DELEM DA-66T Installation manual for CNC Press brake machine (Important passwords)

This manual contains information necessary for installation of a DA-Touch control on a press brake machine. It is meant for service people who are authorised for service and installation of the machine.

●The equipment is supplied by Delem without safety features. The machine manufacturer has to ensure a safe environment. 

●This equipment must be installed and used in accordance with Delem's specifications. The guarantee on the equipment is invalidated in the event of improper installation and/or use of this equipment. 

●The General Terms and Conditions of Delivery of Delem shall apply to this product. These conditions are available from Delem on request. 

●This manual does not entitle you to any rights. Delem reserves the right to change this manual without prior warning. 

●All rights reserved. The copyright is held by Delem. No part of this publication may be copied or reproduced without written permission from Delem BV.

This section contains the hardware specifications of a Delem control of the DA-Touch series.

⒈Introduction

This manual contains information necessary for installation of a DA-Touch control. Such a control is the heart of a pressbrake control system with which a synchronised pressbrake machine is controlled.

A DA-Touch control combines different tasks in one unit: 

- programming products and tools; 

- axis control during bending; 

- adjustment of machine settings.

Product programming and control operation is described in the user manual [4,5] of the relevant control model. Pressbrake control and system I/O between the control and the machine is carried out with 

the help of the DM modules. This is explained in chapter 2 of this section.

⒉System I/O

The system I/O between the DA-Touch control and the machine is carried out by the DM modules. These modules are connected to the DA-Touch control by means of the High Speed Bus (HSB). The meaning of all I/O signals is described in the machine parameter 

manual of the Delem controls.

The maximum allowed number of modules for the HSB is 8. The total length of HSB cable on the bus may not be longer than 30 metres. If more modules are required on the system then a second, optional HSB link can be enabled through a software option. 

Before a module can be used to control an axis, it must be connected to the control and be recognised as a valid DM module. The procedure to install DM modules in the system and assign axes to those modules is described in the machine parameter manual of the Delem controls [1]. 

Specifications of all the DM modules can be found in the Delem modusys manual [2].

⒊ Specifications

3.1 Physical dimensions

For the dimensions of the DA-Touch control, see the included drawings at the end of this section. 

The following environment specification values are valid for every DA-Touch control:

Ambient temperature	0 - 50°C  Warning: Avoid long-term exposure of the control to direct sunlight. Otherwise, the temperature inside the control will rise above tolerance levels.  Operation of the control should be carried out indoors.
Storage temperature	min. -10°C  max. 70°C
Relative humidity	max. 90 % non-condensing
EMC	designed and built to meet the following standards:   • EN50081-2   • EN61000-6-2
Enclosure	Designed and built to meet the requirements for  IP54 standard.

3.2Technical specifications

Power supply	18 - 28 VDC   75W
Display	LCD/TFT   1280 x 1024   Fault tolerance:  - total of 15 pixels defect  - max. 4 pixels defect within 10 mm radius  - max. 10 non-white pixels in white screen  - max. 10 non-black pixels in black screen
Interfaces	2 x HSB   2 x RS-232   2 x USB   1 x 10/100 baseT
disk drive(s)	CompactFlash card, 1GB (DA-66T) or 2GB  (DA-69T)
emergency stop button	Rated insulation voltage: 250 V AC/DC  Rated peak voltage Uimp: 2.5 kV  Rated operating current Ie:  • AC 15 B300 3A / 120V,  1.5A / 240V;  Ithe : 5A  • DC 13 Q 300 0.55A / 120V,  0.27A / 240V;  Ithe : 2.5A  Degree of pollution: 3  Positive opening travel: > 3 mm  Actuation speed: 5 ... 1000 mm / s  Class of protection: II

⒋Spare parts

4.1 Introduction

The table on the next page gives an overview of the available spare parts for the DA-Touch controls. The next chapter contains an exploded view of a DA-Touch control, in which the same spare part numbers are used.

Note: 

When ordering spare parts, always mention control type, model number and serial number of the control for which the spare parts are meant.

