Delem
DAC-250
OPERATION MANUAL
VA 3
L:\Documentation\MANUAL\DAC\DAC-250\V3\250OMGB.WPD
Manual version V1299
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PREFACE
This manual remains the property of Delem bv and will be placed at your disposal free of charge. It is not allowed to multiply the contents of this manual, in whole or in part, or to disclose the contents to third parties without written consent of Delem bv It is not allowed to use the contents of this manual and incorporate them in other designs without Delem's written consent.
Delem bv, Holland
LIMITED WARRANTY
1The DAC-250 offers no protection against the operator and contains no built-in machine safety.
Therefore, application of the DAC-250 controller is the entire responsibility of the customer. Safety measures must be taken outside the DAC-250 controller in order to guarantee safety for the operator, even in case of possible malfunctioning of the DAC-250 controller.
Delem bv cannot be held responsible for any damage caused directly or indirectly by the DAC-250 controller in normal operation or even if it fails to function according to its specifications.
2 Delem bv provides this manual without warranty of any kind, either expressed or implied; including, but not limited to the particular purpose. Delem bv reserves the right at any time to make improvements and/or changes in their product(s) and/or program(s) described in this manual.
This manual may include technical inaccuracies or typographical errors but as it is subject to periodical updatings the necessary corrections will be incorporated in new editions of this publication.
Requests for copies of this manual and for technical information about products can be directed to Delem bv employees authorized to give this information.
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CONTENTS |
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CONTENTS . |
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. . . . . . . . . . . . . . . 0.5 |
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1. |
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
. . . . . . . . . . . . . . . 2.1 |
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2. |
HARDWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
. . . . . . . . . . . . . . . 2.1 |
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2.1. |
Frontpanel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
. . . . . . . . . . . . . . . 2.1 |
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2.1.1. |
Displays and LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
. . . . . . . . . . . . . . . 2.2 |
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2.1.2. |
Keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
. . . . . . . . . . . . . . . 2.2 |
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2.2. |
Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
. . . . . . . . . . . . . . . 3.1 |
3. OPERATING MODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1 3.1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1 3.1.1. Start/stop parameter readout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 3.2. Manual mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 3.3. Automatic mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3 3.4. Semi-automatic mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
4. PARAMETER PROGRAMMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 4.1. Identification of a step . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 4.2. Programmable Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 4.2.1. Programming a value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4 4.2.2. Backgauge position Xm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4 4.2.3. Actual position readout Xp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4 4.2.4. COR(rection) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4 4.2.5. Retract distance DX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 4.2.6. Function Outputs F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 4.2.7. Repetition CY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6 4.2.8. Code C(haining) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7 4.2.9. Stock Counter # . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8 4.2.10. Inch/mm selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8 4.2.11. Programming key lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8 4.2.12. Range checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
5. PROGRAMMING EXAMPLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1
6. MACHINE FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1 6.1. Selecting machine functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1 6.2. Position adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 6.3. Counting (#) mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
7. MACHINE PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1 7.1. List of machine parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2 7.2. Description of the machine parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1
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8. INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1 8.1. Connection example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1 8.2. Encoder Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1
9. DIAGNOSTIC PROGRAM DAC-150/DAC-250 . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1 9.1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1 9.2. Starting the diagnostic program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2 9.2.1. A1: Ram memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2 9.2.2. A2: displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3 9.2.3. A3: frontpanel keys and LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4 9.2.4. A4: digital inputs and outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4 9.2.5. A5: analog output deflection (DC-version only) . . . . . . . . . . . . . . . . . . . . . . . 9.5 9.3. Ending the diagnostic program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
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1.INTRODUCTION
The DAC-250 is a universal programmable controller, designed to control machinery based on incremental displacement of certain machine functions such as the backgauge control of an industrial shear. For a better understanding the backgauge will be referred to throughout this manual but remember, any machine section with a movement, measured by an incremental encoder, could be meant instead. The DAC-250 is not confined to axis positioning but can program parameters, related to other machine functions, as well.
It is possible to program several steps which can be combined to programs. The DAC-250 is capable of controlling servo-loop systems, a oneor two-speed AC or DC drive system.
