INSTRUCTION MANUAL DIGITRAC % 2 DIGITAL TENSION READOUT AND CONTROL

Magnetic Power Systems, Inc. 1626 Manufacturers Drive. Fenton, MO 63026 Tel: 636.343.5550 Fax: 636.326.0608 magpowr@magpowr.com INSTRUCTION MANUAL DIGITRAC % 2 DIGITAL TENSION READOUT AND CONTROL TABLE OF CONTENTS Section Title Page Figure Title Page 1 Introduction... 2 Specifications...20 2 Installation... 2 1 Wiring Isolated Inputs...15 3 Electrical Connections... 3 2 System Types...16 4 Setup and Calibration... 3 3 PA-2 Installation...17 5 PA-2/PA-90 Installation... 5 4 Wiring Diagrams...18 6 Optional Features... 6 5 Outline Dimensions...19 7 Trouble Shooting... 12 6 Screen Flow Chart...21 8 Reset Procedures... 15 All of the information herein is the exclusive proprietary property of Magnetic Power Systems, Inc., and is disclosed with the understanding that it will be retained in confidence and will neither be duplicated nor copied in whole or in part nor be used for any purpose other than for which disclosed. Copyright 2002, all rights reserved. 850A154-1 8/02 Rev. D

1. INTRODUCTION The MAGPOWR % Model DIGITRAC % 2 is a microprocessor based control, designed for precise closed loop tension control of a moving web. All data entry and calibration is done through the touch pad keyboard. The DIGITRAC 2 is capable of controlling web tension in unwind, rewind, or point-to-point applications. Throughout this manual, bold words or symbols represent keystrokes. 2. INSTALLATION INSTALLATION The DIGITRAC 2, Model D2E and its variants are intended for mounting on any flat vertical surface capable of supporting it. See Figure 4 for dimensions. The D2E meets the environmental and mechanical requirements of EN50178 with the exception that the degree of protection provided by the D2E enclosure is IP65 which is more stringent than the standard. If the IP65 rating is required in the final installation, sealing type cable grips should be used for cable entry. Four mounting holes are provided for attachment of the D2E to the mounting surface. The means of attachment should comply with the essential requirements of the appropriate standard(s) and is the responsibility of the installer. The DIGITRAC 2, Model D2 and its variants are intended for installation through a DIN panel opening. The panel itself should exhibit sufficient strength to support the weight of the D2 as well as insure the integrity of the environmental seal. The D2 maintains a degree of protection of IP65 over its front panel. It also meets the environmental and mechanical requirements of EN50178. The D2 mounting clips found on both sides of the enclosure behind the front panel will accommodate panel thickness of 0.06 inches (1.5mm) to 0.5 inches (12mm). Wiring to and from the enclosure must be done with double or reinforced insulation or protective screening which provides protective separation. All wiring outside either of the DIGITRAC 2 enclosures should comply with the essential requirements of the appropriate standard(s) and is the responsibility of the installer. If using a magnetic particle clutch or brake, see Section 5 to install the Model PA-2 or PA-90 Power Amplifier. WARNING: DISCONNECT MAINS BEFORE OPENING ENCLOSURE MAINTENANCE The only maintenance that may be required on DIGITRAC 2 is fuse replacement. Replacement of any fuse requires opening the enclosure, which circumvents the enclosure IP rating. To replace a fuse: On Model D2 and its variants: On Model D2E and its variants: 1. Disconnect the supply mains. 1. Disconnect the supply mains. 2. Remove the two screws on the rear of the D2 2. Open the door of the D2E by loosening the which retain the top cover. two retaining screws. 3. Remove the top cover. 3. Remove the PA-2 or PA-90 power amplifier 4. Remove the PA-2 or PA-90 power amplifier if present. if present 4. Remove and replace the blown fuse. 5. Remove and replace the blown fuse. 5. Re-install the PA-2 or PA-90. 6. Re-install the PA-2 or PA-90 and the top cover. 6. Close the door and re-tighten the retaining screws. 7. Reconnect supply mains. 7. Reconnect supply mains. 2

