Mono DELTA DEPOSITOR User manual

CONTROLLER OPERATION
MANUAL FOR THE
DELTA DEPOSITOR
www.monoequip.com

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1.0 Introduction.
2.0 Use of keypad. –Key Functions
3.0 Use of menu screens.
A) Editing/creating a product program.
1.Tray setup menu…………………………………………………..….page 12
Edge height.
Rows per tray.
Jog height.
Suck back.
Rot(ary) home mode.
Tray length.
Jog up speed.
2.Template menu………………………………………………………..page 16
Template no. (number).
Hopper type.
Nozzle id (identification).
Offset length.
3.Edit/create menu and use of command…………………………..page 18
Move command.
Deposit pump.
Tray conveyor.
Deposit head raise/lower (jog).
Nozzle rotate.
Speed command.
Suck back command.
Wait command.
Man(ual) space command.
End round command.
Delete command.
B) Memory facilities.
1.Memory menu…………………………………………..…………….page 27
Retrieve.
Save new item.
Save.
Delete item.
Sort directory.
View directory.
Del(ete) directory.
000% memory.
INDEX

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2.Run menu……………………………………………………………..page 32
Retrieve item.
Set counter.
Set qty/tray.
Adj(ust) dep(osit) qty.
3.Delete menu…………………………………………………….……page 34
Clear counter.
Delete product.
C) Speed setup menu.
1. Speed deposit……………………………………………………….page 37
2. Speed tray……………………………………………………………page 37
3. Speed jog…………………………………………………………….page 37
4. Speed rotary…………………………………………………………page 38
5. Init(ial) tray vel(ocity)……………………………..…………………page 38
6. Max(imum) acc(eleration) lim(it)…………………………………...page 38
7. Tray acc(eleration) lim(it)…………………………………………...page 39
8. Offset sd hop (soft dough hopper)……………………………..….page 39
9. Offset hd hop (hard dough hopper)………………………………..page 39
D) Diagnostics and axis setup.
1. Set time……………………………………………………………….page 40
2. Set date……………………………………………………………….page 41
3. Run tests……………………………………………………………..page 41
4. Test keypad………………………………………………………….page 42
5. Test DACs……………………………………………………………page 42
6. Test inputs…………………………………………………………...page 43
7. Show status………………………………………………………….page 44
8. Exit to op(erating) sys(tem)………………………………………..page 44
Loading new program.
9. Axis setup procedure……………………………………………...page 46

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E) Up/download system software…………………………….….page 50
1. Getting started
2. Writing programs on your computer (PC)
3. Saving and recalling a program
4. Transferring files
Annex A Delta depositor nozzle identification chart ………………..page 57
Annex B Password set-up menu ………………………………………..page 58
Annex C Program record …………………………………………………page 59

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1.0 INTRODUCTION
This manual covers all functional aspects of the DELTA depositor that can only be
addressed through data entry into the electronic controller situated on its front panel.
Such aspects include
Product creation,
Product program storage into memory and retrieval,
Program deletion,
Machine set up
Diagnostics display.
This manual forms a necessary accompaniment to the DELTA’s “Operation and
Maintenance Manual” to give the complete and necessary information to the user and
maintenance engineer for successful and safe use of the DELTA.
Data entry into the controller is via the membrane covered key switch keypad and the
prompted menu-driven LCD screen display allowing word processor type entry.
All menu screens are logically arranged in hierarchical order and by reference to Fig1a
and 1b, the relative location of all screens can be clearly seen.
Included in Fig 1a and 1b are details of screens which the user will not require normal
access to as these are screens that are made use of by MONO’s production and
maintenance engineers and provide a convenient means of displaying information
regarding machine set-up. These screens are consequently password protected for
MONO use only.
Prior to taking delivery of the DELTA depositor, all controller aspects regarding
machine set-up will have been performed at MONO’s factory. Hence, once
commissioned, the DELTA will be ready for use with all necessary adjustments made.
From this point the user need mainly concern himself with the DELTA’s functional
aspects of creating and storage of a product library.

