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PLC Control System DPL 10188/ 10189 Instruction Manual.
Danish Process Light
PLC Control System DPL: 10188/10189:
DPL Industri A/S introduces a new UV Controlsystem
based on PLC technique. This new control system
have full control over the UV lamp, Ballast, Chiller
and the light sources.
DPL Industri A/S, Fabriksvangen 1, 3550 Slangerup, Denmark.
Instruction manual 10188 1a
Side 1
PLC Control System DPL 10188/ 10189 Instruction Manual.
1. Installation
The PLC control system DPL 10188/10189 is a part of the DPL “plug & play” UV system.
The UV system is very user friendly to install and use.
Control cable:
Connect all the control cables to the PLC with the standard “SUB D cables” by following the Sign on the
PLC box, and connect the cable to the chiller, ballast and UV lamp.
Power Cable:
Connect the ballast and PLC main power cables to the power section of the printing machine.
Important! The main power to the chiller had always to be connected to main power in order to
protect the reflectors. (Cool down).
Remote Cable:
The simple version of remote control, is just a switch to start the curing activation.( Switch application
mode). The switch and cable is standard accessories.
2. Start up the UV system:
The basic set-up is made by DPL, in order to protect the UV-lamp system.
The set-up is blocked by a pass-word only for distributors and factory set-up.
3. Input Select:
Input select is set up by DPL for your application, but it is possible to change to other input type.
By Input select means different possibility to control the UV curing power.
Tacho Input: The tacho generator on the
printing machine, regulate the curing power.
( Speed power control )
Switch Application 0-10V The curing will be
started by a switch, and the curing power will
be regulated by 0-10 V Dc on the remote
Input/output.
Switch application The curing will be started by
a switch, and the curing power will be set
manually on the screen.
Clock input: The PLC will be in Slave mode.
Only together with a Master with tacho input.
DPL Industri A/S, Fabriksvangen 1, 3550 Slangerup, Denmark.
Instruction manual 10188 1a
Side 2
PLC Control System DPL 10188/ 10189 Instruction Manual.
4. Light Source select:
The PLC control system monitors the light sources lifetime, by effective control of start/stop sequence
and burning-hours
Light source select is necessary, because there is different Lifetime for different Types.
Mercury Lamp: By select this Lamp, the
lifetime counter will be preset to 2000
hours. This is the typical lifetime for a
mercury lamp.
Ion-Doped Lamp: By select this lamp, the
lifetime counter will be preset to 1000
hours. This is a typical lifetime for a Iondoped lamp.
Galium- Doped Lamp: By select this lamp,
the lifetime counter will be preset to 1200
hours. This is the typical lifetime for a
Galium-doped lamp
5. Counter Reset:
By replacing the UV-Lamp, it is very important to reset ( preset) the lifetime counter.
In some application, with low UV Power, the lifetime can be more than the typical value.
Reset (preset) the counter again, and use the next periode before replacing the UV-Lamp.
Lifetime of the lamp, will be 1 hours shorter by start/stop of the Lamp.
Therefore keep the lamp in Stand-by, and only stop the lamp by longer machine-stop.
DPL Industri A/S, Fabriksvangen 1, 3550 Slangerup, Denmark.
Instruction manual 10188 1a
Side 3
PLC Control System DPL 10188/ 10189 Instruction Manual.
6. Manual Start UV Lamp:
With Manual/Remote setting in: Manual Position.
 Press “Lamp Power” On
 The PLC controller start the chiller. ( can take up to 30 second )
 When the water flow is ok, “UV-Lamp On” will indicate that UV Lamp is started.
 The UV Lamp power meter indicate the stand-by level 20%
 The UV Lamp heath-up after 30 sec. and wait for indication of “UV lamp ready for Curing”
The UV System is ready for Curing.
7. Remote Start of UV Lamp:
With Manual/Remote setting in: Remote Position.
 Activate “Start UV lamp” on remote connector JP40 pin 1. active low
 The PLC controler start the chiller. ( can take up to 30 second )
 When the water flow is ok, “UV-Lamp On” will indicate that UV Lamp is started.
 The UV Lamp power meter indicate the Stand-by level 20%
 The UV Lamp heath-up after 30 sec. and wait for indication of “UV lamp ready for Curing”
The UV System is ready for Curing.
DPL Industri A/S, Fabriksvangen 1, 3550 Slangerup, Denmark.
Instruction manual 10188 1a
Side 4
PLC Control System DPL 10188/ 10189 Instruction Manual.
8. Curing activation:
The curing activation is only possible by the remote connector JP40 Pin 9 active low or by a switch
between Pin 9 and GND Pin 8.
By using tacho or clock input, the curing activation is generated by the tacho speed.
By Curing activation:
 The UV lamp shutter will open, and the indicator be active.