4.2Spare parts overview

⒌Schematics

5.1 DA-Touch info

5.2 Miscellaneous

This section will describe the necessary settings of a DA-Touch control regarding machine settings. 

A lot of machine settings can be modified through the Windows environment. Windows operation should be done by an authorised person, who knows how to operate Windows.

⒈The machine parameters

The adjustment of machine parameters and axis parameters is done in the Delem application. This procedure is described in detail in the Delem machine parameter manual [1]. 

Note: 

Installation of options is not done within the Delem machine parameters menu. See chapter 3 for more information about option installation. 

Note: 

The software update procedure is not done within the Delem machine parameters menu. See chapter 2 of this part for more information about the update procedure.

⒉Windows tasks

2.1Windows introduction

To access Windows function in a DA-Touch controller, a keyboard and mouse should be connected to a USB port. To open the Windows start menu, press the Windows button on the USB keyboard.

To switch to windows without opening any application, click on the pencil symbol in the lower right corner of the screen. The Delem control application is switched to the background, but remains active. 

To activate a certain application, click on the Start button in the lower left corner of the screen. Choose an application from the list. For many of the machine tasks this procedure will be necessary, so be sure to familiarise yourself with this routine. 

The ‘Reboot’ command right above the Start button serves to restart the control. It will be indicated in this manual when this is necessary.

2.2 Log-in

For several operations and functions in the Windows environment it is nesecary to log-in first with the correct access level. If not logged in with the appropriate level the function will not be carried out or an error message will appear.

The actual acces level will be indicated neer the key lock symbol 

• After a restart/reboot of the control the access level will still be active. 

• The access level is reset when the control is switched off. 

• The mentioned access codes are the same codes as for access to the machine parameters menu.

2.3 Directory structure

The data on the control has been organised into drives and directories, like on a computer. Within the graphical interface of Windows, the term ‘Folder’ is also used for a directory. 

Most directories on the Windows desktop are volatile directories, which means they are lost when the control is shut off and are re-created when the control is started. The following drives are permanent, because it refers to the CompactFlash card of the control:

  Delem 

 Configuration 

 User

This CompactFlash card is the internal storage device of the control. Any data that should be saved for later use should be stored in one of the drives that are located on the CompactFlash.

2.4 Important files

A lot of control settings are stored in files, which are located on the hard disk of the control. This is the case for the Delem application as well as for the Windows platform. Whenever the control is (re)started, the software will search for these files and retrieve the last saved settings.

If for any reason the settings are mixed up, it is possible to delete these files. At the next start-up, the control will assume its default settings. This should only be done as a last remedy, if the control does not function properly anymore. 

If the settings are correct and you do not wish unauthorised people to change them, it is possible to set these files as read-only files. This way settings cannot be changed. To set the file to read-only, proceed as follows:

• open the Windows Explorer 

• browse to the correct location (directory) to find the file 

• click on the desired file 

• open the File menu and select ‘properties’ 

A window like the one shown below should appear:

In the ‘attributes’ section of the window, mark the setting ‘Read-only’ and click on ‘OK’ to save the setting. The file cannot be altered anymore. 

In the example above, the properties of the sequencer file are shown. This means that changes made in the sequencerfile will be ignored.

Another possibility is to mark files as ‘hidden’. A hidden file is not shown in the Windows Explorer and as such it is protected against unauthorised user actions. A hidden file can also not be opened from within Windows applications, such as Wordpad.The Delem application can still open a necessary settings file, even though it is hidden. 

If an authorised person wishes to access hidden files, the Windows Explorer has the setting to view all files. From within the Explorer, open the View menu and select ‘Options...’. The following window appears:

Do not show hidden files and folders

The file Explorer will not show files that have been marked as hidden. 

Hide protected operating system files

The Explorer will not show files that are used by the Windows Operating system. 

Hide file extensions

The Explorer will not show the three-digit extension in file names. 

On the following pages a list of files is given that contain settings for the Windows Operating 

system and for the Delem control application.

2.5Windows Registry

Within the Windows OS, several control settings can be adjusted, such mouse sensitivity, etc. Normally, these Windows settings are reset to factory defaults when the control is restarted or switched off.