3. ELECTRICAL CONNECTIONS Figure 3 shows the connections that are required for the basic DIGITRAC 2 system. They are: 115 or 230 vac power One or two MAGPOWR tension sensors RUN/STOP using the DIGITRAC 2 internal logic supply OUTPUT to clutch, brake, motor controller, etc Power Amplifier input (if used) 115 vac for 90 vdc clutch or brake, or 24 vdc for a 24 vdc clutch or brake. See Section 6 for other options and connections. Route AC power away from sensor and control wiring. MAGPOWR sensor cables are color coded on the nameplate. Run all wiring in shielded cable. Connect shields to the enclosure using the standoffs provided. Maximum shield length and maximum length of wires outside of the shield is 3 inches (75 mm). 4. SETUP AND CALIBRATION Apply power. Screen contrast can be adjusted using SHIFT,B and or. SETUP # STATUS A = AUTOMATIC S = STOPPING H = HOLD M = MANUAL E = E-STOP OFF ANALOG BAR GRAPH OF TENSION DIGITAL READOUT OF TENSION USE CONFIGURE TO SELECT UNITS & LANGUAGE The home screen (above) always appears at power up. HOME also returns you to this screen. Keyboard Layout and Programming See Cover for keypad layout. CLEAR clears numeric inputs and other keystrokes. SHIFT selects the shifted (white) functions NEXT and PRIOR change to next or prior screens. or change the value of the parameter displayed on the screen. See Figure 6 for a complete programming flow chart. 3

4.1 System Set up Basic calibration cannot be performed if E-STOP is open, or if RUN/STOP is in run mode. A complete flow chart is shown in Figure 6. To begin basic calibration, do the following: Press SHIFT, Press PROGram, Use or to select )PROGRAM: CALIBRATE(, Press NEXT to select )CALIBRATE BASIC(, Press NEXT to display )SELECT SYSTEM(. Use or to select desired system type. See Figure 1 for a description of system types. If using a regenerative drive, see Section 6.9 to determine system type. Then continue through the flow chart at right entering the desired data in each screen. 4.2 Tension Sensor Calibration NOTE: Continuing beyond this point will erase any previous sensor calibration in this setup. Sensor calibration will require loading the sensor roll with a known force. The known force will be applied using a weight and a temporary web as shown below. The temporary web should be threaded as the web would normally be threaded in the machine to ensure the same wrap angles. In wide web applications, the known force should be applied near the center of the sensing roll using a narrow web such as a rope. Follow the steps at the right to calibrate the tension sensors. 4

4.3 Dynamic Tuning Use NEXT or PRIOR to enter the DESIRED TENSION screen and enter the desired value. Follow the flow chart, Figure 6, to enter CALIBRATE DYNAMICS. When asked to OPTIMIZE in any of the following steps do the following: 1. Press and hold until the tension becomes unstable. 2. Press and hold until the tension is again stable. System stability can be observed on the bar graph. Run the machine at a moderate speed, with the control in AUTOMATIC mode and perform dynamic calibration using the above procedure in the indicated sequence. STABility is normally optimized at full roll. COMPensation is normally optimized at core. If the tension becomes unstable at some other roll diameter see )Tension Oscillates( in Troubleshooting, Section 7. 5. INSTALLATION OF MODEL PA-90 or PA-2 Power Amplifier (if used) 5.1 PA-90 Install the PA-90 before applying power to the control Remove the D2 cover, or open the D2E door. Set JP6 on the D2 p.c. board to 0-10V and voltage. Set JP1 on the power amplifier for the desired output current range. On Model D2, unplug TB6 and remove the knockout from the rear of the enclosure. Mount Power Amplifier per Figure 2 using the standoffs provided with the PA-90. Resecure cover or door. When using the PA-90, the DIGITRAC 2 s 0 to 10 vdc control output is still active but no longer isolated, and is referenced to the AC line. 5.2 PA-2 Install the PA-2 before applying power to the control. Remove the D2 cover, or open the D2E door. Set JP6 on the main PCB to )0-10V( and )VOLTAGE(. Set JP1 and JP2 on the power amplifier per Figure 2 for the desired output voltage and current range. On model D2 unplug TB7 and remove the knock-out from the rear of the enclosure. Mount Power Amplifier per Figure 2 using the standoffs provided with the PA-2. When using the PA-2, the DIGITRAC 2 s 0 to 10 vdc control output is still active but no longer isolated, and is referenced to the AC line. 5