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2.HARDWARE
The DAC-250 consists of two printed circuit boards and a frontpanel. The two PCBs are:
-I/O board;
-Computer board containing all LEDs, character displays and keyboard interface.
2.1.Frontpanel
Unfold the drawing at the end of this manual, which shows a representation of the front panel with a description of the function keys.
2.1.1. Displays and LEDs
Displays
The DAC-250 has eight character displays. These are 7-segment displays. The eight displays are divided as follows:
-two displays for number and step indication (N,ST).
-six displays for parameter value display.
LEDs
The control panel contains thirteen LEDs:
-nine LEDs indicating the selected parameters; (Xm, Xp, COR, DX, F, CY, C, # and I);
-one LED to indicate that the CH-function 
is active;
-one LED in the stop key, indicating that the DAC-250 is stopped;
-one LED in the Semi-automatic mode key, indicating that the DAC-250 has been started in semi-automatic mode.
-one LED in the Automatic mode key, indicating that the DAC-250 has been started in Automatic mode;
2.1
2.1.2. Keyboard
The keyboard contains the following keys:
-10 numerical keys (0 - 9)
-decimal point
-plus/minus toggle
-clear key, to clear a parameter value
-cursor key, to select the next parameter
-N, program number increment key
-ST, step increment key
-manual movement low speed up key (+)
-manual movement low speed down key (-)
-manual movement high speed key (x key in combination with + or - key)
-stop key (0)
-semi automatic start key
-automatic mode start key
2.2.Memory
The following (external) memory is available:
-32 Kbyte EPROM for program code (optional 64K)
-8 Kbyte RAM
-2 Kbyte EEPROM for step and machine parameter storage.
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3.OPERATING MODES
3.1.General
The DAC-250 has three operating modes: Manual mode, Automatic mode and Semi-automatic mode.
Manual mode is selected if N = 0 and ST = 0.
Automatic and semi-automatic mode are both selected with a key on the frontpanel. These keys also serve as start buttons.
When the automatic or semi-automatic key is pressed the DAC-250 will position the backgauge according to the programmed parameters in the selected step.
The LED of the corresponding key (either automatic or semi-automatic) will light up.
When the stop button (O) is pressed the DAC-250 will control the backgauge at its actual position. The LED of the stop button will light up.
In some situations the "stop" is forced by the DAC-250 itself. In that case the LED of the relevant start button extinguishes and the LED of the stop button lights up.
In the following paragraphs the three operating modes are described.
First the parameter readout after pressing start and stop is described.
Paragraph 3.1.1. describes the inputs and outputs which have a direct relationship with an operating cycle.
3.1.1. Start/stop parameter readout
When the start button is pressed the cursor moves automatically to Xp. This means that when the start button is pressed always the actual position is displayed.
When the stop button is pressed again the cursor moves to Xm.
There are two exceptions:
1.When the cursor is at the parameter # it will stay at # when the start or stop button is pressed.
2.When the counter (#) is used in the downcounting mode the cursor automatically moves to # when the value 0 is reached. In this case the DAC-250 also goes to stop.
3.1
3.2.Manual mode
Manual mode can only be selected if N = 0 and ST = 0.
In Manual Mode all parameters can be programmed. Only the program flow part of code (C) and step repetition (CY) have no meaning. However, Stock Counter (#) can be used.
When the automatic or semi-automatic key is pressed (start function) in manual mode the backgauge moves to the programmed position.
The stock counter (#) will be either incremented or decremented at each manual cycle, depending on the setting (refer to chapter 4.2.8).
When the stock counter reaches zero in downcounting mode the DAC-250 stops. The cursor automatically goes to the #-LED).
If the LED of the stop button is lit the backgauge can be moved manually by pressing the manual movement keys on the frontpanel. These keys are:
+ = slow speed in counting up direction
- = slow speed in counting down direction
X = high speed, must be pressed together with the + or - key.
3.3.Automatic mode
In Automatic Mode a program can be executed.
When the automatic key 
is pressed the backgauge moves to the programmed position of the current step (N,ST).
