—

A B B M E A S U R E M E N T & A N A LY T I C S

Millmate Roll Force Systems

with Millmate Controller 400
User Manual

3BSE023139R0401 en Rev A
Operator unit X2-40
Control unit 3.4-1
 Use of DANGER, WARNING, CAUTION, and NOTE
This publication includes, DANGER, WARNING, CAUTION and NOTE information where appropriate to point out safety
related or other important information.
DANGER Hazards which could result in severe personal injury or death
WARNING Hazards which could result in personal injury
CAUTION Hazards which could result in equipment or property damage
NOTE Alerts user to pertinent facts and conditions
Although DANGER and WARNING hazards are related to personal injury, and CAUTION hazards are associated with
equipment or property damage, it should be understood that operation of damaged equipment could, under certain operational
conditions, result in degraded process performance leading to personal injury or death. Therefore, comply fully with all
DANGER, WARNING, and CAUTION notices.

TRADEMARKS
®
Pressductor is a registered trademark of ABB AB.

NOTICE
The information in this document is subject to change without notice and should not be construed as a commitment by ABB
AB. ABB AB assumes no responsibility for any errors that may appear in this document.
In no event shall ABB AB be liable for direct, indirect, special, incidental or consequential damages of any nature or kind
arising from the use of this document, nor shall ABB AB be liable for incidental or consequential damages arising from use of
any software or hardware described in this document.
This document and parts thereof must not be reproduced or copied without ABB AB’s written permission, and the contents
thereof must not be imparted to a third party nor be used for any unauthorized purpose.
The software described in this document is furnished under a license and may be used, copied, or disclosed only in accordance
with the terms of such license.

CE marking
Millmate Controller 401 fulfills the RoHS Directive 2011/65/EU, EMC Directive 2014/30/EU and Low Voltage Directive
2014/35/EU, provided that the installation is carried out in accordance with the installation instructions given in Chapter 3
Installation, included in this User Manual.

Copyright  ABB AB, 2005-2018

3BSE001264/B

Template: 3BSE001286/D

3BSE023139R0401 Rev A
 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Table of Contents

TABLE OF CONTENTS
Chapter 1 - Introduction
1.1 About This Manual .................................................................................................. 1-1
1.2 Cyber security disclaimer......................................................................................... 1-1
1.3 Disposal and Recycling............................................................................................ 1-1
1.3.1 Environmental Policy.............................................................................. 1-1
1.3.2 WEEE: Waste Electrical and Electronic Equipment............................... 1-2
1.3.3 Recycling the Transport Material............................................................ 1-2
1.3.4 Disposal of the Product ........................................................................... 1-2
1.3.4.1 Dismantling and Recycling of the Product....................... 1-2
1.3.5 Operator Unit HMI differences ............................................................... 1-3
1.4 Safety Information ................................................................................................... 1-3
1.4.1 Personal Safety........................................................................................ 1-3
1.4.2 Equipment Safety .................................................................................... 1-4
1.5 About This System................................................................................................... 1-4

Chapter 2 - Technical Description

2.1 About This Chapter .................................................................................................. 2-1
2.2 System Overview ..................................................................................................... 2-2
2.3 Load Cells ................................................................................................................ 2-3
2.3.1 General .................................................................................................... 2-3
2.3.2 Measuring Principle ................................................................................ 2-3
2.4 Millmate Controller 400........................................................................................... 2-4
2.4.1 Overview ................................................................................................. 2-4
2.4.2 Technical Data......................................................................................... 2-5
2.4.3 Connections............................................................................................. 2-9
2.4.4 Digital Inputs......................................................................................... 2-11
2.4.5 Digital Outputs ...................................................................................... 2-12
2.4.6 Analog Outputs ..................................................................................... 2-13
2.4.7 LAN-connections .................................................................................. 2-14
2.4.8 Optional Units ....................................................................................... 2-15
2.4.8.1 Relay Board PFVK 128.................................................. 2-16
2.4.8.2 Insulation Amplifier PXUB 201..................................... 2-18
2.4.8.3 Media Converter PXUB 231 .......................................... 2-20
2.5 Millmate Operator Unit 410................................................................................... 2-21
2.5.1 Technical Data....................................................................................... 2-22
2.5.2 Connections........................................................................................... 2-22
2.6 Matching Unit PFVO 142 and PFVO 143 ............................................................. 2-23
2.6.1 Technical Data....................................................................................... 2-23
2.7 Junction Box PFXC 141......................................................................................... 2-25
2.7.1 Technical Data....................................................................................... 2-25
2.8 Junction Box PFBC 161......................................................................................... 2-26
2.8.1 Technical Data....................................................................................... 2-26