6. OPTIONAL CONNECTIONS, FUNCTIONS AND OTHER TECHNICAL INFORMATION HARDWARE TABLE OF CONTENTS ALTERNATE TENSION INPUTS... 6.1 DIAMETER INPUT... 6.2 WEB SPEED INPUT... 6.3 RUN/STOP... 6.4 E-STOP... 6.5 REMOTE TENSION ON/OFF... 6.6 ISOLATED LOGIC INPUTS (RUN/STOP, ETC.)... 6.7 SELECTING OUTPUT VOLTAGE/CURRENT... 6.8 +5 vdc SUPPLY... 6.9 PROGRAM OPTIONS OPERATOR SCREENS... 6.10 UNITS OF MEASURE... 6.11 LANGUAGE... 6.12 MANUAL MODE... 6.13 TAPER TENSION... 6.14 INERTIA COMPENSATION... 6.15 HOLD LEVEL CONTROL... 6.16 OPTIMIZE METHOD... 6.17 SETUPS AND COPY SETUPS... 6.18 SECURITY... 6.19 ITEM NUMBERS AND SCREEN DESCRIPTIONS... 6.20 6.1 ALTERNATE TENSION INPUTS 100 mv/v TENSION SENSORS On the main PCB cut jumpers JP11 and JP12. Connect wires to TB2 and TB3 as shown using shielded wiring. Only one full bridge can be used. 10 vdc TENSION SIGNAL On main PCB cut jumpers JP10, JP11, JP12 and JP13. Connect signal between terminals TB2.1(+) and TB2.2(-) using shielded wiring. TB2.2(-) should also be connected to TB3.1 (GND). 6.2 DIAMETER INPUT The DIGITRAC 2 uses the diameter of the roll on unwinds and rewinds for inertia compensated stopping and on rewinds for providing taper tension. When no diameter input is provided the DIGITRAC 2 estimates diameter. Using a diameter input gives more accurate results. Select the DIAMETER INPUT TYPE under PROGRAM-CONFIGURE. Connect a diameter sensor between TB3.7(+) and TB3.6(-) using shielded wiring. VOLTAGE (0 to 10 vdc) Voltage must be proportional to diameter (i.e. the output at core cannot be 0 vdc). Select )VOLTAGE( on JP15 on the main PCB. 6

PULSE (0 to 5 vdc, 0 to10,000 pps) Diameter is calculated by dividing web speed by this signal, which is proportional to unwind/rewind RPM. Select )PULSE( on JP15 on main PCB. TB3.5 can be used to supply 5vdc to the pulse generator. See current limitation in Paragraph 6.9. A web speed signal must be provided if the diameter signal is )PULSE(. 6.3 WEB SPEED INPUT The DIGITRAC 2 needs a web speed input if a PULSE type input is used to calculate diameter of the roll on unwinds and rewinds. Select the SPEED INPUT TYPE under PROGRAM-CONFIGURE. Connect a web speed sensor between TB3.8(+) and TB3.6(-) using shielded wiring. VOLTAGE (0 to 10 vdc) Select )VOLTAGE( ON JP9 on main PCB. PULSE (0 to 5vdc, 0 to 10,000 pps) Select )PULSE( on JP9 on main PCB. TB3.5 can be used to supply 5 vdc to the pulse generator. See current limitation in Paragraph 6.9. 6.4 LOGIC INPUTS The logic inputs may be isolated with an external (5 to 24 vdc) power supply to interface with other equipment or for increased noise immunity. Set JP7-8 (OPTO SUPPLY) to EXT (external) for an external isolated 5 to 24 vdc power supply as shown in Figure 5. The current flowing in the logic inputs switches is 2 madc. 6.4.1 RUN/STOP Connect TB4.4 to TB4.3 to initiate the stopping function. During STOP TIME the DIGITRAC 2 continues to control tension as a closed loop system but INERTIA COMP and STOP MULTIPLIER are also activated. See Section 6.7 to use isolated logic inputs (5 to 24vdc). 6.4.2 E-STOP (E-STOP IS AN AUXILIARY FUNCTION NOT INTENDED TO PROVIDE CATEGORY 1 SAFETY PROTECTION) Open the connection between TB4.2 and TB4.1 to initiate E-STOP. On unwinds the output goes full on. On all other systems the output goes to zero. See Section 6.7 to use isolated logic inputs (5 to 24vdc). 6.4.3 REMOTE TENSION ON/OFF TENSION OFF sets the output to zero for all types of systems. For Type 2 and 3 systems OUTPUT LEVEL will display 100% since these systems are reverse acting (i.e. tension decreases with increasing output). Either of two optional modes of operation are selected using PROGRAM-CONFIGURE. TOGGLE duplicates TENSION ON/OFF on the keypad. A momentary connection should be made between TB4.5 and TB4.3 will toggle between TENSION ON and OFF. The TENSION ON/OFF key remains functional. LEVEL turns TENSION OFF when TB4.5 is connected to TB4.3. The TENSION ON/OFF key is disabled. See Section 6.7 to use isolated logic inputs (5 to 24vdc). 6.5 ISOLATED LOGIC INPUTS If it is desired to isolate the logic inputs on TB4 to interface with other equipment or for increased noise immunity, an external power supply can be used as shown in Figure 15. On the main PCB set JP8-7 (OPTO SUPPLY) to EXT (external). 7

