Delta PLC Programming & Automation Systems
Specialist Delta DVP micro-PLC and AS-series modular PLC programming, ISPSoft control software, DOP-100 HMI design, MS300 variable speed drives, and custom BS EN 61439 control panels. Engineered in the UK and commissioned for industrial clients across the UK and worldwide.
1. INDUSTRIAL HARDWARE OVERVIEW
Why Delta Industrial Automation Drives Modern Machine Value
Delta Electronics is one of the world largest manufacturers of industrial power and motion automation hardware. In a manufacturing climate where capital costs and component lead times dictate project viability, Delta delivers high-performance 32-bit computing, modular I/O, and integrated fieldbus connectivity at a fraction of traditional hardware costs.
Unrivalled Price-to-Performance Ratio
For original equipment manufacturers (OEMs) building packaging machinery, conveyor lines, pumping skids, and material handling systems, control system hardware costs heavily impact market competitiveness. Delta AS and DVP series controllers provide built-in RS-485 Modbus, CANopen, and industrial Ethernet ports directly on CPU modules without requiring expensive add-on communication cards.
At MASK Control Systems, our control engineers leverage this architecture to design high-specification automation panels that maximize operational throughput while keeping capital expenditure strictly within client budgets.
Seamless Vertical Integration
One of the most persistent bottlenecks in modern automation engineering is integrating heterogeneous hardware components across multiple vendors. Delta solves this challenge by delivering a vertically integrated product ecosystem: PLCs, DOP-100 touchscreens, MS300 variable speed inverter drives, and ASDA AC servo systems designed to communicate natively.
Our Devon workshop programs and pre-commissions these components as unified packages, eliminating communication latency, reducing wiring complexity, and ensuring rapid on-site commissioning across the UK and worldwide.
Delta Automation Hardware Platforms Supported by MASK
Delta AS Series Modular PLCs
Delta AS series represents the cutting edge of compact modular automation. Powered by Delta self-developed 32-bit SoC CPUs, the AS series delivers exceptional execution speed of 40k steps per millisecond and supports up to 1,024 I/O points across rackless modular slices.
- 32-bit SoC multi-core processing architecture with fast scan cycles
- Built-in CANopen, EtherNet/IP, Modbus TCP, and RS-485 serial ports
- Supports up to 32 expansion modules with high-density screwless terminals
- Programmed via ISPSoft and DIADesigner supporting all 5 IEC languages
Delta DVP Series Micro-PLCs
The world-renowned DVP series is the backbone of OEM machinery globally. Offering remarkable cost-efficiency, the DVP family delivers reliable logic sequencing, integrated analog I/O, high-speed pulse inputs, and built-in Ethernet on slim-type modules.
- Extremely compact DIN-rail footprint suitable for tight enclosures
- DVP-SE features built-in Ethernet supporting Modbus TCP and mini-USB
- DVP-SV2 high-end model delivers 200kHz 4-axis pulse output for positioning
- Seamless compatibility with ISPSoft and legacy WPLSoft projects
Delta AX Motion & PAC Controllers
For advanced multi-axis packaging, robotics, and continuous processing skids, Delta AX and AH series deliver high-bandwidth real-time control. Powered by Codesys or dual-CPU redundancy, these systems coordinate dozens of coordinated motion axes.
- AX-series features native EtherCAT bus controlling up to 64 synchronized axes
- AH500 offers hot-swapping modules, dual power supplies, and redundant CPUs
- PLCopen motion function blocks for electronic gearing, camming, and CNC
- Integrated OPC UA server and MQTT client for Industry 4.0 data streaming
Delta Drives, Servos & HMIs
Delta strength lies in its vertically integrated automation hardware. By pairing Delta controllers with matched operator interfaces, AC variable speed drives, and precision servo motors, we deliver unified, single-vendor machine architectures.
- DOP-100 touchscreens with 65,536 colors and fast Cortex quad-core processors
- MS300 compact drives supporting open/closed loop induction and PM motors
- ASDA-A3 servo drives with 3.1kHz frequency response and 24-bit encoders
- Single-cable communication over CANopen, Modbus, or EtherCAT fieldbuses
2. OUR DELTA SERVICES
End-to-End Delta PLC & System Integration Services
From fresh software development in ISPSoft to custom control cabinet manufacturing and emergency on-site breakdown response, we deliver complete turnkey engineering solutions.
Delta AS & DVP Software Programming
Turnkey software development in ISPSoft and DIADesigner. We write structured, modular code in Ladder Diagram (LD) and Structured Text (ST) complying with IEC 61131-3 standards for optimal maintainability.
DOP-100 HMI & DIAView SCADA Systems
Intuitive operator interfaces engineered in DOPSoft and DIAView. We create high-resolution widescreen visual displays with dynamic alarming, multi-tier recipe storage, and encrypted user access levels.