 The default UV-Lamp curing power, will be applied to the UV-Lamp
 The UV Lamp power can be set from 0-100% power by press on button down/Up.
 By activating the switch, the Power meter is moving from Stand-by 20%, to 100% if the curing
power is regulated to 100%, with the up/down button.
Printing Machine C ontrol
PLC
( Remote )
1
9
2
10
3
11
4
12
5
13
6
14
7
15
8
Start UV Lamp Output signal Activ e Low
Start Curing Output signal Activ e Low
Optional 0-10V Analog output
PWM Regulation Output 1-5 kHz
Ready f or curing Input signal Activ e High
Common Failure Input signal Activ e High
Water Flow Failure Input signal Activ e high.
UV Lamp Temp Failure input signal Activ e High
Shutter Failure input signal Activ e high
Light Source exchange input signal Activ e High
Ballast Failure input signal Activ e High
Sy stem Failure Input signal, Activ e higk
UV Lamp Failure signal input Activ e High
Analog GND
Digital GND
Start UV Lamp
SW2
SW1
Start C uring Activating
DPL Industri A/S, Fabriksvangen 1, 3550 Slangerup, Denmark.
Instruction manual 10188 1a
Side 5
PLC Control System DPL 10188/ 10189 Instruction Manual.
Remote Control Connection:
Printing Machine Controller with Isolated Input/Output + 0-10V Curing regulation.
Output
R
1
5
2 Input Active Low to DPL PLC controller
Max sink curent 4-7mA. 2 Optocoplers
Start UV Lamp Output signal Activ e Low
Start Curing Output signal Activ e Low
Optional 0-10V Analog output
Optional PWM Regulation Output 1-5 kHz
Ready f or curing Input signal Activ e High
Common Failure Input signal Activ e High
Water Flow Failure Input signal Activ e high.
UV Lamp Temp Failure input signal Activ e High
Shutter Failure input signal Activ e high
Light Source exchange input signal Activ e High
Ballast Failure input signal Activ e High
Sy stem Failure Input signal, Activ e higk
UV Lamp Failure signal input Activ e High
Analog GND
Digital GND
GND
Input
5
R
1
8 Output Activ High from DPL PLC controller
Max. 20mA Led curent. 8 Optocopler
4
ISO1
OPTO ISOLATOR2
2
Standard 1 5 P ins Sub D C able
to D P L P L C c ontroller 1 0 1 8 8 /1 0 1 8 9
1
9
2
10
3
11
4
12
5
13
6
14
7
15
8
2
4
ISO2
OPTO ISOLATOR2
GND
0-10V DC C uring regulation output
V
Analog GND
10V DC
Remote Control description:
PIN Type
1 Active Low Input 24V/0V
2 Linear Input 0-10V DC
3
4
5
6
7
8
9
10
11
12
13
14
15
Active High Output 0V/24V
Active High Output 0V/24V
Active High Output 0V/24V
Active High Output 0V/24V
Active High Output 0V/24V
Digital Ground
Active low Input 24V/0V
PWM Input 0-24V 1-5kHz
Function
Start UV Lamp Input
0-10 V Power Regulation
Input
Ready for Curing Output
Water Failure Output
Shutter Failure Output
Lamp Driver failure Output
UV Lamp Failure Output
Digital Gnd
Start Curing Input
PWM Regulation Input
Note
5,0 mA Sink
Machine Input/ Output
Open Collector Output
0-10V DC Output
6,0mA Source
6,0mA Source
6,0mA Source
6,0mA Source
6,0mA Source
Opto-koppler input with Resistor
Opto-koppler input with Resistor
Opto-koppler input with Resistor
Opto-koppler input with Resistor
Opto-koppler input with Resistor
Direct connected Digital GND
Open Collector Output
Open Collector Output
5,0 mA Sink
7,0 mA
Source
Active High Output 0V/24V Common Failure Output
6,0mA Source
Active High Output 0V/24V UV Lamp Temp Failure
6,0mA Source
Active High Output 0V/24V Light Source Exchange Output 6,0mA Source
Active High Output 0V/24V System Failure Output
6,0mA Source
Analog Ground (0-10V input Analog Gnd
)
DPL Industri A/S, Fabriksvangen 1, 3550 Slangerup, Denmark.
Opto-koppler input with Resistor
Opto-koppler input with Resistor
Opto-koppler input with Resistor
Opto-koppler input with Resistor
Direct Connected Analog GND
Instruction manual 10188 1a
Side 6
PLC Control System DPL 10188/ 10189 Instruction Manual.
9. UV System Errors:
All UV system failure will be displayed in the Control and Status information display.
All failure will stop the UV-lamp, and the failure be displayed.
By UV System Failure:
 UV lamp Power ON/OFF will return to OFF.