If you wish to keep these settings permanently, it is possible to save these settings through the utility ‘SaveRegistry.exe’. This utility can be started from the Windows start menu, Programs->Save Registry. All current settings within Windows are stored and will be retrieved on the next start-up.

The settings are stored in the file ‘user.reg’, which is located in the directory ‘\User\Delem\Boot’. When Save Registry is carried out while logged in with level 1 or higher, the setting will be stored in ‘config.reg’ in the directory ‘\Configuration\Delem\Boot’. At start-up, both registry files are checked and the settings from both files will be used (merged).

If for some reason the settings are not acceptable anymore then delete this file. On the next start-up the factory defaults will be restored. 

Clearing the Registry can also be carried out through the Rescue Procedure. See section 2.10 about the Rescue Procedure.

Note: 

Not all settings of the Internet Explorer are saved in the registry. The Start Page of the Explorer is saved in the registry. Favourite website addresses, however, are saved in the directory \Windows\Favorites. This directory is lost after power-down. To save these settings 

you should copy the files in this directory to the control hard disk. After start-up, these files can be copied back to the directory ‘Favorites’.

Files can be copied automatically after start-up by modifying the file ‘autoexec.bat’. See section 2.9 about this file.

2.6 The Notepad program

The program Notepad can be used to edit plain textfiles on the control. The program can be activated through the Windows Start menu:

Another possible method is to open a suitable file by double-clicking on it with the mouse. A file is suitable if it has a notepad icon.

2.7Networking

2.7.1Configuration

With the network functionality, the Delem application is able to copy or retrieve files to or from a network. The available network locations for the Delem application must be arranged on the Windows platform.

The procedure for offering a network takes roughly four steps: 

1. establish network for the Windows platform 

2. define network paths for Windows 

3. check the network availability on the control 

4. save the settings (registry)

Step one should be arranged by the network administrator. This involves all common tasks like connecting the control to a network, select the correct network protocol for Windows and offer a shared drive. 

Step two must be done on the control. Use the Windows Start menu to activate a command prompt. Type the following command:

2.7.2 Remove a network mapping

To remove an existing network mapping, perform the following steps: 

Activate the command prompt and type the following command: 

net use <path name> /d

2.7.3Network directory structure

When a network connection has been established, it is possible to store or retrieve data from a network.

2.8 Editing the autoexec.bat

The file ‘autoexec.bat’ is a standard file in the Windows system. Any command that can be executed from the command prompt, can also be put in this ‘batch file’. Whenever the control is started or rebooted, the system will first look for the special batch file ‘autoexec.bat’. Any 

command that is written down there will be executed by the system automatically.

Common tasks for such a file can be to connect to a network and copy files to or from the network. In the standard file, one task has been implemented: activate the Delem application. Other tasks can be added if required.

To edit this batch file, the control is equipped with the application Notepad. This program can be started from the Windows Start menu. You can also select the file, open the File menu and select Edit.

⒊DA Control settings

3.1 Introduction

In this chapter some functions are discussed with which the functionality of the DA application is modified.

3.2 Add a KO-Table

A KO-table is a file containing initial Y-axis control parameter setting for a specific type of hydraulics. A default set of KO-tables is always included in the software. In case a KO-table is needed that is not included yet, it can be added manually. 

Just copy the file (KO-7xxx.bin) to the following folder:

\Configuration\Delem\Machine 

The active KO-table can be selected in the machine parameters men (General parameters).

Note: 

To be able to write, delete or modify files on the \Configuration drive you must login with level 1 or higher.

3.3 Option installation

3.3.1Request option on the control

It is possible to install software options on the control. Options can be requested at Delem. Options for a DA-Touch control can be purchased at any moment. It is done by buying an ‘Option Voucher’ for a specific function (3D visualisation, barcode reader etc.). A new option voucher is valid for any DA-Touch control. Hence, it is possible to buyone or more option vouchers and keep them in stock until the option becomes necessary on a control. An option voucher looks as follows:

3.1.2 Request option code at Delem

The UIR file that was generated by the option program must be send to Delem. From this UIR file a license file is generated. This license file can then be used to enable the option on the control. 