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2.0 USE OF KEYPAD
Fig 2. shows the DELTA’s controller keypad and LCD screen.
The keys to the LH and RH side of the screen are for selection of on-screen menu
options, each button indicated as leading from a designated screen area. Press these
keys to select from the menu option currently being offered on-screen.
Data entry into the controller is by use of the numerical/alphabetical keys (9,10,11 &
19), +/- key (17), alpha/numerical (I/A) key (15), and the enter key (18). Exit from
screens is by use of the escape (ESC) key, to a higher-level screen, generally in
accordance with Figs. 1a and 1b.
(5
-
8)
(1
-
4)
(19)
(17)
(18)
(9)
(10)
(15)
(12)
(11)
Fig. 2 DELTA Control panel
(13)
(14)
(16)

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3.0 DESCRIPTION OF CONTROL PANEL –
KEYFUNCTIONS
DRAWING REF. FUNCTION DESCRIPTION
1-8 FUNCTION KEYS For the selection of screen menu
options and to start pop up menus
9 PRIME This button activates the hopper pump
for as long as it is depressed provided
either edit/create or run menus are
on screen, and all safety guards are
properly closed.
It fulfils four functions: -
A. To prime the hopper pump and
nozzles with product mix.
B. Aids the engagement of
the hopper drive gear
into the drive shaft.
C Aids the engagement of the
rotary template drive gear
into the machine drive gear.
D Allows alphabetical
character (G & H) entry
when naming product
programs for storage into
memory.
10 MANUAL - Runs product program for one tray
only then returns tray to the operator
and stops.
- Allows alphabetical character (O
& P) entry when naming product
programs for storage into memory.
- Allows the removal of a partially
completed tray from the machine if
the program is interrupted before
completion of the depositing
sequence
- Press the key twice to remove tray.

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11 AUTOMATIC Activates an automatic machine cycle so
long as a tray is positioned correctly on the
table. At the end of the cycle the tray
conveyor will continue running to move the
full tray from the machine and introduce an
empty tray to the deposit start position.
NOTE>If two trays are placed too close
to each other the machine will interpret
this as one long continuous tray and will
continue to feed both trays through the
machine until a gap is detected.
This button also allows alphabetical
character (Y & Z ) entry when naming
product programs into memory.
12 ESCAPE Enables exit from menus to higher-
level menus and exit from current on
screen operation.
13 EMERGENCY STOP Immediately isolates all power circuits.
To release –turn clockwise.
14 START Activates all power circuits and all
machine facilities can be used once
pressed providing that all safety
guards are properly closed and the
emergency stop button is released.
15 ALPHA / NUMERIC Allows the operator to toggle
between alphabetical and numerical
button characters. Used when
putting names to stored product
programs.
16 STOP Stop button for either the manual or
automatic modes. Stops machine cycle
but not power to the drives.

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17 PLUS / MINUS Allows (when required) negative
values as well as positive to be input
to product programmes and machine
set up parameters. The controller will
not allow negative values where not
appropriate.
18 ENTER Enters typed and displayed
information into product program as
well as machine set up program.
19 0 –9 numeric keys Allows data entry of numerical values
into product program and machine
set up program. Also allows
alphabetical character entry (when
used in conjunction with
alpha/numeric button) when naming
product programs for storage into
memory.

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4.0 USE OF MENU SCREENS
(Refer to Figs 1a and 1b. at the beginning of this manual)
User screen functionality can be regarded as serving five areas of machine use as follows
A) Creating/editing product program
B) Memory facilities
C) Speed set up menu
D) Diagnostics and axis set up.
E) Up/Download system.
Once familiar with the DELTA the usual sequence of user steps will be as Fig. 3.0.
A) Editing/Creating a product program
When creating a new product program, data entry into 3 separate menus has to be achieved -
Tray Set-Up menu, Template menu and the Edit/Create menu. Information contained within all
3 of these menus is stored in the controller’s memory for each product program.
1. Tray Set-Up menu
Firstly, consideration needs to be given to the trays onto which the product(s) are to be
deposited and the depositing head motion between each product on the tray.
These relevant and important factors are all addressed in the Tray Set-Up menu, and are
detailed on the next page:
1. Tray set up menu
2. Template menu
3. Edit/create menu
1. Memory menu
2. Run menu
3. Delete menu