 UV Lamp On indication dissapears
 UV Lamp system Failure: indication for failure
10. Help Function:
Press Help to get a failure hint.
11. Start again after UV system failure
The PLC controller latch all fail information. To reset the failure press “UV Lamp OFF”.
The UV System is ready to start again. If the failure come back, try to solve the problem
Or contact DPL Industri A/S for Help.
12. PLC Connection Diagram:
DPL Industri A/S, Fabriksvangen 1, 3550 Slangerup, Denmark.
Instruction manual 10188 1a
Side 7
PLC Control System DPL 10188/ 10189 Instruction Manual.
Tacho Encoder ( Printing Speed )
Hengstler Encoder RI 58 0
1
6
2
7
3
8
4
9
5
+24V DC Supply
Output A OC
Tacho Encoder Input Cable
Output B OC
Digital Ground
Printing Machine Control
PLC ( Remote )
1
9
2
10
3
11
4
12
5
13
6
14
7
15
8
Printing Machine Control Cable ( Remote ), 15 Pin Standard SUB D
1
9
2
10
3
11
4
12
5
13
6
14
7
15
8
Start UV Lamp Output signal Active High
Start Curing Output signal Active High
Optional 0-10V Analog output
PWM Regulation Output 1-5 kHz
Ready for curing Input signal Active High
Common Failure Input signal Active High
Water Flow Failure Input signal Active high.
UV Lamp Temp Failure input signal Active High
Shutter Failure input signal Active high
Light Source exchange input signal Active High
Ballast Failure input signal Active High
System Failure Input signal, Active higk
UV Lamp Failure signal input Active High
Analog GND
Digital GND
Ballast Nedap 3 kW
JS31
JP31
1
2
3
4
5
6
7
8
3kW Ballast Cable + Screen
1
14
2
15
3
16
4
17
5
18
6
19
7
20
8
21
9
22
10
23
11
24
12
25
13
1
2
3
4
5
6
7
8
PWM Input 1-5 kHz
Lamp Driver failure OC Active High
Remote ON/OFF High= ON
System Failure Output OC Active High
Lamp ON-Ready Output OC Active low
Lamp Failure Output OC Active High
Output power supply 14V
Common Return
See 3 kW Electronic Lamp Driver Manual
6kW Ballast Cable + Screen
JS61
UV Lamp Control Cable, 15 Pin SUB D
JS4
1
9
2
10
3
11
4
12
5
13
6
14
7
15
8
1
9
2
10
3
11
4
12
5
13
6
14
7
15
8
White
Black
S1
SW SPDT
1
2
3
4
5
6
7
8
9
10
Ballast Connector JP 36
Nedap 3kW Lamp Driver
Nedap 6kW Lamp Driver
UV Lamp Shutter & Thermoswitch cirquit
JS3
Ballast Nedap 6 kW
JP61
1
2
3
4
5
6
7
8
9
10
1
9
2
10
3
11
4
12
5
13
6
14
7
15
8
1
6
2
7
3
8
4
9
5
1
9
2
10
3
11
4
12
5
13
6
14
7
15
8
Powerset 0-10V Analog Input ( Optionaly )
Powerset Return ( Analog GND )
PWM Input 1-5kHz
Remote ON/OFF Input High=ON
Output Internal Power Supply 14V/25mA
System failure OC Output Active Low
Lamp Failure OC Output Active Low
Lamp Driver Failure OC Output Active Low
Lamp ON-Ready OC Output Active low
Common Return
See 6 kW Electronic Lamp Driver Manual
Shutter Motor
Green
+
S2
Grey
SW SPDT
A
Earth
Phase
Cooling Machine Control
Neutral
-
Yellow
Red
1
6
2
7
3
8
4
9
5
TSW 1
Thermoswitch
1
6
2
7
3
8
4
9
5
GND
Neutral
Alarm
OFF Delay RELAY SPDT
11
24V
15
K4
K3
A2
18
JP4 JP3
Start Cool
Cooling Machine Control Cable. 9 Pins Sub D Standard
Dongle to Factory set-up 5-7
Flow Alarm
Fluss Alarm
Bürkert 8032
Type: 436473
+ DK1904
J6
+12V
NC
GND
Alarm
PE
1
2
3
4
5
Cool Unit
Kühl-Einheit
Phase L1
A1
A1
A2
J4
1
2
3
4
5
16
Brown
White
Blue
Black
Grey
RELAY SPDT
14
B1
Start signal
Nyt 24V Relæ, samt PNP output til GND
CON5
DPL Industri A/S, Fabriksvangen 1, 3550 Slangerup, Denmark.
Instruction manual 10188 1a
Side 8
PLC Control System DPL 10188/ 10189 Instruction Manual.
