1、DUPLOMATIC E.M.6427 400V RELEASE 7.1 11-026427071-400-en 1SM-TURRETSCONTROL UNIT DDC2-10-J*/22CONTROL UNIT DDC2-18/10-J*/22Software: SFW062G402, SFW062G403, SFW062G406, SFW062G412, SFW062I403, SFW062I406,SFW062I412, SFW062I421, SFW062I429, SFW062I438, SFW062I439, SFW062I444, SFW062I445INSTALLATION M
2、ANUALINSTRUCTIONS FOR ELECTRICAL CONNECTIONS OF INTEGRATED CONTROL UNITCorrespondence between electronic unit code and softwareElectronic unit Code Software Turret NotesDDC2-18/10-J20/22 0496066J20 SFW062G402SFW062I402SM-*-25/2*-400 Std. 8/12 positionsDDC2-18/10-J*/22 0496066J* SFW062I444 SM-*-25/2*
3、-400 8/12 positions high inertiaDDC2-18/10-J20/22 0496066J20 SFW062G412SFW062I412SM-*-25/2*-400 6 and 12 positionsDDC2-18/10-J*/22 0496066J* SFW062I439 SM-*-25/2*-400 12 and 24 positionsDDC2-10-J20/22 0496032J20 SFW062G403SFW062I403SM-*-20/2*-400 Std. 8/12 positionsDDC2-10-J20/22 0496032J20 SFW062G4
4、06SFW062I403SM-*-20/2*-400 6 and 12 positionsDDC2-10-J*/22 0496032J* SFW062I438 SM-*-20/2*-400 12 and 24 positionsDDC2-10-J16/22 0496032J16 SFW062G403SFW062I403SM-*-16/2*-400 Std. 8/12 positionsDDC2-10-J16/22 0496032J16 SFW062G406SFW062I406SM-*-16/2*-400 6 and 12 positionsDDC2-10-J*/22 0496032J* SFW
5、062I421 SM-*-16/2*-400 8 and 12 positionsDDC2-10-J*/22 0496032J* SFW062I445 SM-*-16/2*-400 8 and 16 positionsDDC2-10-J16/22 0496032J16 SFW062G407 SM-*-12/2*-400 8/12 positionsDDC2-10-J*/22 0496032J* SFW062I407 SM-*-12/2*-400 8 and 12 positionsNotes: Software release G will be replaced by software re
6、lease I that is fully compatible andadds more functionalities.DUPLOMATIC E.M.6427 400V RELEASE 7.1 11-026427071-400-en 2Contents1. GENERAL INFORMATION 3CODE OF THE CONTROL UNIT 3IMPORTANT NOTE FOR SAFETY 3EMC COMPLIANCE 3TECHNICAL CARACTERISTICS OF THE CONTROL UNIT 42. ELECTRICAL CONNECTIONS 5SUPPLY
7、 5POWER SUPPLY 400 VAC 3 F 5POWER SUPPLY 230 VAC 2 F 5POWER SUPPLY 24VDC FOR I/O 5TECHNICAL SPECIFICATIONS FOR POWER TRANSFORMER DESIGN 5I/O SIGNALS 6OUTPUTS TO CNC 6OUTPUTS TO ELECTROVALVE 6INPUTS FROM CNC 6SELECTION OF THE NUMBER OF POSITIONS 6SELECTION OF LOW/HIGH INERTIA 6SELECTION OF STANDARD/M
8、AINTENANCE SPEED 6CONNECTION BOX AND TERMINALS LAY-OUT 73. INTERFACING TO CNC 8OPERATING FUNCTIONS 8ZERO SEARCH 8OPERATING FUNCTIONS DESCRIPTION 9OPERATING FUNCTION N0: EMERGENCY / RESET 11OPERATING FUNCTION N1,2,3: AUTOMATIC 11OPERATING FUNCTION N4: JOG 12OPERATING FUNCTION N5: SERVICE 12OPERATING
9、FUNCTION N6: MAINTENANCE 12OPERATING FUNCTION N 7: SAFETY 134. DIAGNOSTIC 15ALARMS AND WARNINGS 15EXTENDED ALARM DESCRIPTION/TROUBLESHOOTING 16The information described in this manual may be subject to variations due to technical modifications.DUPLOMATIC S.p.A. reserves the right to modify the conte
10、nts of this manual without prior notice.DUPLOMATIC E.M.6427 400V RELEASE 7.1 11-026427071-400-en 31. GENERAL INFORMATIONThe Duplomatic control unit is a compact system that controls all functions regarding positioningand driving of the SM* turrets Duplomatic. The interfacing to the lathe is powerful
11、 and simplifiedfor an easy installation.Serial line RS232 is set for diagnostic and remote control by PC.CODE OF THE CONTROL UNITIt is possible to see all the data concerning the control unit looking at this stamp, applied on itsrack.Correspondence:Model: DDC2-10-J20/ 22Software version: SFW062I403
12、for SMA-20IMPORTANT NOTE FOR SAFETYDo not manipulate the inside of the unitOnly personnel authorized by Duplomatic may manipulate theinside of this unit.Do not manipulate the connectors with the unit connected to AC power.Before manipulating the connectors (inputs/outputs, feedback, etc.)make sure t
