Duplomatic DDC1-30/12-K20/22

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DUPLOMATIC E.M.6427 RELEASE 7.1 05-03

6427071-230-en 1

SM-TURRETS

CONTROL UNIT DDC1-12-H**/22

CONTROL UNIT DDC1-30/12-H**/20

Software: SFW062G002, SFW062G003, SFW062G006, SFW062G012, SFW062I238

SFW062I239, SFW062I229, SFW062I245, SFW062I003

INSTALLATION MANUAL

INSTRUCTIONS FOR ELECTRICAL CONNECTIONS OF INTEGRATED CONTROL UNIT

Correspondence between electronic unit code and software

Electronic unit Code Software Turret Notes

DDC1-30/12-K20/22 0496053K20 SFW062F002

SFW062G002

SFW062I002

SMA-*-25/2*-*-230 Std. 8/12 positions

DDC1-30/12-K**/22 0496053K** SFW062I244 SMA-*-25/2*-*-230 8/12 positions high inertia

DDC1-30/12-K20/22 0496053K20 SFW062G012

SFW062I012

SMA-*-25/2*-*-230 6 and 12 positions

DDC1-30/12-K**/22 0496053K** SFW062I239 SMA-*-25/2*-*-230 12 and 24 positions

DDC1-12-H20/22 0496006H20 SFW062G003 SMA-*-20/2*-*-230 Std. 8/12 positions

DDC1-12-H20/20 0496006H20 SFW062I003 SMA-*-20/2*-*-230 8 and 12 positions (Compatible with

SFW062E003)

DDC1-12-H20/22 0496006H20 SFW062I003 SMA-*-20/2*-*-230 8 and 12 positions (Compatible with

SFW062E003)

DDC1-12-H20/22 0496006H20 SFW062G006

SFW062I006

SMA-*-20/2*-*-230 6 and 12 positions

DDC1-12-H**/22 0496006H** SFW062I238 SMA-*-20/2*-*-230 12 and 24 positions

DDC1-12-H16/22 0496006H16 SFW062G003 SMA-*-16/2*-*-230 Std. 8/12 positions

DDC1-12-H16/22 0496006H16 SFW062I003 SMA-*-16/2*-*-230 8 and 12 positions (Compatible with

SFW062E003)

DDC1-12-H16/20 0496006H16 SFW062I003 SMA-*-16/2*-*-230 8 and 12 positions (Compatible with

SFW062E003)

DDC1-12-H16/22 0496006H16 SFW062G006

SFW062I006

SMA-*-16/2*-*-230 6 and 12 positions

DDC1-12-H**/22 0496006H** SFW062I245 SMA-*-16/2*-*-230 8 and 16 positions

Notes: Software release ‘E’,’F’, and ‘G’ will be replaced by software release ‘I’.

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Summary

INSTALLATION MANUAL

INSTRUCTIONS FOR ELECTRICAL CONNECTIONS

Guidance for electrical connections of the integrated control unit.

GENERAL INFORMATION

CODE OF THE CONTROL UNIT

Details on identifying the control unit via its label.

IMPORTANT NOTE FOR SAFETY

Crucial safety precautions for handling the control unit.

EMC COMPLIANCE

Information on Electromagnetic Compatibility standards met.

TECHNICAL CHARACTERISTICS

Specifications and features of the control unit.

ELECTRICAL CONNECTIONS

SUPPLY

Details on power supply requirements (230 VAC 3 Φ, 230 VAC 2 Φ, 24 VDC).

TECHNICAL SPECIFICATIONS FOR POWER TRANSFORMER DESIGN

Specifications for designing the power transformer.

I;O SIGNALS

Description of Input/Output signals for the control unit.

SELECTION OF NUMBER OF POSITIONS

How to configure the number of turret positions.

SELECTION OF LOW;HIGH INERTIA

Configuration for selecting low or high inertia settings.

SELECTION OF STANDARD;MAINTENANCE SPEED

How to select standard or maintenance speed.

CONNECTION BOX AND TERMINALS LAY-OUT

Diagram and layout of connection box and terminals.

INTERFACING TO CNC

ZERO SEARCH

Procedure for executing the reference cycle after power-on.

OPERATING FUNCTIONS

Overview of different operating modes and their settings.

INDEXD SIGNAL

Explanation of the INDEXD output signal and its use.

JOG MODE

How to use the Jog mode for turret movement.

ALARM CONDITIONS

Identification and handling of alarm states.

DIAGNOSTIC

ALARMS AND WARNINGS

Table of alarm codes, their meanings, and reset procedures.

EXTENDED ALARM DESCRIPTION;TROUBLESHOOTING

Detailed 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.