13. PLC Controlbox Diagram:
PLC 001
+24VCC 3 0 mA
A1
Start UV Lampe input Act H
A2
Start Curing Input Act H
Ready For Curing Input Act L A3
A4
3kW lamp driv er f ailure
3 kW Sy stem Failure Input Act A5
H
+24VCC
3 kW Lamp Failure Input Act H A6
6 kW Lamp Failure Input Act L A7
6 kW Lamp Driv er Failure InputA8
Act L
A9
A10
A11
PWM Output UV Lamp Power regA12
A13
Tacho Cascade Output
Start UV lamp Output Act H A14
A15
Shutter Relais Open Act H
Start Cooler Output Act H A16
UV lamp Failure Output Act H A17
Sy stem Failure Output Act H A18
A19
Lamp Driv er Failure Output Act H
B1
B2
B3
B4
B5
B6
B7
B8
B9
B10
B11
B12
B13
B14
B15
B16
B17
B18
B19
10k0
Output X1
Output X2
Light Source Exchange Output Act H
Shutter Failure Output Act H
UV Lamp temp Failure Output Act H
Water Failure Output Act H
Common Failure Output Act H
Ready f or Curing Output Act H
JP7
Remote C ontrol C onnec tor
1 5 P in SU B D M ale
1
Start UV Lampe input Act H
9
Start Curing Input Act H
2
0-10V Regulation Input
10
PWM Regulation Input
3
Ready f or Curing Output Act H
0E
11
Common Failure Output Act H R12 0E
R21
4
Water Failure Output Act H
0E
12
UV Lamp temp Failure Output Act HR14 0E
R15
5
Shutter Failure Output Act H
0E
13
Light Source Exchange Output Act HR16 0E
6
Lamp Driv er Failure Output Act H R17 0E
R18
14
Sy stem Failure Output Act H
0E
R19
7
UV lamp Failure Output Act H
0E
R20
15
8
R30
10k0
R29
10k0
R22
10k0
R23
10k0
R24
10k0
R25
10k0
R26
10k0
R27
10k0
R28
10k0
PLC Plug Ty co CA7
Analog GND
+24VCC
PWM Output UV Lamp Power reg
R8
J1
Start UV Lamp Output Act H
1
2
3
4
5
6
7
8
9
10
11
R9
R10
R11
0E
10k0
0E
10k0
LT3301 Analog Plug
Nc Analog Input
R7
22k0
R36
Output X1
R38
R37
Analog GND
Nc out
Output X2
Digital GND
Shutter Relais Open Act H
R39
NC out
+24VCC
0E
10k010k010k0
R3 R2 R1
R6 R5 R4
16
Shutter Closed Input
Shutter Open Signal Act H
15
UV Lamp Temp Failure Act: L
14
IC1AULN2004A
OUT
IN
COM
IC1BULN2004A
OUT
IN
COM
IC1CULN2004A
OUT
IN
COM
GND Power
1
9
2
9
JS56
C ooling Water C ontrol I nput/O utput
9 P in Sub D Female
+24VCC
3
9
8
+12VCC
Water Flow ok Input Act H
Start Cooler Output Act H
1
2
3
JP36
1
9
2
10
+12VCC
3
11
K2
4
RELAY DPDT
12
5
13
6
14
7
15
8
+12VCC
22k022k022k0
JP40
U V L amp C ontrol C onnec tor
1 5 P in Sub D Female
0E
22k0
+24VCC
Digital GND
L amp D river C ontrol C onnec tor
2 5 P in SU B D M ale
1
14
2
3kW lamp driv er f ailure
15
3
16
4
3 kW Sy stem Failure Input Act H
17
5
Ready For Curing Input Act L
18
6
3 kW Lamp Failure Input Act H
19
7
6 kW Lamp Failure Input Act L
20
8
6 kW Lamp Driv er Failure Input Act L
21
9
6 kW Sy stem Failure Input Act L
22
10
23
Powerset 0-10V Analog Output
11
24
12
25
13
0-10V Regulation Input
22k0
T ac ho / D ongle I nput C onnec tor
9 P in SU B D M ale
1
Tacho "A" Input eller slav e
6
Tacho "B" Input
2
7
3
8
Tacho Cascade Output
R33
4
R35
9
0E
5
Tacho "A" Input eller slav e
Tacho "B" Input
PWM Regulation Input
UV Lamp Temp Failure Act: L
+24VCC
6 kW Sy stem Failure Input Act L
Water Flow ok Input Act H
Shutter Open Signal Act H
Shutter Closed Input
JP1
P ower Supply C onnec tor
R31
0E
R32
10k0
1
6
2
7
3
8
4
9
5
JS26
Serial Resistor 0E = Fuse
DPL Industri A/S, Fabriksvangen 1, 3550 Slangerup, Denmark.
Instruction manual 10188 1a
Side 9