13、hat the unit is not connected to AC power.The control unit, even after the power off of the supply, stores internally electricpower until the power capacitors are charged.Be careful when operate on it.EMC COMPLIANCEThe turret has been tested under the condition reported as follows and obtained the c
14、ompliancefor: CEI EN 61800-3 and CEI EN 61800-4.DUPLOMATIC E.M.6427 400V RELEASE 7.1 11-026427071-400-en 4CHARACTERISTICS OF THE CONTROL UNIT TYPE DDC2-10-J*/22 Best path research. External selection of rotation direction. Automatic reference search. Parity control on position code. Enhanced diagnos
15、tic. Selection of two ranges of positions (eg. 8 and 12 or 6 and 12) with dedicated inputs. Selection of inertia on disc with dedicated input. Speed reduction for maintenance purposes with dedicated input. Safety behaviour can be set by CNC or PC.The entire unit is insulated from the external with o
16、ptoinsulators to satisfy safetystandards.Parameters of the system are optimised and cannot be modified by the customer.TECHNICAL CARACTERISTICS OF THE CONTROL UNITPower supplyPower input 3 F 400V +15% - 10 %50/60Hz 2Hz 3 10A max.Auxiliary input 2 F 230V10%50/60Hz 2Hz 2 35VAtab 1Supply for I/ODigital
17、 inputs Type Voltage CurrentoptoinsulatedSink24 VDC 10%5 mA 24 VDCDigital outputs Type Voltage Max current for signalsElectrovalve Type VoltageMax current for electrovalveOptoinsulated Transistor NPN (Source) 24 VDC 10% 0.2A 24 VDCOptoinsulated Transistor NPN (Source) 24 VDC 10% 0.5A 24 VDCtab 2Gene
18、ral specificationsOperative Temperature 0 55 CHumidity 30 95%Vibrations 4G RMS (for short period)0,5 RMS (continuously)tab 3DUPLOMATIC E.M.6427 400V RELEASE 7.1 11-026427071-400-en 52. ELECTRICAL CONNECTIONSRefer to the annex diagrams:1. : wiring diagram for standard turrets.2. : cables3. : timings4
19、. : instructions for RS-232 serial cableSUPPLYPOWER SUPPLY 400 VAC 3 F(see tab1)The control unit requires a three-phase 400 VAC input for the power card.A power contactor on the 400 AC line must be used for emergency stop (see wiring diagram).The 400 VAC line must be protected with external fuses 10
20、 A T.(or 4-6.3 A motor start)An inrush current can happen at power-on due to the internal 100uF power capacitors.An external filter is required to meet E.M.C. compliance (optional).POWER SUPPLY 230 VAC 2 F(see tab1)The control unit requires a single-phase 230 VAC input for the logic card.A 500mA T F
21、2 fuse must be used to protect this supply.POWER SUPPLY 24VDC FOR I/O(see tab 2)On the control unit are present two different connections +24VDC.The +24VDC on terminal P10-2 is used to supply the electrovalve and must be protected with a500 mA T fuse (F5).The +24VDC on terminal P10-6 is used to supp
22、ly the signals outputs and must be protected witha 500mA FF fuse (F4).0VDC is connected at terminal P10-24.Note: during turret start-up, use P10-1 and P10-7 connections for 24V DC. In this way the fusesinside the connection box are used and can protect the unit against mistakes on wirings. Afterthe
23、positive test switch to P10-2 and P10-6 and use the fuses in the cabinet that are morereachable.TECHNICAL SPECIFICATIONS FOR POWER TRANSFORMER DESIGNImportant: check the voltage drop on the 400 VAC supply during acceleration, to be sure thatthis doesnt approach the indicated voltage limits.Rated pri
24、mary voltage VariableSecondary rated voltage 400 VCA 10% 3 Rated Power 1000 VAMax voltage drop at 10 A rms (duringacceleration)5%Connection star-star or delta-starSecondary voltage deviation 2%tab 4DUPLOMATIC E.M.6427 400V RELEASE 7.1 11-026427071-400-en 6I/O SIGNALSOUTPUTS TO CNCLOCKED: turret lock
25、ed.INDEXD: turret in position (can be used to start axis movement).ALBIT1, ALBIT2, ALBIT4: alarms code.OUTPUTS TO ELECTROVALVEEVLOCK: locking valve.EVULCK: unlocking valve.INPUTS FROM CNCPBIT01, PBIT02, PBIT04, PBIT08, (PBIT16): position code bits.PARITY: parity for position codes.PSTART: signal for