Delta Servo Motion & Inverter Drive Integration
Precision multi-axis motion synchronization pairing Delta PLCs with ASDA-A2, ASDA-A3, and ASDA-B3 servo systems, alongside MS300, ME300, and C2000+ variable speed inverter drives.
BS EN 61439 Control Panel Manufacturing
Bespoke industrial electrical enclosures designed and built at our UK facility. Every cabinet is constructed to BS EN 61439 and BS 7671 standards with laser-etched wiring and complete electrical CAD schematics.
Legacy WPLSoft to Modern ISPSoft Migrations
Planned, risk-free modernization converting obsolete DVP brick controllers to contemporary modular AS-series PLCs. We eliminate legacy hardware obsolescence while improving machine productivity.
24/7 Breakdown, Fault Tracing & Site Support
Rapid diagnostic callouts across the United Kingdom and global remote VPN assistance. Our controls engineers trace intermittent fieldbus faults, hardware failures, and corrupted machine parameters.
3. ARCHITECTURE MATRIX
Delta PLC Hardware Family Comparison
Selecting the appropriate Delta controller architecture ensures optimum cycle execution times, sufficient I/O scalability, and long-term hardware availability for your facility.
| Technical Spec | Delta DVP Micro | Delta AS Modular | Delta AX Motion | Delta AH Process |
|---|---|---|---|---|
| Target Application | Compact micro-machines, standalone skids | Mid-to-high modular machines, packaging | High-speed multi-axis motion, robotics | Large plantwide process & infrastructure |
| CPU Architecture | 16-bit / 32-bit compact brick | 32-bit Delta SoC multi-core processor | High-speed multi-core motion processor | Dual-CPU redundant modular backplane |
| Max I/O Points | Up to 512 points (DVP-SV2) | Up to 1,024 points (32 extension slices) | Up to 2,048 distributed EtherCAT points | Up to 4,096 points with rack expansion |
| Primary Fieldbus | RS-485 Modbus RTU, Ethernet (SE) | EtherNet/IP, Modbus TCP, CANopen | Native EtherCAT, Modbus TCP, OPC UA | Profinet, EtherNet/IP, Modbus TCP |
| Software Environment | ISPSoft / Legacy WPLSoft | ISPSoft / DIADesigner | ISPSoft / PMSoft Process Suite | |
| Motion Capability | Up to 4 axes 200kHz pulse train (PTO) | Up to 8 axes CANopen / pulse motion | Up to 64 synchronized EtherCAT axes | Modular multi-axis motion positioning |
4. PROBLEM SOLVING
Real-World Challenges We Solve for Delta Automation Users
Industrial facilities encounter specific operational roadblocks with control hardware. Here is how our engineering team eliminates bottlenecks and secures production lines.
Rising Component Costs on Legacy European PLC Brands
OEM machine builders facing soaring prices and long lead times on legacy European controllers can transition to Delta without sacrificing capability. Delta modular AS series provides high-speed 32-bit computing, integrated Ethernet, and open communication at a fraction of traditional hardware costs.
Complex Integration Between Inverters, Servos, and Controllers
Mismatching fieldbus protocols between mixed-brand drives and controllers causes configuration headaches. We configure unified Delta systems where PLCs, DOP-100 touchscreens, MS300 drives, and ASDA servos communicate over pre-configured Modbus TCP, CANopen, or EtherCAT networks.
Vulnerability Caused by Unlocked or Undocumented Legacy Code
Many machine owners suffer from previous contractors locking PLC programs or providing incomplete documentation. MASK delivers 100% unlocked, fully annotated ISPSoft source code, electrical schematics, and complete I/O cross-reference tables upon commissioning.
Obsolete DVP Micro-PLCs and Discontinued Expansion Modules
Older DVP-ES or DVP-SS brick controllers face obsolescence when spare parts dry up. We manage planned migrations to contemporary AS200/AS300 platforms, converting legacy ladder logic into modern function blocks with zero unplanned factory downtime.
5. PROJECT LIFECYCLE
Our 6-Step Delta Automation Engineering Process
Every control panel build and software project follows a structured engineering workflow designed to ensure complete safety compliance, transparent milestone delivery, and flawless commissioning.
Discovery & Functional Audit
We analyze your machine process, mechanical dynamics, and electrical requirements to select the exact Delta controller, drive, and I/O architecture suited to your throughput demands.
Electrical CAD & Enclosure Design
Our design team produces comprehensive multi-line electrical schematics using Eplan and AutoCAD Electrical, engineering power distribution and safety circuits to BS EN 61439.
ISPSoft & DOPSoft Software Development
We write clean, modular control logic in ISPSoft and intuitive operator graphics in DOPSoft, implementing standardized state machines, alarm management, and recipe structures.