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Table of Contents

CONTENTS (continued)
2.9 External Display QDIL 451 ................................................................................... 2-27
2.9.1 Technical Data....................................................................................... 2-27
2.9.2 Dimensions............................................................................................ 2-27

Chapter 3 - Installation
3.1 About this Chapter ................................................................................................... 3-1
3.2 General Installation Information .............................................................................. 3-1
3.3 Packaging and Delivery ........................................................................................... 3-1
3.4 Storage...................................................................................................................... 3-2
3.5 Mounting Load Cell Cabling and Accessories......................................................... 3-2
3.5.1 Cable Routing.......................................................................................... 3-2
3.5.2 Cable Protection ...................................................................................... 3-4
3.6 Installation of Matching Unit PFVO 142 and PFVO 143........................................ 3-4
3.7 Installing Junction Boxes PFXC 141 and PFBC 161............................................... 3-5
3.7.1 Junction Box PFXC 141.......................................................................... 3-6
3.7.2 Junction Box PFBC 161.......................................................................... 3-7
3.8 Electrical Connection of Load Cells ........................................................................ 3-8
3.8.1 Connecting PFVL 141 Load Cells to MC 400........................................ 3-8
3.8.2 Connecting QGPR 102/104 Load Cells to MC 400.............................. 3-12
3.8.3 Connecting QGPR 102/104 Load Cells with
Phase Matching Board PFBK 401 ........................................................ 3-17
3.9 Installing Millmate Controller 400......................................................................... 3-22
3.9.1 Mounting MC 400 Control Unit ........................................................... 3-22
3.9.2 Installing Wall Cabinet.......................................................................... 3-22
3.9.3 Installing MNS Select Floor Cabinet .................................................... 3-23
3.9.3.1 Mounting Cabinets Together .......................................... 3-23
3.9.3.2 Mounting Cabinets to the Floor...................................... 3-23
3.9.3.3 Space Requirements ....................................................... 3-24
3.9.4 Connecting Cables ................................................................................ 3-25
3.9.4.1 Power Supply Cables...................................................... 3-25
3.9.4.2 Signal Cables .................................................................. 3-26
3.9.4.3 Cable Specifications ....................................................... 3-26
3.9.4.4 Connection of Excitation Unit........................................ 3-28
3.9.4.5 Mains Connection........................................................... 3-28
3.9.4.6 Synchronisation (SYNC)................................................ 3-29
3.9.4.7 Connecting Millmate Operator Unit 410 to LAN. ......... 3-29
3.9.4.8 Connecting Redundant +24 V Supply to Millmate
Operator Unit 410 and Network switch.......................... 3-30
3.10 Installing Optional Units ........................................................................................ 3-31
3.10.1 Connecting Insulation Amplifier PXUB 201........................................ 3-31
3.10.2 Connecting Relay Board PFVK 128 ..................................................... 3-32
3.10.3 Mounting External Display QDIL 451 ................................................. 3-33
3.10.3.1 Dimensions ..................................................................... 3-33

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CONTENTS (continued)
3.10.4 Connecting External Display QDIL 451............................................... 3-33
3.10.4.1 General ........................................................................... 3-33
3.10.4.2 Terminating RS-485 Cable Connected to QDIL 451 ..... 3-34
3.10.4.3 Power Supply for QDIL 451 .......................................... 3-34
3.10.5 Connecting Serial Ports......................................................................... 3-34