A new step (N,ST) is loaded at each change of the status of the START input.
If the value for step repetition CY is higher than 1, only the value of CY in the current step is decremented by 1 and no new step will be loaded.
Note:
A step with CY = 0 will be skipped.
In some situations the DAC-250 stops instead of moving to the new backgauge position. This depends on the program flow code (C) (refer to chapter 4.2.7).
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3.4.Semi-automatic mode
The execution cycle in Semi-automatic Mode is mainly equal to the Automatic Mode.
In semi-automatic mode the DAC-250 stops at the end of a cycle.
If the programmed value for CY is higher than 1 a number of cycles equal to this value must have been executed before the DAC-250 stops.
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4.PARAMETER PROGRAMMING
The DAC-250 is a programmable backgauge controller.
The DAC-250 can also program parameters, related to other machine functions. One such set of parameters is referred to as a "step".
Several steps can be combined to build a program. During the execution of the program the steps within a program are executed one after another in an automatic cycle.
4.1.Identification of a step
A step is identified by a 2-digit number in the range 0-99.
This means that up to 100 steps can be programmed and stored into memory.
The number of the selected step is displayed on two character displays. The digit, highest in order (left-hand), is called "N", the lowest in order (right-hand) is called "ST".
The keys N and ST are used to increment the value of N and ST. If N or ST = 9 it will become 0 after the next increment. If you pass the required numeral you can only increment until this numeral appears again, i.e. you cannot decrement.
Holding the keys N and ST will speed up the effect.
If in manual mode two LEDs light up:
-the selected parameter;
-the LED at the right of the ST-display.
Note:
"N" can be considered as a program number and "ST" as a step number within the program. This definition enables the programming of 10 programs of maximum 10 steps each. However, you are free to make programs consisting of more than 10 steps or to let a program start at every N,ST combination.
The current N,ST is memorized after power down. At power up this step is automatically loaded again.
4.2.Programmable Parameters
A parameter can be programmed upon selection. The selected parameter is indicated by a LED. Each parameter is represented by its own LED. Selecting a parameter is done by pressing the < key. The actual value of the selected parameter is displayed on the 6-character display.
There are five step dependant parameters and two general parameters. The function Xp, which is also indicated by a LED, is not a programmable parameter. If Xp is selected the actual position of the backgauge is displayed.
4.1
The step dependant parameters are:
-Xm = position of the backgauge
-COR = correction of the position of the backgauge
-DX = retraction of the backgauge
-F = function outputs
-CY = number of (step) repetitions
-C = code
The general parameters are:
# = Stock counter: counting of products I = inch/mm selection
Each time the < key is pressed the next parameter becomes active. The sequence is as follows:
< Xm < Xp < COR < DX < F < CY < C < # < I ... < Xm and so on.
Holding the key < will speed up the effect.
4.2.1. Programming a value
When a parameter is selected its value can be programmed.
To program a value the following keys are available:
-10 numerical keys (0-9)
-decimal point
-plus/minus
-clear key (
)
When programming a value each new digit is added as follows:
-left of the decimal point:
all existing digits are shifted one place to the left, the last programmed digit will be the least significant.
-right of the decimal point:
the digits appear from the left to the right
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Example:
Suppose the value 367.25 has to be programmed. The table below shows the order of the keys to be pressed. The number of decimals depends on the setting of the machine parameter and may as well be limited to only one digit.
key pressed |
value on display |
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0.00 |
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3 |
3.00 |
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6 |
36.00 |
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7 |
367.00 |
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. |
367.00 |
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2 |
367.20 |
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5 |
367.25 |
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Plus/minus key:
If the plus/minus key is pressed a minus sign is displayed in the first free digit left of the value. If the plus/minus key is pressed and all the digits are already used the minus sign is placed in the leftmost digit (the leftmost digit of the value is blanked out).
If the plus/minus key is pressed a second time the value becomes positive again (toggle function).
Clear key:
When the clear key (
) is pressed the value on the display is set to zero.
The value which is displayed after clear is one "0" left of the decimal point. The number of zeros at the right of the decimal point depends on the parameter format. The minus sign is also reset after clear.