6.6 SELECTING OUTPUT VOLTAGE/CURRENT The output voltage/current at TB5.1(+) and TB5.2(-) is set by positioning jumpers on JP6 as shown below. JP6 must be set for 0 to 10 vdc when the PA-2 or PA-90 Power Amplifier is used. The 10 vdc to +10 vdc output is normally used with regenerative drives in torque mode. If the drive is wired so that +10vdc creates torque in the first quadrant, use SYSTEM TYPE 2 or 4. Otherwise use SYSTEM TYPE 1 or 3. In either case tension can now increase or decrease from T1 to T2. See Figure 1. If the PA-2 or PA-90 Power Amplifier is used, select current and voltage per Figure 2. 6.7 +5vdc SUPPLY (TB3.5(+) to TB3.6(-)) Total current capacity is 150 madc. Subtract sensor current of: 30 madc per MAGPOWR sensor 45 madc per 120 ohm sensor connected per Section 6.1 6.8 OPERATOR SCREENS The operator screens are those normally used during machine operation and are accessed using NEXT ITEM or PRIOR ITEM from the HOME screen. These are the only screens affected by the language selected per Section 6.10 and the only screens which are accessible when security is set per Section 6.17. The operator screens are )TENSION(, )DESIRED TENSION(, )MANUAL LEVEL(, )OUTPUT LEVEL(, )TAPER PERCENT( (if TAPER TENSION is selected), and )WEB SPOOL WIDTH( (if INERTIA COMPENSATION is selected). 6.9 UNITS OF MEASURE PROGRAM-CONFIGURE can be used to select units of measure from: 6.10 LANGUAGE ENGLISH (lb, in) METRIC (kg, mm) METRIC (n, mm) PROGRAM-CONFIGURE can be used to select different languages. The selected language is used for the operator screens which are )TENSION(, )DESIRED TENSION(, )MANUAL LEVEL(, )OUTPUT LEVEL(, )TAPER PERCENT( and )WEB SPOOL WIDTH(. The available languages are: ENGLISH (factory default) FRANCAIS DEUTSCH ESPANOL ITALIANO 8

6.11 MANUAL MODE Switch to MANUAL mode at any time using SHIFT,. The output is now fixed at the level set in the MANUAL LEVEL screen. Switch back to AUTOMATIC mode using SHIFT, 6.12 TAPER TENSION Taper tension is used on rewinds to make better rolls by reducing full roll tension compared to core tension. Use PROGRAM-CONFIGURE to select TAPER TENSION. Input the CORE DIAMETER and FULL ROLL DIAMETER. TAPER PERCENT can now be entered on an operator screen. Percent taper is defined as the percent decrease in tension from core to full roll. If a diameter input is not used the DIGITRAC 2 estimates diameter. More accurate results are obtained if a diameter input is provided. See Section 6.2. Either way, diameter must be calibrated using PROGRAM- CALIBRATE-DIAMETER. When calibrating diameter, set TAPER PERCENT to 0. 6.13 INERTIA COMPENSATION Extra torque is often needed to help stop large unwind rolls. STOP MULTIPLIER is available to increase the output as a multiple of the present running torque. If better stopping results are required, they can be attained by selecting INERTIA COMP using PROGRAM-CONFIGURE. The DIGITRAC 2 asks for information needed to calculate the inertia of the unwind roll. The DIGITRAC 2 needs this information to calculate the inertia and required stopping torque as the roll diameter changes. If a diameter input is not used, the DIGITRAC 2 estimates diameter. More accurate results are obtained if a diameter input is provided. See Section 6.2. Either way, diameter must be calibrated using PROGRAM- CALIBRATE-DIAMETER. You must select INERTIA COMP before calibrating diameter. Diameter must be calibrated while the machine is running, so required stopping torque can be calculated. The DIGITRAC 2 must also know roll width to calculate roll inertia. A new screen now appears in the operator loop to input this information when INERTIA COMP is selected. 6.14 HOLD LEVEL CONTROL During normal automatic operation the output changes to correct for changes in DESIRED TENSION, roll diameter, etc. During the STOP TIME the DIGITRAC 2 is still in automatic mode, but the output is momentarily changed by STOP MULTIPLIER or INERTIA COMP to help stop the unwind roll. At the end of STOP TIME the DIGITRAC 2 switches to HOLD mode. In HOLD mode the output is fixed at the HOLD LEVEL. PROGRAM- CONFIGURE can be used to set HOLD LEVEL CHANGES WITH TENSION and / or HOLD LEVEL CHANGES WITH DIAMETER. 6.15 OPTIMIZE METHOD You should normally select PI (Proportional-Integral) for tension control applications. OPTIMIZE changes P and I to give optimum response. For special applications PID (Proportional-Integral-Derivative) can be selected using PROGRAM-CONFIGURE. 9

