Delem DAC-360 Installation Manual
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Delem DAC-360 Installation Manual

Delem DAC-360 Installation Manual

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Delem
DAC-360
Installation manual
Version 1
Manual version V0208

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Summary of Contents for Delem DAC-360

  • Page 1 Delem DAC-360 Installation manual Version 1 Manual version V0208...
  • Page 2 PREFACE In this installation manual you find information how to connect and program a DAC-360 shear control for operation with an industrial shear. LIMITED WARRANTY • The equipment is supplied by Delem without safety features. The machine manufacturer has to ensure a safe environment.

  • Page 3: Table Of Contents

    Delem Table of contents Parameter index ..........5 Part I - Hardware description 1.
  • Page 4 1.3. Test functions ..........3.3 1.4.

  • Page 5: Parameter Index

    Delem Parameter index Gap reference table ....2.29 Gap2 reference table ....2.31 I-gain .
  • Page 6 V0407, 0.6...

  • Page 7: Part I - Hardware Description

    Delem Part I - Hardware description This section contains the hardware specifications of a Delem DAC-360 control. V0407, 1.1...

  • Page 8: Introduction

    Introduction The DAC-360 is a universal programmable control, designed to control positioning of machine parts such as the backgauge control of an industrial shear. The control is capable of controlling servo-loop systems, a one- or two-speed AC or DC drive system.

  • Page 9: Specifications

    Physical dimensions For the dimensions of the control, see the included drawings at the end of this section. 2.2. Environmental conditions The following environment specification values are valid for a DAC-360 control: Ambient temperature 5 - 50°C Storage temperature min. -20°C max.

  • Page 10: Technical Specifications

    2.3. Technical specifications Power supply 18 - 28 VDC 5W (I/O excluded) Display LCD/STN resolution 320 x 240 black/white Interfaces 1 x Encoder, max. 1 MHz 1 x RS-232 8 x Digital input, 24V 16 x Digital output, 24V 1 x analog output 0 +/- 10V 2 x analog output 0 - 10V 3 x analog input 0 - 10V (each incl.

  • Page 11: System I/O

    Delem System I/O 3.1. Introduction The backside of the control is equipped with a set of connectors for various functions: - system I/O - encoder feedback - communication The various connectors are discussed in the following sections. Warning: Connectors may not be plugged or unplugged when power is ON. Connectors may only be connected or disconnected when power is OFF.

  • Page 12: Power Supply / Analog Output

    3.2. Power supply / Analog output Connector CN4 contains the connection for the power supply and the analog output for axis movement. Power supply 18 - 28 VDC 5W (I/O excluded) Analog output 0 +/- 10V 10mA max. 3.3. Analog I/O The Analog connector CN19 provides several analog signals, two analog outputs and three analog inputs.

  • Page 13: Digital I/O

    Delem 3.4. Digital I/O 8 inputs, 16 outputs. See schematic 8062-101 for connection details. The use of I/O pins depends on the application and machine settings. For the purpose of all assigned I/O signals please consult part 2 of this manual.

  • Page 14: Encoder

    3.5. Encoder 9-pole SUBD female encoder interface power supply: 5V DC/250 mA or 12V DC/200 mA possibilities: 12 V single ended 5 V single ended 5 V differential Max. count frequency 1 MHz See schematic 8062-101 for connection details. Notes: •...

  • Page 15: Spare Parts

    Delem Spare parts The following table gives an overview of the available spare parts for the DAC-360 control. Number Description FRONT-360 Front panel DAC-360 DLCD-360 LCD screen D-7453-001 Mainboard DAC-360 V0407, 1.9...