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Edge Height
The depth, in millimetres, of the highest edge (leading or trailing) of the tray.
This will provide information to park the depositing nozzle at the correct height between the
completion of the depositing sequence on one tray and the start of the depositing
sequence on the next tray and, also, prior to the introduction of the first tray. For additional
safety it is worthwhile adding 10mm to the actual tray edge height to avoid any possibility
of collision between depositing nozzles and a tray that might be slightly buckled.
i.e. for actual edge height of 20mm
Entered value should be 20mm + 10mm = 30mm (See Fig. 3.1.1.1b).
IMPORTANT - No automatic tray edge height detector exists on the DELTA and this
programmed height value is stored into the controller’s memory for the particular product in
question, hence, it is imperative that no tray with an edge height greater than the
programmed value is used, otherwise damage to the machine may result.
Rows per Tray
The number of repeated rows of deposited product required along the tray’s length.
NOTE - this value does not correspond to the number of products deposited across the
tray, i.e. the number of nozzles on the template in use. When the LH side key
corresponding to this option is pressed, in order to allow data entry, the maximum
allowable number of products per tray will be displayed in the on-screen prompt message.
This value is automatically calculated based on tray length value, rotary template nozzle
offset length (see 3.2.4) and individual product length.
Fig. 4
Fig. 5
Edge height illustration
Fig. 6

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Jog Height
The height, in millimetres, that the depositing head is raised vertically up away from the
last height position in the product program - that is at the end of each product row on the
tray.
If a product program dictates that two deposits are made at height 20 and then 30mm
above the top of the tray (height 0), then a jog height value of 25mm will raise the head up
by 25mm
from 30mm, i.e. 55mm above the tray.
(See fig. 3.1.1.3b)
Machine limits of 110mm vertical head travel are automatically prevented by the controller
and an on-screen warning provides information in this event.
Suck Back
The amount of reverse rotation by which the depositing pump is subjected to achieve the
retraction of product mix back into the depositing nozzle(s) on completion of each
individual row of products on the tray.
The value has a linear relationship to the amount of pump rotation but is, by necessity,
uncalibrated in product mix quantity terms as any attempt to do so would be inaccurate
should either the template arrangement, product mix or pumping speed change.
The suck back effect is achieved automatically and in sequence with the upward
movement effected by the value entered under the ‘jog height’ instruction (see fig 7) within
this menu, i.e. whilst the depositing head is raising itself upward at the end of each
deposited product, then, simultaneously, the deposit pump will operate in reverse rotation
to withdraw product mix into the nozzles. If either no suck back effect or jog up motion is
required between products, then zero values can be entered as appropriate.
Fig. 7
Fig. 8 Jog height illustration
Fig. 9

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Rot(ary) Home Mode
A toggle type on/off instruction applicable to rotary template use.
If selected ‘on’, the rotary template nozzle assembly will automatically return to its ‘home’ or
‘start’ position for the start of each product row, regardless of where it had previously
finished. This may be necessary for the depositing of some products - particularly if an
offset nozzle holder is being used (see fig. 11).
If selected ‘off’, then the rotary position of the rotary template/nozzle assembly will remain in
the same position for start of each product as it was at the end of the previous product (see
fig. 11).

Tray Length
The length, in millimetres, of the tray being used for the depositing of products onto.
Dimension of tray to be considered is that in the direction of tray conveyor travel. (see fig.13)
IMPORTANT - No automatic tray length detector exists on the DELTA and this programmed
length value is stored in the controller’s memory for the particular product in question.
Hence, it is imperative that no tray with a length shorter than the programmed value is used,
otherwise damage to the machine may result and the controller will be unable to complete
its full program. Use of longer trays than the programmed value will only result in inefficient
use of the trays with the last deposit being positioned somewhat further away from the tray’s
trailing edge than it’s leading edge.
Fig. 10
Fig. 12
Fig. 13 Tray length illustration
Fig. 11