6.16 SETUPS AND COPY SETUPS There are six independent setups. Each contains its own complete set of parameters. Switch between setups only while stopped using SHIFT, 1, etc. Each setup can be calibrated individually as described in Section 4, or the sensor calibration and parameters in any one setup can be copied to any other setup. Complete setups can be copied using PROGRAM-COPY SETUPS. COPY SETUPS always copies from a selected setup to the present setup. You can also copy the factory DEFAULTS to the present setup. 6.17 PROGRAM-SECURITY PROGRAM-SECURITY can be used to prevent changes to all the programming parameters. When secured, only values in the operator screens can be changed. 6.18 ITEM NUMBERS AND SCREEN DESCRIPTIONS The numbers following each screen parameter can be used to change the value using SHIFT, ITEM. OPERATOR SCREENS TENSION DESIRED TENSION (18) CORE TENSION (18) MANUAL LEVEL (48) OUTPUT LEVEL TAPER PERCENT (20) WEB SPOOL WIDTH (10) Displays current measured tension, setup number and operating mode. The tension set point for AUTOMATIC mode and STOPPING mode. (Does not appear when taper tension is used). This is the DESIRED TENSION at CORE DIAMETER when taper tension is used. The output set point percent when in MANUAL mode. Current output as a percent of maximum. Appears only when taper tension is used. The core tension is reduced by this percentage as the rewind roll increases to FULL ROLL DIAMETER. Appears only when inertia comp is used. Enter the width of the present web to enable calculation of roll inertia. PROGRAM-PARAMETER SCREENS BAR GRAPH TIME (29) DERIVATIVE TIME (34) ERROR LIMIT (19) HOLD LEVEL (26) INTEGRATOR TIME (32) NUMERIC DISPLAY TIME (28) OUTPUT LIMIT (21) Update time for the tension / output bar graph. Default is.050 sec. Part of PID control. Gives an output adjustment proportional to the rate of change of tension error. Error is the difference between the desired tension and the measured tension. This value limits the percent of error that is acted upon. The output will stay at this percent level while in HOLD mode. This time adjusts the response to errors. Larger values slow down the response to rapidly changing error. Update time for the tension / output digital readout. The output will not go above this percent of maximum.

PROPORTIONAL GAIN (33) START TIME (22) STOP MULTIPLIER (24) STOP TIME (23) Generates an output adjustment proportional to the error. Provides a soft-start when starting with a slack web. The output is limited to the HOLD LEVEL at start, but the limit level is increased with time. This is the time taken to increase the limit to full output. A longer start time will provide a softer start. Upon receipt of a stop signal, the output is increased by this multiplier (1 creates no increase). Since the output is proportional to roll diameter, this is a simple adjustment for roll inertia. This is the time that DIGITRAC 2 stays in STOPPING (automatic) mode after the stop signal is received. At the end of this time the control goes to HOLD mode. Stop time should be slightly longer than actual machine stopping time. PROGRAM-CONFIGURE SCREENS DIAMETER INPUT TYPE (11) IS INERTIA COMP USED IS TAPER TENSION USED HOLD LEVEL CHANGES WITH DIAMETER HOLD LEVEL CHANGES WITH TENSION OUTPUT RANGE OPTIMIZE METHOD (44) SELECT LANGUAGE SELECT UNITS (42) SPEED INPUT TYPE (47) TENSION ON/OFF NONE, VOLTAGE, or PULSE. YES, NO YES, NO YES, NO YES, NO Normal, -10 vdc to +10 vdc PI or PID. ENGLISH, FRANCAIS, DEUTSCH, ESPANOL, or ITALIANO (lb, in), (kgm, mm), (n, mm) NONE, VOLTAGE, or PULSE. TOGGLE, LEVEL. The following appear only if taper tension is used: CORE DIAMETER (14) FULL ROLL DIA. (12) CORE TENSION is commanded at this diameter. At this diameter the tension will be reduced by the taper percent. 11