There are different ways to send the UIR file to Delem. The simplest (and slowest) way is put the file on a floppy disk and send this floppy to Delem. After a certain period, you will receive a floppy disk with the license file. 

Another method is to send the UIR file by e-mail to Delem and request the option. You will receive a license file shortly. 

The third method is to use an internet connection and connect to a special Delem license 

3.3.3 Delem Identification Module (DIM)

When an option is activated, it is stored in the Delem Identification module (DIM). The DIM is a small card that is inserted in the mainboard. The activated options can be transferred to another control of the same type (DA-66T or DA-69T) by simply inserting the DIM in the new control.

3.3.4 Disable an option

Once an option is activated, it is registrated on the DIM. It is not possible to remove an option from the DIM. If for some reason an option should be (temporary) switched off, it can be disabled with the AppOpt application. 

To disable an option, select the option from the list and press the button “Disable license”.

3.4  Sequencer adjustment

The sequencer is the built-in PLC function of the Delem system. The text file with sequencer code is stored on the hard disk of the control, in the file sequencer.txt. The default Delem sequencer is stored in the folder \Delem\Sequencer. This folder also contains the standard 

sequencer include files, like delem.def.

3.5  Screen Colours

The control screens of the DA application can be modified to meet customer’s wishes. This is carried out by modifying a file called ‘colours.ini’. Upon delivery, this file contains factory standard values. The default colours.ini file is located in the folder\Delem\Style\Default\1280x1024. To be able to edit the colour settings, perform the following steps: 

• Login with level 1 or higher 

• Create the sub-folder \Style\Default\1280x1024 in \Configuration\Delem 

• Copy the default colours.ini file from \Delem\Style\Default\1280x1024 to 

\Configuration\Delem\Style\Default\1280x1024 

• Now colours.ini can be edited with a text editor, for example the built-in Notepad application.

3.6 Company logo

In the upper left corner of the control screen the Delem product logo ‘DA-Touch’ is displayed.

This logo is a small picture, which is stored on the control disk as a standard PNG image file: logo.png. If necessary, this logo can be replaced or changed to the appropriate company logo:

3.7 Backup system / Restore system

It is possible to make a full backup of the DA-Touch control. This backup includes: 

- The application software 

- All additional files on the \Configuration drive (sequencer etc.) 

- Machine parameters 

- All user data (products, tools, settings)

Make a system backup 

Perform the following steps to make a full system backup: 

• Insert a USB memory stick to one of the USB ports.

• Select the System Information page of the Machine menu. 

• Press the softkey “backup system”. The following window appears:

3.8 Touchscreen calibration

The Touchscreen is calibrated and ready for use upon delivery. 

Sometimes, it may be necessary to recalibrate the Touchscreen, for example after the control has been mounted on the machine. Calibration is carried out quick and easy. 

• Select the Maintenance page in the Machine menu. 

• Tap the button ‘calibrate touchscreen’. 

• A white screen appears, with a black cross. Touch the black cross very carefully. 

• Repeat this every time the cross has moved to a new position.

3.9 Analysis program

The control is equipped with a program for analysis of a pressbrake cycle. This analysis program can run parallel to the DA application. 

The working principle is as follows. During one bend cycle, the program records the values of a number of analog and digital I/O signals. All this data is immediately stored in a file on the control disk and can be represented graphically. 

First login with level 2 or higher.Then start Programs->Analyse from the Windows start menu to activate the analysis tool.

4. Update control software

4.1  DelemInstaller

DelemInstaller.exe is a small program that runs on a PC. It is used to generate an update file to be installed on a DA-Touch control. 

Furthermore additional tools can be installed with DelemInstaller or a rescue USB stick can be generated. 

When DelemInstaller.exe is started on a PC, the following screen will appear:

4.2 Software update procedure

Note: The update procedure as described in this paragraph will only update the application software of a DA-Touch control. Modification made on the \Configuration drive and data on the \User drive will remain unaffected.

4.3 OEM update set

With the procedure as described in paragraph 4.2, only the standard application of the DATouch control will be updated. With an OEM update set additional files, like a sequencer file, can be installed at the same time.