Chapter 4 - Commissioning
4.1 About This Chapter .................................................................................................. 4-1
4.2 Recommended Equipment ....................................................................................... 4-1
4.3 Actions Before Mains Supply is Switched On......................................................... 4-1
4.3.1 Visual Inspection..................................................................................... 4-2
4.3.2 Checking Connections ............................................................................ 4-2
4.3.3 Checking Power Supplies ....................................................................... 4-3
4.3.3.1 Millmate Controller 400 ................................................... 4-3
4.3.3.2 Millmate Operator Unit 410 ............................................. 4-3
4.3.3.3 Additional Supplies .......................................................... 4-3
4.4 Starting the Equipment............................................................................................. 4-3
4.4.1 Starting Millmate Controller 400 ............................................................ 4-3
4.4.2 Starting Millmate Operator Unit 410 ...................................................... 4-3
4.5 Commissioning the Control Unit ............................................................................. 4-4
4.5.1 Menu Map for Millmate Controller 400 ................................................. 4-4
4.5.2 Overview of Service Menus for the Control Unit................................... 4-5
4.5.3 Actions During the Commissioning........................................................ 4-6
4.5.4 Setting Up the Operator Unit .................................................................. 4-7
4.5.4.1 Set screen saver ................................................................ 4-7
4.5.4.2 Set Backlight Brightness .................................................. 4-8
4.5.4.3 Touch Screen Calibration ................................................. 4-8
4.5.5 Establishing Communication Between the Operator Unit and
the Control Unit, Millmate Controller 400 ............................................. 4-9
4.5.6 Setting Up Network Data For the Operator Unit .................................. 4-10
4.5.7 Setting Up Basic Data in the Control Unit............................................ 4-11
4.5.8 Defining a Measuring Object ................................................................ 4-12
4.5.8.1 Modifying an Existing Measuring Object ...................... 4-13
4.5.9 Objects Types ........................................................................................ 4-14
4.5.10 Changing Load Cell Data...................................................................... 4-15
4.5.11 Setting Force Measurement Parameters................................................ 4-17
4.5.11.1 Setting Filter Response Time ......................................... 4-18
4.5.11.2 Selecting Load Unit........................................................ 4-19
4.5.12 Setting Indication Parameters ............................................................... 4-20
4.5.12.1 Setting Up Level Detectors ............................................ 4-21
4.5.12.2 Setting Analog Output.................................................... 4-23
4.5.12.3 Setting Up Step Detector ................................................ 4-24
4.5.12.4 Object Information ......................................................... 4-27

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Table of Contents

CONTENTS (continued)