The following appear only if inertia comp is used: DIAMETER AT THIS WEIGHT ROLL WEIGHT RUNNING VELOCITY TIME TO ZERO SPEED WIDTH AT THIS WEIGHT The roll diameter at the entered weight. Diameter must be calibrated while the web is running. It is not necessary to calibrate at the maximum velocity. The roll weight at any diameter in lbs or kgm. The maximum running web velocity. Typical velocity can be used. The time it takes the machine to stop when running at the above velocity. This width is used to calculate density for the above roll weight. 7. TROUBLE SHOOTING PROBLEM POSSIBLE CAUSE SOLUTION OR DIAGNOSTIC Screen blank or hard to read Contrast misadjusted Power select switch improperly set. Press SHIFT, B and or to adjust. Set 115/230 vac power select switch to the appropriate voltage. Output always low Output always high Cannot enter PROGRAM, CALIBRATE, BASIC )EXCESSIVE ROLL WEIGHT( TENSION ON/OFF set to OFF E-STOP is active (except unwind). E-STOP is wired incorrectly. JP8-7 not set for the proper logic supply. E-STOP is active (unwinds only). E-STOP is wired incorrectly. JP8-7 not set for the proper logic supply. Not in HOLD mode: RUN/STOP not wired correctly. JP8-7 not set for the proper logic supply. Sensor(s) misapplied If REMOTE TENSION ON/OFF is set to )TOGGLE( press TENSION ON/OFF on the keypad once. If REMOTE TENSION ON/OFF is set to )LEVEL( one or more of the remote tension off switches are closed. If the internal logic is being used (the factory default) TB4.2 must be connected to TB4.1 to disable E-STOP. Also verify JP8-7 set to )INT(. If an external logic supply is used see Section 6.5. See above. If the internal logic supply is being used (the factory default) TB4.4 must be connected to TB4.3 to be in HOLD mode. Also verify JP8-7 set to )INT(. If an external logic supply is used see Section 6.5. The total weight of the sensor idler roll and shaft must be less than of sensor rating. When two sensors are used this is the combined rating of both (i.e. 100 lbs for two 50 lb sensors).

)MAXIMUM TENSION TOO HIGH( )SENSOR SIGNAL TOO LOW( Selected maximum tension is out of sensor range. Maximum tension is out of sensor range. Calibration can be completed by using a smaller maximum tension. See )Maximum tension is out of range( below. 1. This problem is often caused by loading the sensor in the wrong direction. It can be corrected by reversing +SIG and -SIG (TB2-1 and TB2-2). 2. If signal direction is correct, calibration can often be completed by using a larger maximum tension. See )Maximum tension is out of range( below. Maximum tension is out of sensor range. When maximum tension is applied the load on the sensors must be less than the total sensor rating and greater than 1/8 of total sensor rating. When two sensors are used this is the combined rating of both (i.e. 100 lbs for two 50 lbs sensors). Calculate this load from: LOAD = 2*MAX*SIN(WRAP/2) where: MAX = maximum tension entered during sensor calibration. WRAP=wrap angle. Tension oscillates DIAGNOSTIC: 1. From the home screen use NEXT or PRIOR to go to OUTPUT LEVEL. 2. While the machine is running record the approximate output level. 3. Enter this value in the MANUAL LEVEL. 4. Switch to MANUAL mode. 5. If the tension continues to oscillate there is an out of round roll or other machine generated tension variation. 6. If oscillation stops the control may be mistuned. See ERROR LIM needs adjustment. ERROR LIM needs adjustment 1. Go to OPTIMIZE ERROR LIM. 2. Press and hold until the oscillation stops. If ERROR LIM is max go to )COMP needs adjustment(. COMP needs adjustment 1. Go to OPTIMIZE COMP (ignore reference to core). 2. Press and hold until the oscillation stops. 3. If oscillations cease, optimize ERROR LIMIT. 3. If COMP is max go to )STAB needs adjustment(.