UK Workshop Assembly & Rig Testing
Control panels are fabricated in our Devon workshop with neat wire dressing, laser labeling, and extensive Factory Acceptance Testing (FAT) on live hardware simulation test rigs.
On-Site Installation & Hot Commissioning
Our site engineers wire field sensors, calibrate analog loops, verify servo tuning, and conduct live product trials across the UK and on international production lines worldwide.
Handover, Training & 100% Code Ownership
We provide complete unencrypted source code, as-built electrical schematics, operator training manuals, and ongoing 24/7 technical breakdown support.
6. SECTOR EXPERTISE
Where Our Delta PLC Solutions Are Deployed
We engineer Delta automation solutions tailored to the hygienic, precision, and environmental standards of major manufacturing sectors across the UK and worldwide.
Packaging & FMCG Machinery
High-speed flow wrapping, carton forming, case packing, and multi-lane indexing conveyors using Delta AS series PLCs and ASDA servo electronic camming profiles.
Water & Effluent Treatment
Automated pump stations, dosing skids, filtration backwash cycles, and flow monitoring utilizing Delta DVP-SE controllers communicating via Modbus TCP.
Material Handling & Conveyors
Palletizer cells, sorting belts, roller conveyor lines, and automated guided vehicles (AGVs) driven by Delta MS300 inverters and CANopen fieldbuses.
Plastics & Extrusion Lines
Multi-zone PID temperature control, blow moulding sequences, take-up reels, and thickness gauging monitored by Delta DOP-100 touchscreens.
7. TECHNICAL FAQ
Frequently Asked Questions About Delta PLC Systems
Clear technical answers regarding our Delta DVP, AS, and AX engineering capabilities, communication protocols, and control panel manufacturing.
Which Delta PLC series and software platforms do you program?
We program the entire Delta Industrial Automation portfolio. This includes compact DVP series controllers (DVP-SS2, DVP-SA2, DVP-SX2, DVP-SV2, DVP-ES2, and DVP-SE with built-in Ethernet), high-performance modular AS series PLCs (AS200, AS300, and AS500), high-end AH500 modular PACs, and AX-series motion controllers. Our software development covers ISPSoft, DIADesigner, DIAStudio, and legacy WPLSoft applications.
Why do machine builders choose Delta PLCs over traditional European platforms?
Delta Electronics delivers exceptional price-to-performance value without sacrificing reliability. With 32-bit SoC processors, built-in CANopen, Modbus TCP, EtherNet/IP, and high-speed pulse outputs on standard units, Delta controllers allow OEMs and machine builders to drastically lower bill-of-materials costs while maintaining robust IEC 61131-3 logic execution and fast scan times.
Can you migrate legacy Delta DVP micro-PLCs programmed in WPLSoft to modern AS-series PLCs?
Yes. We regularly convert aging DVP-ES, DVP-EX, and DVP-SS brick controllers programmed in legacy WPLSoft to modular AS series PLCs programmed in ISPSoft. We modernize instruction sets, rewrite monolithic ladder networks into structured function blocks, configure modern Ethernet communication, and preserve electrical terminal compatibility to minimize production disruption.
Do you integrate Delta PLCs with third-party networks like Siemens Profinet or Allen-Bradley EtherNet/IP?
Yes. Delta controllers excel at multi-protocol connectivity. We configure Delta AS and DVP-SE PLCs as Modbus TCP servers, EtherNet/IP adapters, or CANopen masters. For facilities running plantwide Siemens or Rockwell infrastructure, we install certified fieldbus gateways such as Anybus or Delta communication cards to bridge real-time data seamlessly between systems.
Can MASK build custom control panels incorporating Delta PLCs, HMIs, and inverter drives?
Absolutely. At our dedicated engineering workshop in Devon, we build bespoke industrial electrical control panels compliant with BS EN 61439 and BS 7671 standards. We integrate Delta PLCs alongside Delta DOP-100 touchscreens, MS300 or C2000 variable speed drives, and ASDA servo systems with complete schematics and factory acceptance testing.
Where do you provide Delta PLC engineering and emergency breakdown callouts?
We provide rapid on-site emergency troubleshooting, software modifications, and commissioning services throughout the UK from our Devon engineering headquarters. Additionally, we deliver remote VPN telemetry support, turnkey software engineering, and panel export services for international clients worldwide.
Engineered in the UK, Delivered Worldwide
MASK Control Systems Limited operates an integrated engineering facility in Cullompton, Devon. We bridge the gap between world-class electrical design, software craftsmanship, and reliable ongoing field support.
Technical Specifications Summary
Need Expert Delta PLC Programming & Control Panel Engineering?
Whether programming a high-speed Delta AS300 modular system, integrating DOP-100 touchscreens, upgrading aging DVP micro-controllers, or manufacturing a custom BS EN 61439 control cabinet, MASK Control Systems delivers dependable engineering across the UK and worldwide.