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Jog Up Speed
The speed value by which the depositing head travels vertically upwards (jogs) through
the ‘Jog Height’ distance (see fig. 7) at the end of each product depositing sequence.
The speed value entered has a linear relationship, up to a maximum preset value, to the
constant speed portion of the depositing head’s movement whilst jogging upwards, it being
after accelerating up to the speed value and prior to decelerating back to rest at the top of the
jogging movement.
2. Template Menu
Consideration needs to be given to the template assembly being used in the creation of a
product. These relevant and important factors are all addressed in the Template Menu and
are detailed below.
Template No. (number)
The 5 digit number stamped on the exposed upper surface of the template body.
Enter this number as the last 5 digits of the allowable 6 digit Template No. identification code
(the 1st digit being 0, and is available for possible future use).
The template identification number is stamped onto the template body at MONO’s factory and
templates of like types are grouped as follows:
Template Template type Description
No. Group
01---- SHEETING TEMPLATES - SOFT DOUGH
02---- ROTARY TEMPLATES - SOFT DOUGH
03---- STANDARD TEMPLATES - SOFT DOUGH
04---- STUB TEMPLATES - SOFT DOUGH
05---- SPECIAL TEMPLATES - SOFT DOUGH
06---- SHEETING TEMPLATES - HARD DOUGH
07---- ROTARY TEMPLATES - HARD DOUGH
08---- STANDARD TEMPLATES - HARD DOUGH
09---- SPECIAL TEMPLATES - HARD DOUGH
The 5 digit template number entry is stored with each product program but serves only as a
visual reminder to the user to ensure fitment of correct template body.
Fig. 14
Fig. 15

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Hopper Type
A toggle type HD/SD (Hard Dough/Soft Dough) visual reminder instruction to ensure correct
hopper assembly is used for the particular product program in question.
Nozzle ID (identification)
User defined numerical identification code for nozzle type (serrated, plain, special etc). Acts
as a visual reminder instruction to ensure correct nozzle type is used in the template assembly
for the particular product program in question. It is suggested that the user keeps nozzle ID
records on the sheet provided for this purpose in ANNEX A of this manual.
Offset Length
The distance in millimetres between the centre of rotation and the end of an offset type
nozzle holder (see fig.3.1.2.4b).
This value is in effect the radius through which the extreme tip of the nozzle travels when the
holder is rotated in a rotary type template body. Whilst acting as a visual reminder instruction
to the user to ensure the correct holder is used for the particular product program in question,
the value entered is also used by the DELTA’s controller to calculate automatically the correct
positioning of products on a tray to avoid possible collision between either leading or trailing
edges of the tray and the nozzle holder throughout all possible angular positions (this being so
provided the ‘Tray Length’ value (see fig. 3.1.6) in Tray Set Up menu has been correctly
entered).
Fig. 16
Fig. 17
Fig. 18
Fig. 19
IMPORTANT - No automatic offset length detector exists on the DELTA and this programmed
length is stored in the controller’s memory for the particular product in question, hence, it is
imperative that no longer offset type nozzle holder is used than that which is programmed,
otherwise damage to the holder, nozzle, template or machine may result.

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3. Edit/Create menu and use of commands
Most significant consideration needs to be given to the product program. The product
program is the sequence of events and command instructions, imparted via the
controller and the user written program, necessary to describe the simultaneous and
related movements of each of the DELTA’s 4 axes to deposit one product row only.
This individual product program then gets repeated by the value programmed in under the
‘Rows per Tray’ (see fig. 6) instruction within the ‘Tray Set Up’ menu.
Creating a product program requires the appropriate use of available commands along with
numerical data entry to describe simultaneous machine movements as applicable to each of
the DELTA’s 4 axes.
The available machine movement control commands are as follows:
MOVE -- SPEED -- SUCK BACK -- WAIT -- MAN SPACE -- END ROUND –DELETE
To invoke any of the above commands, use the top RH key to the side of the LCD screen
once the EDIT/CREATE menu is current (see fig. 6).
The available commands will appear on a pop-up menu onto the existing EDIT/CREATE
menu screen - use the up and/or down arrow key on the main keypad area to move the
cursor onto the command required and press enter key to select.
The command will be inserted into the main program above the line that the cursor is
currently on; hence, the cursor needs to be positioned correctly before the introduction of a
new command into the program. To remove pop-up command menu from the EDIT/CREATE
screen, press escape key. The pertinent rules for correct data entry and the effect of each of
the available commands are outlined below:

