;

 The second bend: X axis position is 100.0mm; Y axis position is 85.00mm, concession 50mm;

 The third bend: X axis position is 300.0mm; Y axis position is 85.00mm, concession 50mm;
Edit processing program of this work piece on No. 2 program.
Operation procedure is shown in Table 2-4.

Table 2-4 Operation steps of multi-step programming example

No.	Operation
Step1	On single step parameter setting page, press to enter program selection page.
Step2	Input “2”, press , enter multi-step general parameter setting page of program 2.
Step3	Select “Program step”, input “3”, press , the setting takes effect.
Step4	Select “number of preset work piece”, input “50”, press , the setup takes effect.
Step5	Similar to step 3 and step 4, set “current work piece number”, “concession delay” and “pressurize time” to 0, 400, 200 respectively.
Step6	Press to enter first step setup page of step parameter
Step7	Select “X target position”, input 50, press , the setup takes effect.
Step8	Select “Y target position”, input 85, press , and the setup take effect
Step9	Similar to step 7, 8, set up “concession distance” and “repeat times” to 50, 1 respectively.
Step10	Press to enter second step setup page of step parameter, the setup method is similar to that of step one.
Step11	Press again, to enter third step setup page of step parameter, the setup method is similar to that of step one and step two.

<Note>

■ In completion of multi-step programming, return to start step before launching the system; otherwise, the program will start position processing at current step.

■ Press left and right direction key to circulate page turning and browsing among all step parameters.

■ Program can be called and revised again.

■In completion of processing all work pieces (50 in the example), system stops automatically. Restart directly will start another round of processing 50 work pieces.

2.3 Parameter setting

User can setup all parameters required for normal operation of the system, including system parameter, X axis parameter and Y axis parameter.
Step 1 On program management page, press to enter programming constant page, as shown in Figure 2-8. On this page, programming constant can be set.

Range of programming constant setup is shown in Table 2-5.

Table 2-5 Range of programming constant setup

Step 2 Input password “1212”, press to enter the Teach Page, as shown in Figure 2-9.

Step up parameter, parameter setup range is shown in Table 2-6.

Table 2-6 System parameter setup range

<How to Teach>: You can directly measure the positions of slider and back gauge. If the measurement is difficult, you can program and operate any one process, and then measure the accomplished workpiece.

Step 3 Press , return to programming constant page.
—-End

2.4 Manual adjustment

In single-step mode, axis movement can be controlled by pressing key manually. This method helps user to adjust machine tool and work piece.
Step 1 On single step parameter setup page, press or to enter manual page, as shown in Figure 2-10.

Step 2 According to your actual requirement, following the above table to adjust the position of the axis. — If the drive mode of the corresponding axis is common motor:

Press Key	Status	Direction	Running Time	Speed
	Stop	increasing	Press time	Slow
Run	increasing	 Press time (if it is less than “Pulse Time”)  Pulse Time (If it is less than Press time)	Slow
	Stop	decreasing	Press time	Slow
Run	decreasing	 Press time (if it is less than “Pulse Time”)  Pulse Time (If it is less than Press time)	Slow
	Stop	increasing	Press time	Slow
Run	increasing	Press time	Slow
	Stop	decreasing	Press time	Slow
Run	decreasing	Press time	Slow

<Note>: When the system is on run status, the operation of manual adjustment is just valid for the X-axis.

— If the drive mode of the corresponding axis is frequency:

Press Key	Status	Direction	Running Time	Speed
	Stop	increasing	Press time	Slow
Run	/
	Stop	decreasing	Press time	Slow
Run	/
	Stop	increasing	Press time	Fast
Run	/
	Stop	decreasing	Press time	Fast
Run	/

Step 3 Press return to single step parameter setting page.
—-End

Part3 — Alarm

The device can detect internal or external abnormity automatically and send out alarm prompt. Alarm message is available on alarm list.
Step 1 On programming management page, press to enter programming constant page.
Step 2 On programming constant page, press to enter “Alarm history” page to view all alarm history.
As shown in Figure 3-1, the latest 6 alarms, alarm number and causes can be viewed on this page

Alarm history and message is shown in Table 3-1.

Table 3-1 Alarm number and alarm message

Appendix Common Fault and Troubleshooting

—End