  • Page 16: Schematics

    Schematics The following pages show several schematics about the DAC-360 control: 8062-901 Mounting dimensions 8062-912 Cables and connectors 8062-101 Connection diagram 8062-103 Connection diagram 8062-104 Connection diagram 8062-107 Connection diagram 8062-108 Connection diagram 8062-907 Default I/O Allocation V0407, 1.10...
  • Page 19 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 6 7 8 9...
  • Page 20 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 6 7 8 9...
  • Page 21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 6 7 8 9...
  • Page 22 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 6 7 8 9...
  • Page 23 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 6 7 8 9...
  • Page 24 Timing diagrams DAC-360 with stroke potentiometer S0 = Controller Stopped Status S1 = Positioning S2 = Wait for ST low Stroke-pot S3 = Wait for EOS S4 = Wait for UDP S5 = Wait for ST high T6+T5+½T1 T1 = Delay before cutting force...
  • Page 25 DAC-360 Interrupted cycle with Blade Return (BR) S0 = Controller Stopped Status S1 = Positioning S2 = Wait for ST low S3 = Wait for EOS S4 = Wait for UDP S5 = Wait for ST high DAC-360 Interrupted cycle with PEDAL...
  • Page 26 T3 = Delay before opening RetractEnable X-IP T8 = Retract hold BusyRetract DAC-360 Retrac t Tim ing (W ait for Retrac t) S 0 = Controller S topped Status S 1 = P os itioning S 2 = W ait for S T low...

  • Page 27: Part Ii - Machine Settings

    Delem Part II - Machine settings This section will describe the necessary settings of a DAC-360 control regarding machine settings. V0208, 2.1...

  • Page 28: Machine Parameter Types

    Machine parameter types 1.1. Menu The machine parameters are only accessible with a special entry code. Machine parameters should be adjusted by authorized personnel only. To enter the machine parameters menu: • go to the screen with program constants; • scroll to the parameter ‘language’;...
  • Page 29 Delem The following adjustment procedure can be followed to set the parameters to correct values. Changes in the settings should be checked by moving the axis from one position to another. This stroke should be large enough, so that the axis will reach its maximum speed.
  • Page 30 • one analog output signal. The type of control can be specified as on-off control. When there is a position error, the control signal is on. When there is no position error, the control signal is off. • 1-speed AC axis For a 1-speed axis, the parameter 'axis type' must be set to 1.
  • Page 31 Delem speed for the axis movement. As with the 1-speed axis, the parameter 'Stop time' (T) can be used to improve positioning. If the analog output is used for axis control, the parameters 'DC high speed' and 'DC low speed' must be programmed at two different values. These values determine the voltage levels at the analog output for the two different speed settings.

  • Page 32: Spindle Correction Table

    Bipolar: Unipolar: A unipolar system can be implemented for servo and AC drives. 1.3. Spindle correction table The spindle correction table is meant to overcome axis position errors due to mechanical inaccuracies in the spindle. If a spindle shows deviations then they should be measured systematically on certain setpoints.
  • Page 33 Delem Cor1 Cor2 Cor n All measured axis positions and their corresponding corrections can be entered in a table on the control. To access the correction table, proceed as follows: • enter the machine parameters menu as described in chapter 1, •...

  • Page 34: The Machine Parameters

    The machine parameters 2.1. General parameters Parameter 13 Maximum thickness Range : 0.1 - 99.9 Unit : mm Default : 1.0 Function The maximum sheet thickness the machine can cut. Parameter 14 Maximum cutting length Range : 0.0 - 15000.0 Unit : mm Default...
  • Page 35 Delem When this parameter is set to 1 (default value), all operation modes are available for the operator. When set to 0, the operation modes “Programming” and “Program selection” are not available for the operator. The other modes will remain available. The tabs of these remaining modes are aligned to the left in the Navigation bar.