Example:
A parameter with two digits right of the decimal point is displayed as "0.00" after clear.
The range of values which can be programmed is machine dependant and will be discussed in the next paragraphs.
4.3
4.2.2. Backgauge position Xm
When the cursor is at Xm a value is displayed with a format depending on the installed machine parameter.
This format represents the stepping resolution of the backgauge movement.
Note 1:
The backgauge position can also be programmed negative if chaining is used (see chapter 4.2.8).
Note 2:
If the cursor is at Xm and a correction (COR) has been programmed (see chapter 4.2.4) this will be indicated by a flashing "COR" LED.
4.2.3. Actual position readout Xp
If Xp is selected the actual backgauge position is displayed.
If the reference has not passed yet only small squares are displayed: the lower four segments of each display are lit.
4.2.4. COR(rection)
Correction on the programmed backgauge position.
The value to be programmed at COR appears in the same resolution as Xm.
Default: 0
4.2.5. Retract distance DX
In some cases it may be necessary to clear (retract) the material from the backgauge. This may occur at the moment when the mechanical action begins. The retract distance is a programmable displacement of the motor axis in the upcounting direction.
The value at DX appears in the same resolution as Xm.
Default: 5
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4.2.6. Function Outputs F
There are two function (on/off) outputs: F1 and F2.
These outputs can be used in two ways:
1.) The value of these two outputs can be programmed as one parameter.
2.) They can be used by the stroke length limitation function as a warning signal.
Use machine parameter 28 to select one of these functions.
1.) In case the outputs are programmed as one parameter, there are four combinations:
Value |
F2 |
F1 |
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00 |
off |
off |
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01 |
off |
on |
|
|
|
10 |
on |
off |
|
|
|
11 |
on |
on |
|
|
|
Default: 00 (both off)
A combination can be programmed with function F.
The digital outputs will be set to the programmed value when the start-enable input becomes high while the DAC has been started. The outputs stay at the actual value during the program step and will be reset when the DAC is stopped.
2.) In case the stroke length limitation function is programmed through machine parameter 28, the function outputs have a different function. Then the machine has a maximum stroke length, dimensioned in seconds. With function F, you can program a stroke length as a percentage of that maximum stroke length. When the desired time has elapsed, output F1 will become active. Output F2 is not used in this function and remains inactive.
4.2.7. Repetition CY
Step repetition: the number of times a step is repeated before the next step is executed.
Range : |
0 - 9999 |
Default: |
1 |
Note 1:
The value 0 means that the step must be skipped.
Note 2:
This parameter has no meaning in Manual mode and is equal to 0.
4.5
4.2.8. Code C(haining)
This parameter is a combination of two functions:
-Chaining indication
-Program flow code
Chaining:
0 = The programmed backgauge value (Xm) is an absolute position. 1 = The programmed backgauge value (Xm) is a chain value.
This means that the new value is obtained by adding or subtracting the programmed value to/from the previous position. Consequently the value may be negative as well.
Program flow code:
5 = Start of program: this indicates the first step of a program.
6 = Program end code: after this step has been completed the first step (= code 5) is loaded and the DAC-250 stops. The program counter will be adjusted.
7 = Program end code: after this step has been completed the first step (= code 5) is loaded and the program is executed again as long as the stock counter (#) is not equal to 0. After each completion of the program the repetition counter is decremented (if decrement mode is selected). On reaching value 0 the DAC-250 stops.
8 = Program end code: after this step has been completed the first step (= code 5) is loaded and the program is executed again. This is repeated endlessly.
9 = Program end code: after this step has been completed the DAC-250 stops.
The chaining code can be combined with a program flow code. In that case two digits have to be programmed. The order in which these digits are programmed is not important.
Example:
If the programmed backgauge position in a step must be a chain value and it is the last step, the value for the code (C) can be 16 or 61. Both combinations have the same meaning (code 1 and code 6).
Note 1:
If the chain/absolute code is omitted the position is assumed to be an absolute backgauge position.
Note 2:
If the chaining code is set (code = 1) in a step it will be indicated by the " 
" LED (at the right of the upper display).
4.6
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