26、 starting turret cycle.PTAB01, PTAB02: set 8/12 positions.PTAB03: set low/high inertia.MODE01, MODE02, MODE03: mode selection code bits.SPDSEL: selection of standard or maintenance speed.SELECTION OF THE NUMBER OF POSITIONSThe turret can be easily configured for two different number of positions sim
27、ply setting twosignals in the control unit. No mechanical operations or part replacement are requiredSoftware 8/12 tools 6/12 12/24 8/16Tools N 8 12 6 12 12 24 8 16PTAB01 24VDC 0VDC 24VDC 0VDC 24VDC 0VDC 24VDC 0VDCPTAB02 0VDC 24VDC 0VDC 24VDC 0VDC 24VDC 0VDC 24VDCThe 24VDC for selections must be don
28、e at the same time with 230 VAC 1 (max lag time 500 ms).If the 24 VDC is done with a lag time over 500 ms, the turret can not start and ALARM 78 (or 77)appears.SELECTION OF LOW/HIGH INERTIAThe turret can be easily configured to drive two ranges of inertia just setting a signal in thecontrol unit.No
29、mechanical operations or part replacement are requiredStandard inertia High inertiaPTAB03 connected to 24VDC not connectedSELECTION OF STANDARD/MAINTENANCE SPEEDThis input can be used to slow-down immediately the turret in front of dangerous operations(door opening, maintenance operations). The spee
30、d is about the 20% of the nominal speed.Connect the SPDSEL input to the 24VDC supply if not used.Standard speed Maintenance speedSPDSEL connected to 24VDC not connectedDUPLOMATIC E.M.6427 400V RELEASE 7.1 11-026427071-400-en 7CONNECTION BOX AND TERMINALS LAY-OUTName Terminal Name TerminalCM2-FUSE-F2
31、 P10-1 MODE03 P10-21CM2 P10-2 SPAREINP1 P10-22EVLOCK P10-3 SPDSEL P10-23EVULCK P10-4 COM 0V P10-24SPAREOUT1 P10-5PTABO1 LK1CM1 P10-6 PTABO2 LK2CM1-FUSE-F1 P10-7 PTABO3 LK3LOCKED P10-8INDEXD P10-9 R E1ALBIT1 P10-10 S E2ALBIT2 P10-11 T E3ALBIT4 P10-12 PE E4PBIT01 P10-13 L E5PBIT02 P10-14 N E6PBIT04 P1
32、0-15PBIT08 P10-16 P9-2 RS232-RXDPARITY P10-17 P9-3 RS232-TXDPSTART P10-18 P9-4 RS232-DTRMODE01 P10-19 P9-5 RS23-2SGMODE02 P10-20 P9-7 RS232-RTSDUPLOMATIC E.M.6427 400V RELEASE 7.1 11-026427071-400-en 83. INTERFACING TO CNCOPERATING FUNCTIONSThe control unit offers several operating functions (also c
33、alled MODES).Setting MODE01, MODE02, and MODE03 signals can make the selection of the operatingfunctions.INPUTS DESCRIPTIONN OPERATINGFUNCTIONS MODE01 MODE02 MODE030 Emergency/Reset0 0 0 Setting this mode will stop immediately the turret. Alarmscan be reset setting this mode and the setting another
34、mode.1 Automaticshortest path1 0 0 The turret will use the shortest path to reach the positionrequired.2 Automatic CW 0 1 0 The turret will always use the CW direction path to reach theposition required.3 Automatic CCW 1 1 0 The turret will always use the CCW direction path to reachthe position requ
35、ired.4 Jog, next tool inCW or CCW0 0 1 The turret will reach the next position.5 Service 1 0 1 Enables a series of functionality to simplify the start-up phaseand troubleshooting6 Maintenance(only by PC)- - -7 Safety 1 1 1 Enables a series of functionality to overcome conditions thatnormally would s
36、top the turret for a long time.ZERO SEARCHAfter any power-on of the control unit (230 V -1 phase auxiliary supply) the turret mustexecute the reference cycle.At the end of the reference cycle the turret is locked in position 1.To execute the reference cycle proceed as follows1. Set an automatic func
37、tion (1,2 or 3)2. Set this code.POSITION PARITY PBIT01 PBITO2 PBIT04 PBIT08 (PBIT16)Zero cycle 0 0 0 0 0 03. Set impulsive PSTART to reach out the zero position(PSTART must stay on for more than 30 ms).4. Wait 500 ms after INDEXD and LOCKED signals give the end of the cycle.DUPLOMATIC E.M.6427 400V
