Duplomatic DDC1-12-H16/20

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Summary

General Information

Control Unit Identification

Details on identifying the control unit via its label or stamp.

Safety Precautions

Critical safety precautions for handling the control unit and its components.

EMC Compliance Information

Information regarding electromagnetic compatibility testing and standards.

Technical Specifications Overview

Detailed specifications of the control unit's electrical and operational features.

Electrical Connections

Power Supply

Information on AC and DC power supply requirements for the control unit.

I;O Signal Definitions

Details on input and output signals for communication with CNC and electrovalves.

Turret Configuration Settings

Covers turret settings for position count, inertia, and speed modes.

Terminal Connections Layout

Diagram and list of terminal connections on the control unit's connection box.

Interfacing to CNC

Operating Function Modes

Overview of various operating modes and functions controllable via input signals.

Zero Reference Cycle Procedure

Procedure for executing the reference cycle after unit power-on.

Diagnostic

Alarm and Warning Codes

Table detailing alarm codes, their causes, and corresponding ALBIT outputs.

Extended Alarm Troubleshooting

Comprehensive descriptions and troubleshooting steps for specific alarm codes.

Summary

General Information

Control Unit Identification

Details on identifying the control unit via its label or stamp.

Safety Precautions

Critical safety precautions for handling the control unit and its components.

EMC Compliance Information

Information regarding electromagnetic compatibility testing and standards.

Technical Specifications Overview

Detailed specifications of the control unit's electrical and operational features.

Electrical Connections

Power Supply

Information on AC and DC power supply requirements for the control unit.

I;O Signal Definitions

Details on input and output signals for communication with CNC and electrovalves.

Turret Configuration Settings

Covers turret settings for position count, inertia, and speed modes.

Terminal Connections Layout

Diagram and list of terminal connections on the control unit's connection box.

Interfacing to CNC

Operating Function Modes

Overview of various operating modes and functions controllable via input signals.

Zero Reference Cycle Procedure

Procedure for executing the reference cycle after unit power-on.

Diagnostic

Alarm and Warning Codes

Table detailing alarm codes, their causes, and corresponding ALBIT outputs.

Extended Alarm Troubleshooting

Comprehensive descriptions and troubleshooting steps for specific alarm codes.

Overview

The Duplomatic control unit is a compact system designed to manage all positioning and driving functions for Duplomatic SM* turrets. It offers a simplified and powerful interface for easy integration with a lathe. The unit also includes an RS232 serial line for diagnostics and remote control via a PC.

Control Unit Identification

The control unit can be identified by a stamp on its rack, which provides key data:

Model: DDC1--K-/22 (e.g., DDC1-12-K20/22)
Set for motor: P8-R03/11
Code: 049*****
Software: SFW 062**** (e.g., SFW062I003 for SM-20)
Supply: 230 Vac 3~, 230 Vac 1~, 24 Vdc
S/N: ********
In: * A
Ipk: * A
Made in: Italy

Safety Information

Caution: 230 V

Do not manipulate the inside of the unit: Only authorized personnel should access the internal components.
Do not manipulate connectors with AC power: Ensure the unit is disconnected from AC power before handling any connectors (inputs/outputs, feedback, etc.).
Internal power storage: Even after power-off, the control unit retains electric power in its capacitors. Exercise caution when working on it.
Main line switch: Turn off the main line switch before handling any parts in the unit.
Wait time: After turning off the main line switch, wait 4 minutes before opening the driver protection cover.

EMC Compliance

The turret has been tested and complies with CEI EN 61800-3 and CEI EN 61800-4 standards.

Technical Characteristics

The control unit features include:

Best path research for efficient positioning.
External selection of rotation direction.
Automatic reference search.
Parity control on position code for data integrity.
Enhanced diagnostic capabilities.
Selection of two ranges of positions (e.g., 8 and 12 or 6 and 12) using dedicated inputs.
Selection of inertia on disc (low/high) with a dedicated input.
Speed reduction for maintenance purposes with a dedicated input (not available for software 1003).
Configurable 'Safety' behavior via CNC or PC.

The entire unit is insulated from external interference using optoinsulators to meet safety standards. System parameters are optimized and cannot be modified by the customer.

Power Supply (tab 1)

Power input 3 Φ: 230V +10% - 10%, 50/60Hz ±2Hz 3 Φ, 12A max.
Auxiliary input 2 Φ: 230V±10%, 50/60Hz ±2Hz 2 Φ, 35VA

Supply for I/O (tab 2)

Digital inputs: Optoinsulated, Sink type, 24 VDC ±10% voltage, 5 mA @ 24 VDC current.
Digital outputs: Optoinsulated, Transistor NPN (Source) type, 24 VDC ±10% voltage.
- Max current for signals: 0.2A @ 24 VDC.
Electrovalve: Optoinsulated, Transistor NPN (Source) type, 24 VDC ±10% voltage.
- Max current for electrovalve: 0.5A @ 24 VDC.

General Specifications (tab 3)

Operative Temperature: 0 ÷ 55 °C
Humidity: 30.. 95%
Vibrations: 4G RMS (for short period), 0.5 RMS (continuously)

Electrical Connections

Refer to annex diagrams for wiring, cables, timings, and RS-232 serial cable instructions.