  • Page 36: Backgauge Control Parameters

    2.2. Backgauge control parameters Parameter 19 Control type Range : 0 - 3 Unit Default Function The type of motor system that is to be controlled. 0 = No control 1 = 1-speed AC or DC drive 2 = 2-speed AC or DC drive 3 = Servo motor drive According to this setting, parameters for Servo or for AC will appear for programming.
  • Page 37 Delem Unit : mm Default : 1000.00 Function Maximum backgauge position. The axis will never be controlled to a higher position than programmed here. Parameter 23 Manual speed high Range : 1 - 100 Unit Default : 50 Function Speed of the axis, when it is moved in manual mode with the ‘manual move’ function. This is the travel speed when the arrow key is pressed continuously.
  • Page 38 Parameter 26 Enable display correction Range : 0 - 1 Unit Default Function When the axis reaches the programmed position, the display can show the real measured position or it can show the programmed position. This can be programmed with this parameter.
  • Page 39 Delem Unit : counts/mm Default : 50.000 Function Sets the scaling between encoder pulses and millimeters. The encoder gives an exact number of count pulses over a mm displacement. This value must be programmed here. The value can be calculated by the formula:...
  • Page 40 Function To choose whether or not to have a reference search cycle at start-up of the control. 0 = no reference search at power-on 1 = reference search If programmed to 0, the control memorises the position when switched off. During operation, the actual position of the axis can be programmed with a parameter in the Program Constants, ‘Actual X position’.
  • Page 41 Delem Function Axis speed during reference searching. Parameter 35 RSD switch mounted Range : 0 - 1 Unit Default Remark Only if ‘Reference Search’ (31) is set to 1. Function 0: reference search system without Reference Search Direction switch (RSD-switch).
  • Page 42 Function When set to 1, the retract function is enabled. Several parameters (37-40) will become available and can be programmed. Parameter 37 Auto retract enable Range : 0 - 1 Unit Default Remark Only if ‘Retract programmable’ (36) is set to 1. Function When set to 1, retract is automatically started on the high-to-low transition of the input ST, which is the moment to start cutting.
  • Page 43 Delem Range : 0.0 – 9999.9 Unit : mm Default : 0.0 Remark Only if ‘Retract programmable’ (36) is set to 1. Function Default value for the retract distance when a new program is created. Parameter 41 Safety Zone Range : 0.0 –...
  • Page 44 Function Overrun distance in case of one side positioning. One-side positioning is chosen with the parameter ‘spindle allowance’(42). An overrun is also done when an AC-drive must change position over a small distance, smaller than BLS(55). If such a situation occurs, the axis is first moved to the overrun position and then back to the required position.
  • Page 45 Delem If the X-axis position is smaller than X-limit, the X-axis moves at normal speed. If the X-axis position is larger than X-limit, the X-axis moves at the speed, as programmed at ‘Limit speed’(47). Parameter 47 Limit speed Range : 0.0 - 100.0...
  • Page 46 Only if ‘Control type’ (19) is set to 3. Function This is the nominal deceleration of the axis, used to control the axis from maximum to zero speed when the axis comes into position. This parameter must be programmed as the time in which the axis decelerates from maximum to zero speed.
  • Page 47 Delem Parameter 53 Positioning tolerance Range : 0.01 - 9999.99 Unit : mm Default : 0.01 Remark Only if ‘Control type’ (19) is set to 1 or 2. Function To set a range in which no new positioning takes place.
  • Page 48 Parameter 56 Brake point low speed < Range : 0 - 9999 Unit : counts Default : 10 Remark Only if ‘Control type’ (19) is set to 1 or 2. Function Switch point from low speed to zero in the downcounting direction. Parameter 57 Brake point low speed >...
  • Page 49 Delem Switch point from high speed to low speed in the upcounting direction. Parameter 60 Stop time Range : 0 - 9999 Unit : msec Default Remark Only if ‘Control type’ (19) is set to 1 or 2. If ‘AC brake enabled’ (54) is set to 1, this parameter is not available.
  • Page 50 Range : 1 - 100 Unit Default : 80 Remark Only if ‘Control type’ (19) is set to 2. Function This is the output voltage for high speed movement in the negative direction. This parameter must be programmed if a 2-speed DC motor drive is controlled with the analog output. It is programmed as a percentage of the maximum output voltage (10 V).