Tension oscillates (continued) STAB needs adjustment 1. Go to OPTIMIZE STAB (ignore reference to full roll). 2. Press and hold until the oscillation stops. 3. If oscillations cease, optimize COMP and then optimize ERROR LIM. 4. If STAB is max go to )STAB is max(. Tension oscillates (continued) STAB is max This is extremely rare. You have a system that needs more than a 150 sec integrator to be stable. Verify this result by performing the diagnostic under )Tension oscillates(. If verified this system may need to use PID for the OPTIMIZE METHOD. Consult the factory. Front panel TENSION ON/OFF does not work Cannot change to a different setup DIGITRAC 2 configured for LEVEL for external TENSION ON/OFF E-STOP is active E-STOP is wired incorrectly JP8-7 not set for the proper logic supply. Not in HOLD mode RUN/STOP not wired correctly JP8-7 not set for the proper logic supply When LEVEL is selected for TENSION ON/OFF only external tension on/off can be used. If the internal logic is being used (the factory default) TB4.2 must be connected to TB4.1 to disable E-STOP. Also verify JP8-7 set to )INT(. If an external logic supply is used see Section 6.7. If the internal logic supply is being used (the factory default) TB4.4 must be connected to TB4.3 to be in HOLD mode. Also verify JP8-7 set to )INT(. If an external logic supply is used see Section 6.7. 14

8. RESET PROCEDURES If it is desired to reset parameters to factory default values perform one of the following reset procedures: A. 1. Simultaneously press and and hold for 2 seconds. )RESETTING PARAMETERS( will appear on the screen for 1 second. 2. Program reset is complete. The basic (tension sensor) calibration is still in memory, but dynamic calibration must be reprogrammed. or B. 1. Connect TB4.6 to TB4.3 for 2 seconds. 2. When )REMOVE FORMAT SIGNAL TO START( appears, remove connection. 3. Program reset is complete. The basic (tension sensor) calibration is still in memory, but dynamic calibration must be reprogrammed. or C. 1. Turn the power to the DIGITRAC 2 )OFF( for 5 seconds. 2. Press SHIFT and 3 simultaneously. 3. While holding the keys down, turn the power )ON(. 4. Release both keys when the screen appears. The screen will display )TEST OR NORMAL? TEST( 5. Press ENTER to display )DISABLE WATCHDOG NO( 6. Press PRIOR ITEM to display )TEST OR NORMAL? TEST( 7. Press to display )TEST OR NORMAL? NORMAL( 8. Press ENTER. 9. Program reset is complete. The basic (tension sensor) calibration has been erased, and all other programming has been reset to factory default values. Begin at Section 4 to reprogram. 15

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DIGITRAC % 2 Specifications Supply Voltage 115 or 230 volts rms, 10% Supply Frequency: 50 or 60 cycles per second, sinusoidal Fuses: F1, F2 1.6 amp, Littelfuse Part No. 21601.6, or Wickmann Part No. 19194-053-FS Enclosure D2 Front Panel IP65 (IEC529) D2E Enclosure IP20 (IEC529) IP65 (IEC529) Climatic Class: 3K3 (EN60721) Temperature Range: Operating 0-C to 40-C Storage -30-C to +80-C Relative Humidity 5% to 85% Pollution Degree: 2 (IEC664-1) Altitude: 0 to 2000 m Compatible Residual Current Devise Types: Worst Case Fault Current: A or B (IEC755) 1.6 amp Inputs: Tension Sensor Diameter Web Speed E-Stop Run/Stop Tension Off Format Outputs: Torque Tension Reference 2.1 mvdc using +5 and -5 vdc (10 vdc) across one 350 ohm sensor or two 350 ohm sensors in parallel, or 100 mvdc, using 5 volts across one 100 ohm full bridge, or 0 to +10 vdc analog 0 to +10 vdc analog, or 20 to 10,000 pulses per second, 5 volt TTL 0 to +10 volts analog, or 20 to 10,000 pulses per second, 5 volt TTL switch closure or 5 vdc or 24 vdc logic switch closure or 5 vdc or 24 vdc logic switch closure or 5 vdc or 24 vdc logic switch closure or 5 vdc or 24 vdct logic 0 to +10 vdc., 1 madc maximum 4 to 20 madc, 500 ohms maximum -10 to +10 vdc, 1 madc maximum 0 to +5 vdc., 1 madc maximum 20