4.5.13 Defining a Multi View Object............................................................... 4-28

4.5.13.1 Combined Object Type (Multi View Object) ................. 4-29
4.5.14 Configuring Analog and Digital Inputs and Outputs ............................ 4-30
4.5.14.1 Configuring Digital Inputs ............................................. 4-31
4.5.14.2 Configuring Digital Outputs........................................... 4-34
4.5.14.3 Configuring Analog Inputs............................................. 4-36
4.5.14.4 Configuring Analog Outputs .......................................... 4-37
4.5.15 Setting Up External Communication .................................................... 4-38
4.5.16 Setting Up Ethernet LAN...................................................................... 4-39
4.5.17 Setting Up Profibus ............................................................................... 4-40
4.5.18 Setting up Vendor Internet Protocol (VIP)............................................ 4-41
4.5.19 Setting Up Serial Ports .......................................................................... 4-42
4.5.19.1 Setting Up External Display........................................... 4-43
4.5.19.2 Setting up Serial Communication................................... 4-44
4.5.20 Switching On Load Cell Excitation ...................................................... 4-46
4.5.21 Adjusting Load Cell Excitation............................................................. 4-47
4.5.21.1 Checking of Load Cell Excitation in PFVI 401 ............. 4-47
4.5.21.2 Procedure for Phase Compensation................................ 4-48
4.5.22 Adjusting Phase Matching Board PFBK 401........................................ 4-49
4.5.23 Simulate Load Cells .............................................................................. 4-50
4.5.24 Performing Manual Sensitivity Adjustment.......................................... 4-51
4.5.25 Performing Zero Adjustment ................................................................ 4-52
4.5.26 Selecting a Start Object for the Operator Unit ...................................... 4-53
4.5.27 Performing a System Reference Test (Self Test) .................................. 4-54
4.5.27.1 Starting the Self Test....................................................... 4-54
4.5.27.2 System Test Errors.......................................................... 4-55
4.5.28 Setting Up System Lock........................................................................ 4-55
4.5.29 Printing Out Data .................................................................................. 4-56
4.5.29.1 Printing Out Setup Information ...................................... 4-57
4.5.29.2 Printing Out Profibus GSD-file ...................................... 4-57
4.5.29.3 Printing Out System Test Results ................................... 4-57
4.5.30 Setting up Load and Dump ................................................................... 4-58
4.5.30.1 Saving a Backup Copy (Dump) of a Complete
Object Setup ................................................................... 4-58
4.5.30.2 Loading a Complete Object Setup.................................. 4-59
4.5.31 Removing An Object............................................................................. 4-62
4.5.32 Removing All Setup.............................................................................. 4-63
4.6 Commissioning Optional Units.............................................................................. 4-64
4.6.1 Insulation Amplifier PXUB 201 ........................................................... 4-64
4.6.2 Media Converter PXUB 231................................................................. 4-66
4.7 Commissioning External Units .............................................................................. 4-67
4.7.1 External Display QDIL 451 .................................................................. 4-67
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 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Table of Contents

CONTENTS (continued)
Chapter 5 - Operation
5.1 About This Chapter .................................................................................................. 5-1
5.2 Safety........................................................................................................................ 5-1
5.3 Indications ................................................................................................................ 5-2
5.3.1 LED Indications ...................................................................................... 5-2
5.3.2 Fault Indications During Run.................................................................. 5-3
5.4 Start-up ..................................................................................................................... 5-4
5.5 Measurement During Normal Operation ................................................................. 5-5
5.6 Shutdown.................................................................................................................. 5-5
5.7 Operation.................................................................................................................. 5-6
5.7.1 Operation from the Operator Unit........................................................... 5-6
5.7.1.1 General ............................................................................. 5-6
5.7.1.2 Operator Unit Buttons ...................................................... 5-7
5.7.1.3 Operator Unit Display ...................................................... 5-8
5.7.2 Operation from an Optional Web Browser ............................................. 5-9
5.7.3 Selection List (List of Connected Objects) ........................................... 5-11
5.7.4 Service Menus....................................................................................... 5-11
5.7.4.1 Service Menu Settings for the Control Unit ................... 5-12
5.7.5 Settings for the Operator Unit ............................................................... 5-12
5.7.5.1 Set Screen saver.............................................................. 5-12
5.7.5.2 Set Backlight Brightness ................................................ 5-13
5.8 Connecting to a Measuring Object......................................................................... 5-14
5.8.1 Selecting an Object from the Selection List.......................................... 5-14
5.8.2 Changing to an Object in Another Control Unit ................................... 5-14
5.9 Operation Menus for Roll Force Measurement ..................................................... 5-15
5.9.1 Standard Measurement (720, 730, 740) ................................................ 5-15
5.9.1.1 Key Functions................................................................. 5-16
5.9.1.2 Operation Messages........................................................ 5-16
5.9.2 Single Input Measurement (710)........................................................... 5-17
5.9.2.1 Key Functions................................................................. 5-17
5.9.2.2 Operation Messages........................................................ 5-18
5.10 Multi View (750).................................................................................................... 5-18
5.11 Sub Functions for Operation Menus ...................................................................... 5-19
5.11.1 System Test (761, 762, 763).................................................................. 5-19
5.11.2 Changing to Single Cell Operation (775, 776, 777).............................. 5-20
5.11.3 Setting Load Cell Set Number .............................................................. 5-21
5.11.3.1 Key Functions................................................................. 5-21
5.11.4 Error Inspection..................................................................................... 5-22