  • Page 51: Angle Control Parameters

    Delem Only if ‘Control type’ (19) is set to 1 or 2. Function The nominal deceleration time, in which the axis decelerates from high speed to low speed. This parameter must be programmed if 2-speed DC motor drives are used.
  • Page 52 Range : 0.0 - 45.0 Unit : degrees Default : 0.0 Remark Only if the parameter ‘control enable’ (68) is set to 0. Function If there is no angle control, the (fixed) angle of the cutting blade can be programmed with this parameter.
  • Page 53 Delem The value is programmed in AD-points: a converted digital value of the position feedback voltage of the potentiometer. Parameter 73 Angle prestop negative Range : 0 - 99 Unit : AD value Default Function This parameter has the same definition as parameter "Angle Prestop Positive" but only in the negative direction of the angle adjustment (smaller angle).

  • Page 54: Gap Control Parameters

    Unit Default Function Press ENTER to open the screen with the angle material table. In this table the cutting angle can be programmed as a function of sheet thickness and sheet material. If this table is programmed, the angle is precomputed for each cutting step in a program.
  • Page 55 Delem Unit : AD value Default Function Due to the inertia of the Gap system there can be some overshoot after the control output has been switched off. To prevent such overshoot, the 'Gap prestop' can be programmed. This parameter can be regarded as a programmable offset. The control will take this offset into account when positioning the Gap.
  • Page 56 Gap: program a known gap value for the blade. AD-value: program the required feedback voltage for this gap. The voltage must be programmed in the range 0-4095, it will be converted to an input voltage in the range 0-10V. The adjustment procedure to find the correct AD-values is similar to the procedure for angle values as described in the previous section.
  • Page 57 Delem The sheet thickness is indicated in the vertical column, as a percentage of the maximum thickness (parameter 13, ‘Maximum thickness’). For various plate thickness values, the required gap value can be programmed. These setpoints can be programmed for each material (column M1-M6).

  • Page 58: Stroke Control Parameters

    Press ENTER to open a screen with the gap2 reference table. See parameter ‘Gap reference table’ (79) for more information. 2.5. Stroke control parameters Parameter 85 Stroke mode Range : 0 - 2 Unit Default Function 0 = No stroke option (‘Stroke length’ not available in user interface) 1 = Stroke length using timer 2 = Stroke length using analog feedback (using input ‘SFB’) In case of 1and 2, the following I/O an be used:...
  • Page 59 Delem Range : -999 - 0 Unit : mm Default Remark This parameter must be programmed when ‘stroke mode’ is set to 1. Function This is the stroke distance when the blade is positioned on the upper dead point. Stroke...
  • Page 60 Stroke: program a known stroke value for the blade. AD-value: program the required feedback voltage for this stroke. The input voltage must be programmed in the range 0-4095, representing an input voltage in the range 0-10V. The adjustment procedure to find the correct AD-values is similar to the procedure for angle values as described in section 2.5.

  • Page 61: Force Control Parameters

    Delem Due to the inertia of the system it is possible that the shear has a slight overshoot when it is stopped at the computed value. The programmed ‘prestop’-value is subtracted from the computed value, creating an EOS (end of stroke) output signal at an earlier moment than the programmed moment.
  • Page 62 Cut: program a known force value (in kiloNewtons) for a cut. DA-value: program the required output voltage for this force. The output voltage must be programmed in the range 0-4095, it will be converted to an output voltage in the range 0-10V. Parameter 96 Main force ramp Range...
  • Page 63 Delem This is the time the output B_UP must remain active after UDP has been reached. Parameter 99 Opening force Range : 0 - 100 Unit Default : 50 Function The force for steering the blade up. This value is programmed as a percentage of the maximum force (as programmed in the reference table).
  • Page 64 Force value for the main force during clamping. It is programmed as a percentage of the maximum main force. Parameter 103 Clamping force delay Range : 0 - 9999 Unit : msec Default Function Delay before the output is controlled for clamping. Parameter 104 Clamping time Range...
  • Page 65 Delem Parameter 107 Clamping force delay Range : 0 - 999 Unit : msec Default Function After the ‘ST’ input goes low, the control will start force control. This parameter can be used to program a delay before force control is started.