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MOVE –
The DELTA has 4 axes of controlled movement; deposit pump, tray conveyor, deposit
head raise/lower (jog) and nozzle rotate (rotary template only). A MOVE command will
instruct each of the motors associated with the axes to start to move (i.e. rotate) and to
finish simultaneously.
By appropriate programming each axis’s motor may also be made to remain stationary or to
move in reverse to its normal forward movement when carrying out its MOVE command.
SPECIAL NOTE - The very first MOVE line on any product program is preceded by an
unseen program line that is automatically introduced by the DELTA’s controller and is not
printed out on screen. This line sets the start positions for all the 4 axes of the DELTA and
obviates the need for the user to do so. All MOVE start values are set to zero with the
exception of the ‘MOVE-Height’ value which sets itself to the same value set by the user in
the first programmed MOVE line. This enables the head movement) at any point during the
product creation program. The command, allowing WAIT periods in increments of 1
second, can be used to allow the complete depositing of mix before continuation onto the
next deposit.
The resultant effect of each axis’s movement and the programmability using this command
is as follows:
Deposit pump (Axis 0) - enter a positive numerical value under the ‘Dep qty’ column
on the MOVE command line to achieve rotation of the deposit pump and a quantity of
product mix extruded through the selected template assembly. The entered value is
proportional to the amount of pump rotation but is, by necessity, uncalibrated in product mix
quantity terms as any attempt to do so would be inaccurate should the template
arrangement, product mix or either pumping speed change
To increase the amount deposited at any particular stage in the product depositing
sequence, move the cursor onto the value to be edited by using the up, down, left and right
arrow key, as appropriate, and enter a new value.
Use the +/- key to enter a negative numerical value to achieve reverse rotation of the pump
and hence a suck back effect instead of a deposited quantity.
Enter a zero value for ‘Dep qty’ for the deposit pump to remain stationery and not deposit.
All values entered for ‘Dep qty’ are absolute values, i.e. each entered value will correspond
to a proportionate amount of pump rotation.
Fig. 21 product length illustration

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Tray conveyor (Axis 1)- enter a positive numerical value under the ‘Prod L’ column
on the MOVE command line to achieve horizontal movement of the tray conveyor in a
direction away from the operator and the control panel. The entered value is the
horizontal position; measured in millimetres, relative to the initial start position for each
product that is regarded as position zero (see fig. 22).
IMPORTANT - on a multi line product program consideration needs to be given to the
value entered in the previous MOVE command line, as the tray will be progressed from
this position to its new position as measured from position zero, i.e. the following program
will progress the tray as shown in fig.22 and produce a product as shown in fig.23.
No. Command Dep qty Prod L Height Ang
00 Move 200 100 10 0
01 Move 100 100 20 0
02 Move 100 50 20 0
Deposit Head Raise/Lower - Jog (Axis 2) - enter a positive numerical value
under the ‘height’ column on the MOVE command line to achieve vertical movement of
the deposit head. The entered value is the vertical position, measured in millimetres,
relative to the top surface of a tray of 2mm thickness placed directly on top of the
conveyor belts, which is regarded as position zero. In this sense the motion behaviour of
the jog axis is similar to that of the tray conveyor.
IMPORTANT - on a multi line product program, consideration needs to be given to the
value entered in the previous MOVE command line as the head will be moved from this
position to its new position as measured from position zero, i.e. consider the program in
fig 22 the actual head height positions are shown in fig.24:
Notice that the head height for the 3rd MOVE command remains at a constant position
as it is instructed to MOVE from a value of 20 on line 01, to 20 on line 02, i.e. no vertical
movement. Hence, if the head height is required to remain at a constant position for a
multi line product program then the height value figures must be repeated on every line.
To achieve vertical head movement, the ‘Height’ values entered on successive MOVE
command lines need to differ by the distance required to MOVE, i.e. consider the program
in fig 22 - the head movement for the 2nd MOVE command is 10mm vertically up as it is
instructed to MOVE from a ‘Height’ value of 10 on line 00, to 20 on line 01 (see fig.24).
Posn
0
Posn
100
100mm
Posn
50
50mm
Leading
edge
Tray movements between products
Trailing
edge
Leading
edge
Tray movements between products
Trailing
edge
Fig. 23
Fig. 22 Nozzle horizontal movements –multi line program