Chapter 6 - Maintenance
6.1 About This Chapter .................................................................................................. 6-1
6.2 Periodical Maintenance............................................................................................ 6-1

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Table of Contents

CONTENTS (continued)
6.3 Operator Unit ........................................................................................................... 6-2
6.4 Cabinets.................................................................................................................... 6-2
6.5 Load Cells ................................................................................................................ 6-2
6.6 Changing Battery in the Control Unit ...................................................................... 6-3
6.7 Replacing Battery in the Operator unit .................................................................... 6-4

Chapter 7 - Fault Tracing

7.1 About This Chapter .................................................................................................. 7-1
7.2 Interchangeability..................................................................................................... 7-1
7.2.1 Load Cells ............................................................................................... 7-1
7.2.2 Matching Units........................................................................................ 7-1
7.2.3 Millmate Controller 400.......................................................................... 7-1
7.3 Fault Indications....................................................................................................... 7-2
7.4 Fault Inspection........................................................................................................ 7-2
7.4.1 System Error List .................................................................................... 7-2
7.4.1.1 Errors Detected at Commissioning or During Normal
Operation .......................................................................... 7-3
7.4.1.2 Errors Detected when Running the System Test,
(Error Types No 201-264) ................................................ 7-6
7.5 Fault Tracing Procedure ........................................................................................... 7-9
7.6 System Test .............................................................................................................. 7-9
7.6.1 Starting the System Test........................................................................ 7-10
7.6.2 Starting a Part Test ................................................................................ 7-11
7.6.3 System Test List .................................................................................... 7-11
7.6.4 Fault Tracing Diagram .......................................................................... 7-14
7.7 Single Cell Operation ............................................................................................. 7-15
7.8 Checking Matching Units PFVO 102/142 and PFVO 201/143 ............................. 7-16

Appendix A - Vendor Internet Protocol (VIP)

A.1 About This Chapter ................................................................................................. A-1
A.1.1 Terminology ........................................................................................... A-1
A.2 General Description ................................................................................................ A-1
A.2.1 VIP Implementation in MC 400............................................................. A-1
A.2.2 Communication Establishing ................................................................. A-1
A.2.3 Communication Procedure..................................................................... A-1
A.2.4 Message Configuration .......................................................................... A-2
A.2.5 Supported Data Types ............................................................................ A-2
A.2.6 General VIP Telegram Structure ............................................................ A-3
A.2.6.1 Header Part ...................................................................... A-3
A.2.6.2 Data Part in MC 400........................................................ A-3
A.3 Specific Functions................................................................................................... A-5
A.3.1 Overview ................................................................................................ A-5
A.3.2 Data Conversion..................................................................................... A-5

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Table of Contents

CONTENTS (continued)
A.3.3 Strip Tensiometer and Roll Force Meter Communication ..................... A-6
A.3.3.1 Input Package Sent to MST and MRF............................. A-6
A.3.3.2 Output Package Produced by MST and MRF ................. A-7
A.3.4 Strip Scanner Communication ............................................................... A-8
A.3.4.1 Input Package Sent to MSS ............................................. A-8
A.3.4.2 Output Package Produced by MSS ................................. A-9