38、RELEASE 7.1 11-026427071-400-en 9OPERATING FUNCTIONS DESCRIPTIONAUTOMATIC OPERATING FUNCTIONS (1,2,3) Set the code of the position required. Wait until the position code output is stable (it depends on what type of PLC/CNC outputsare used - relay, static). Give the PSTART command (active on its risi
39、ng front). PSTART must stay ON for morethan 30 ms (T2). The turret confirms the reception of the start signal by setting low both INDEXD andLOCKED signal after approximately 30 ms (T3). When the position requested has been reached, but the disc is not yet locked, the INDEXDsignal is set high (this s
40、ignal can be used to start the approach of the tool to the part to beworked on). After the disc has been locked, the LOCKED signal is set to high. The turret can work. Position bits and parity bit must be stable for at least 30 ms. from PSTART signal. After thistime and once the turret confirmed the
41、 start reception, position bits, parity bit, and start signalcan be changed until the INDEXED signal is low. However it is strongly recommended tokeep position bits and parity code set to the last position called. The PSTART signal can be reset after the confirmation of the reception, typically it m
42、ust stayon for at least 30 ms (T2).Important: the end of cycle must be detected by the LOCKED signal that changes fromlow to high and with the INDEXD signal high and no alarms are present.SAME TOOL CALLIn case of the turret is already in the position called (for example change in tool offset T1.01T1
43、.02) the turret will not move or unlock/lock but the INDEXD and LOCKED signals will havethe same behaviour as a normal rotation (INDEX and LOCKED low after the PSTAR and thenafter approx. 200ms the INDEX goes HIGH and after 50 ms more the LOCKED signal goesHIGH).DUPLOMATIC E.M.6427 400V RELEASE 7.1
44、11-026427071-400-en 10INDEXD SIGNALThe INDEXD signal must be used with the LOCKED signal to detect the end of cycle of theturret and can be ignored once the turret is locked.The INDEXD output goes and stay LOW also when the emergency mode is set and if the three-phase power supply is OFF.In this cas
45、e, if the turret management from PLC/CNC uses the emergency mode or open thepower contactor, the INDEXD signal must be used only when the turret is in cycle and thenignored.The CNC/PLC program must check the LOCKED signal while the turret is not in cycle: if thissignal goes LOW stop immediately the
46、machine and check the cause.JOG MODEThe turret does not output the position code, so in JOG mode the actual position must bememorised by the CNC / PLC.Be sure to not show in the screen of CNC a tool position different from the reality.We suggest to use always the automatic mode in order to force CNC
47、 to keep track of the turretposition.ALARM CONDITIONSWhen an alarm condition is detected, one or more of the ALBIT1, ALBIT2, ALBIT4 is high andthe INDEXD signal is low.In this case the machine must be immediately stopped and the three-phase power contactorshould be opened.Important: the turret can s
48、how alarms in any time (also if it is not on cycle) so check always thealarm output of the turret. EXCESSIVE ELECTRICAL NOISE OR BAD WIRING DETECTIONIf the turret is not in cycle and in automatic mode, any variation in POSITION BITS and PARITYmust be followed by the PSTART signal.If the PSTART does
49、not came in about 5 seconds (T1) an alarm 7 (73) is output from the turret.Avoid to change the position code just after the turret LOCKED signal goes high (end of cycle)because this can be detected as a new position request.See the diagnostic section to have more details.AUTOMATIC RECOVER FOR PRESSURE/VALVES PROBLEMSThe turret will attempt three times to lock or unlock before giving an alarm (41 or 51).If the opera