  • Page 66: I/O Assignments

    I/O assignments 3.1. Inroduction The control has several programmable features. These features can be enabled or disabled in software. Depending on these featues, a number of logical signals can be mapped to the I/O pins of the control. This means the system programmer can enable the necessary signals and assign them to output pins.
  • Page 67 Delem Each choice opens a sub-menu with an array of the logical signals and available connector pins. The screen for digital inputs looks as follows: In the top row, the available connector pins are shown. In the left column, the logical signals are listed.

  • Page 68: List Of I/O Signals

    3.2. List of I/O signals Digital input signals Code Name Description UDPIN UDP input Input to indicate blade is in the mechanical Upper Dead Point. Machine Ready Signal that indicates the machine is ready. When it is low, the control cannot be started and digital outputs and pressure outputs are disabled.
  • Page 69 Delem NC Start Control is started. End Of Stroke Stroke is finished, either position is reached or stroke time has elapsed End Of Cycle Program step is finished Function output 1 General purpose programmable output Function output 2 General purpose programmable output...
  • Page 70 GFB2 Gap2 feedback Position feedback of the Gap2 opening, in case Gap system with position feedback is enabled. GFB1 Gap1 feedback Position feedback of the Gap1 opening, in case Gap system with position feedback is enabled. Angle feedback Feedback of angle value, in case angle control is installed.

  • Page 71: Software Settings

    • Delem back-up software for transmission of machine settings. The Delem back-up software must be installed on the PC. All actions, storage and restoration of settings, are done with this program. Just make sure the necessary cables are connected and the DAC control is switched on.
  • Page 72 After start-up, the two large buttons for back-up and restore cannot be selected yet. First, click on the button ‘Connect...’ to establish a connection between the software and the DAC control. If not succesful, select a different serial port (COM1, COM2, etc.) and try again. If this still gives no positive result, check your cabling.

  • Page 73: Upgrade Control

    PC (COM1). You also need a program that will load the new software into the control. This program can be requested from Delem. Note: before starting an update, first perform a back-up of your control settings. When the control is updated, all data is erased and the control is reset to factory default settings.

  • Page 74: Special Access Codes

    4.3. Special access codes There are several access codes to enter special menus of the control. These access codes should only be known and used by authorised service personnel. Each code is entered on the page of the program constants, when the cursor is on the parameter Language.

  • Page 75: Display Codes

    Delem 4.4. Display codes In the upper richt corner of the screen, a status code is shown that indicates the current status of the control. Such a code can either be a status code or and error code. The following table shows the possible status codes:...
  • Page 76 V0208, 2.50...

  • Page 77: Part Iii - Diagnostic Program

    Delem Part III - Diagnostic program To be able to test a DAC-360 control, it has been equipped with a diagnostic program. V0407, 3.1...

  • Page 78: Introduction

    Introduction 1.1. Remarks With the test functions of the diagnostic program a service engineer can test the control and the interfacing with the system. Before starting the diagnostic program it is wise to check the machine for moving parts. This is because during the diagnostic operation of the control no regulation of the axis is performed.
  • Page 79 Delem 1.3. Test functions Digital Inputs 5 - 8, 13 -16 These digits refer to the digital inputs of the control. To test the digital inputs, apply 24V to the inputs and check if they change to '1'. Digital Outputs 1-4, 9-12, 17-24 These digits refer to the digital outputs of the control.
  • Page 80 In this screen, the status of all internal I/O signals is shown. In this screen, the programmed and actual values of parameters is shown. In this screen, the status of all physical I/O is shown. V0407, 3.4...
  • Page 81 Delem A program (step) can be started in order to view the I/O behaviour. In the service mode, it is not possible to program parameters or I/O. Press the keys <arrow down> and <arrow up> to browse through the service screens.
  • Page 82 V0407, 3.6...

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