Power Supply 230 VAC 3 Φ (see tab 1)

Requires a three-phase 230 VAC input for the power card.
A power contactor on the 230 AC line is necessary for emergency stop.
The line must be protected with external 10 A T fuses (or 4-6.3 A motor start).
An inrush current can occur at power-on due to internal 300uF power capacitors.
An external filter is recommended for E.M.C. compliance (optional).

Power Supply 230 VAC 2 Φ (see tab 1)

Requires a single-phase 230 VAC input for the logic card.
A 500mA T F2 fuse protects this supply.

Power Supply 24VDC for I/O (see tab 2)

Two different +24VDC connections are present on the control unit.
P10-2: Supplies the electrovalve, protected by a 500 mA T fuse (F5).
P10-6: Supplies the signals outputs, protected by a 500mA FF fuse (F4).
OVDC: Connected at terminal P10-24.
Note: During turret start-up, use P10-1 and P10-7 for 24V DC to utilize internal fuses for protection. After positive testing, switch connections to P10-2 and P10-6 for easier access to cabinet fuses.

Technical Specifications for Power Transformer Design (tab 4)

Rated primary voltage: Variable
Secondary rated voltage: 230 VCA ± 10% 3 Φ
Rated Power: 1000 VA
Max voltage drop at 20 A rms (during acceleration): 5%
Connection: star-star or delta-star
Secondary voltage deviation: ± 2%
Important: Check voltage drop on the 230 VAC supply during acceleration to ensure it stays within indicated limits.

I/O Signals

Outputs to CNC

LOCKED: Indicates the turret is locked.
INDEXD: Indicates the turret is in position (can be used to start axis movement).
ALBIT1, ALBIT2, ALBIT4: Alarm codes.

Outputs to Electrovalve

EVLOCK: Controls the locking valve.
EVULCK: Controls the unlocking valve.

Inputs from CNC

PBIT01, PBIT02, PBIT04, PBIT08, (PBIT16): Position code bits.
PARITY: Parity bit for position codes.
PSTART: Signal for starting the 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 (not for software SFW062I003).

Usage Features

Selection of the Number of Positions

The turret can be configured for two different numbers of positions by setting two signals in the control unit, without mechanical operations or part replacement.

Software	8/12 tools	6/12	12/24	8/16
Tools N°	8	12	6	12
PTAB01	24VDC	0VDC	24VDC	0VDC
PTAB02	0VDC	24VDC	0VDC	24VDC

Note: 24VDC selections must be made simultaneously with 230 VAC 1 Φ (max lag time 500 ms). If the 24 VDC lags by over 500 ms, the turret will not start and ALARM 78 (or 77) will appear.

Selection of Low/High Inertia

The turret can be configured to drive two ranges of inertia by setting a signal in the control unit, without mechanical operations or part replacement.

	Standard inertia	High inertia
PTAB03	connected to 24VDC	not connected

Selection of Standard/Maintenance Speed

This input allows immediate slowing down of the turret for dangerous operations (e.g., door opening, maintenance). The speed is approximately 20% of the nominal speed. Connect the SPDSEL input to the 24VDC supply if not used.

	Standard speed	Maintenance speed
SPDSEL	connected to 24VDC	not connected

Interfacing to CNC

Operating Functions

The control unit offers several operating functions (MODES) selected by setting MODE01, MODE02, and MODE03 signals.

Index Signal (INDEXD)

The INDEXD signal is used in conjunction with the LOCKED signal to detect the end of the turret cycle. It can be ignored once the turret is locked.

The INDEXD output goes and stays LOW when emergency mode is set or if the three-phase power supply is OFF.
If the turret management from PLC/CNC uses emergency mode or opens the power contactor, the INDEXD signal should only be used when the turret is in cycle and then ignored.
The CNC/PLC program must check the LOCKED signal when the turret is not in cycle. If LOCKED goes LOW, immediately stop the machine and investigate the cause.

Jog Mode

In JOG mode, the turret does not output the position code. The actual position must be memorized by the CNC/PLC.

Avoid displaying an incorrect tool position on the CNC screen.
It is recommended to always use automatic mode to ensure the CNC tracks the turret position.

Alarm Conditions

When an alarm condition is detected, one or more of ALBIT1, ALBIT2, ALBIT4 will be HIGH, and the INDEXD signal will be LOW.

The machine must be immediately stopped, and the three-phase power contactor should be opened.
Important: The turret can show alarms at any time (even if not in cycle), so always check the alarm output.

Excessive Electrical Noise or Bad Wiring Detection

If the turret is not in cycle and in automatic mode, any variation in POSITION BITS and PARITY must be followed by the PSTART signal.
If PSTART is not received within approximately 5 seconds (T1), an alarm 7 (73) will be output.
Avoid changing the position code immediately after the turret LOCKED signal goes HIGH (end of cycle), as this can be detected as a new position request.
Refer to the diagnostic section for more details.

Automatic Recover for Pressure/Valves Problems

The turret will attempt to lock or unlock three times before issuing an alarm (41 or 51). If the valve operates multiple times during tool change, investigate and resolve the underlying problem to prevent permanent failure.

Diagnostic

Alarms and Warnings

The electronic unit continuously performs self-diagnosis and signals alarm conditions. Alarm codes are provided on ALBIT1, ALBIT2, and ALBIT4 outputs.