An OEM updare set is a .zip file containing the application software and the additional files, organized in the same folder structure as they are installed on the DA-Touch control. 

With the DelemInstaller application a template .zip can be generated that can be used as a starting point to compose your own update set. This .zip file already contains the most commonly used folders.

4.4  Control Rescue procedure

4.4.1  Introduction

The Rescue procedure for the Delem control is meant to re-install all original software on the control. It is meant as a last resort, when other attempts to ‘cure’ the control have failed and/or the control does no longer boot from the internal hard disk (the compactflash card). 

When this procedure is carried out, all existing data on the hard drive is erased: products, tools, etc. The license codes for control options are note erased. These options are not stored on the CompactFlash card but on the DIM.

This procedure can only be succesfull when all hardware is still functional.

4.4.2 Requirements

To perform the procedure on the control, the following equipment is necessary: 

- a complete DA-Touch software set; 

- a PC running the Windows operating system (Windows XP, Windows 7); 

- a USB stick;

4.4.3 Rescue procedure

The rescue procedure is carried out with a USB stick, which is recognised by the control as an external USB disk. The USB stick is equipped with the necessary software and the control is booted from USB stick to re-install the control software.

To be able to test a DA-Touch control, it has been equipped with a diagnostic program. With the test functions of the diagnostic program the service engineer can test the control itself and the communications to externally connected system components.

Before starting the diagnostic program it is required to check if the hydraulic pump of the pressbrake is not running. This is because during the diagnostic operation of the control no regulation of the pressbeam is performed.

⒈General remarks

1.1 Valve outputs 

With the diagnostic program you have to be very careful because the proportional valves can be deflected. The high-retaining valves have to be in the closed position in order to prevent the top beam coming down. It is good practice to place the top beam in its lowest position 

before starting the diagnostic program.

1.2 Components check

In the description of the tests it is indicated which component(s) is(are) responsible for correct functioning of that particular part.

See for exploded view drawing with all internal cables and cards of the DA-Touch controls the included diagrams at the end of part I.

The mainboard assembly of the control can be exchanged easily, since all specific data is stored on the hard disk. 

If the internal hard disk (the CompactFlash card) must be replaced, it is recommended to make a back-up of all user-specific data: products, tools, program constants and machine parameters. Use the ‘product backup’ and ‘tools backup’ tools in the Setting menu for this 

purpose. Together with the tools automatically the parameters from the Settings and Machine menu (entered by the user) will be written to the backup medium. To save the machine parameters, you have to go the machine parameters menu and and select option 5, Parameter backup.

⒉Test-menu

When the diagnostic program has been started the screen shows the menu as indicated in figure 2.a (example of diagnostic main menu).

⒊Front panel test

Function 

This test is meant to check the functioning of the start and stop button and the handwheel. 

Description 

The follwing screen appears, like in figure 3.a.

⒋Screen test

Function 

To get a good idea about the colour setting and correct functioning of the colour screen you will see a number of horizontal bars. It is important that the 3 main colours are available (red, green and blue). 

By tapping the button “colortest” a white screen will be displayed (toggle function).

⒌ DM module test

Function 

This test checks the inputs and outputs of the connected DM modules.

⒍Test of HSB

Function 

With this test the High Speed Bus (HSB) connector of the control is checked. Description 

With this test the HSB circuitry of the control is checked. To perform this test: 

• open the control; 

• remove the standard HSB cable that is connected to the mainboard; 

• take a small HSB cable and put one end on the first HSB connector and put the other end on the second HSB connector; 

• close the control; 

• activate the control and go to the diagnostic main menu; 

• Tap on item 4 in the main menu of the diagnostic mode.

⒎Test of the serial ports

Function 

With this test the serial interface (RS-232) connectors of the control are checked. 

Description 

• open the control; 

• mount a loopback connector on the RS-232 port to test; 

• close the control; 

• activate the control and go to the diagnostic main menu; 

• Tap on item 5 in the main menu of the diagnostic mode. 

• Both connections are tested at the same time. 

• The result will be displayed on the screen.