Appendix B - Profibus-DP Fieldbus Communication

B.1 About This Appendix .............................................................................................. B-1
B.2 General Description ................................................................................................ B-2
B.2.1 General Data about Profibus DP ............................................................ B-2
B.2.2 Master-slave Communication ................................................................ B-3
B.2.3 Variants of Communication Blocks ....................................................... B-3
B.2.4 Block Description................................................................................... B-4
B.2.4.1 Input Buffer, Communication Block from MC 400 to
PLC.................................................................................. B-4
B.2.4.2 Output Buffer, Communication Block from PLC to
MC 400............................................................................ B-4
B.2.5 Blocks..................................................................................................... B-5
B.2.5.1 Input Buffer, Communication Block from MC 400 to
PLC.................................................................................. B-5
B.2.5.2 Output Buffer, Communication Block from PLC to
MC 400............................................................................ B-5
B.2.5.3 Resolution for Roll Force and Tensiometer Objects ....... B-6
B.2.5.4 Resolution for Strip Scanner Objects .............................. B-6
B.2.6 GSD File................................................................................................. B-7
B.3 Installation............................................................................................................... B-8
B.3.1 Profibus Physical Media ........................................................................ B-8
B.3.2 MC 400 Profibus Interface....................................................................B-11
B.4 Commissioning ..................................................................................................... B-12
B.4.1 Safety Information ............................................................................... B-12
B.4.1.1 Personal Safety .............................................................. B-12
B.4.1.2 Equipment Safety .......................................................... B-12
B.4.2 Setting up Fieldbus............................................................................... B-13
B.4.3 Configuring Boolean Inputs................................................................. B-14
B.4.4 Configuring Boolean Outputs .............................................................. B-16
B.4.5 Error Handling ..................................................................................... B-18
B.5 Technical Specifications........................................................................................ B-18
B.6 Examples of Recommended Setup........................................................................ B-18
B.6.1 One Standard Load Cell Object for MRF or MST............................... B-19
B.6.2 Two Standard Load Cell Objects for MRF or MST............................. B-20
B.6.3 Millmate Strip Scanner Object............................................................. B-21

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Table of Contents

CONTENTS (continued)
Appendix C - Drawings
C.1 Millmate Controller 400 in Wall Cabinet, Dimension Drawing,
3BSE017454, Rev. B............................................................................................... C-1
C.2 Wall Cabinet Cylmate/Millmate Controller, Dimension Drawing,
3BSE022232D0064, Rev. C.................................................................................... C-2
C.3 MNS Select Cabinet, Dimension Drawing, 3BSE017052D64, Rev. B .................. C-3
C.4 Millmate Controller 400, Dimension Drawing, MC 400 on 19” Mounting Plate,
3BSE017453D0064, Rev. A ................................................................................... C-4
C.5 Millmate Controller 400, Dimension Drawing, 3BSE017585, Rev. A................... C-5
C.6 PFVI 401 Excitation Unit, Dimension Drawing, 3BSE028251, Rev. - .................. C-6
C.7 Vibration Isolators for Millmate Controller 400, Erection Drawing,
3BSE017462D0090, Rev. - ..................................................................................... C-7
C.8 Millmate Operator Unit 410 (PXAH 411), Dimension Drawing,
3BSE086846, Rev. - ................................................................................................ C-8
C.9 Relay Board, PFVK 128, Circuit Diagram, 3BSE010547D0002, Rev. B .............. C-9
C.10 Relay Board, PFVK 128, Arrangement Drawing, 3BSE010547D0004, Rev. E .. C-10
C.11 Matching Board, PFBK 401, Circuit Diagram, 3BSE027078D0002, Rev. -.........C-11
C.12 Matching Device, PFVO 142, Circuit Diagram, 3BSE023732D2, Rev. A .......... C-12
C.13 Matching Device, PFVO 143, Circuit Diagram, 3BSE023150D2, Rev. A .......... C-13

8 3BSE023139R0401 Rev A
 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section 1.1 About This Manual

Chapter 1 Introduction

1.1 About This Manual

This User Manual describes Millmate Roll Force Systems with
Millmate Controller 400 (MC 400).
The purpose of the User Manual is to provide necessary information of:
• Safety
• System design and functions
• Installation
• Commissioning
• Operation
• Maintenance
• Fault tracing

1.2 Cyber security disclaimer

This product has been designed to be connected and communicate data and information via a
network interface which should be connected to a secure network. It is the sole responsibility of
the person or entity responsible for network administration to ensure a secure connection to the
network and to take the necessary measures (such as, but not limited to, installation of firewalls,
application of authentication measures, encryption of data, installation of antivirus programs,
etc.) to protect the product and the network, its system and interface included, against any kind
of security breaches, unauthorized access, interference, intrusion, leakage and/or theft of data or
information. ABB is not liable for any such damages and/or losses.

1.3 Disposal and Recycling

1.3.1 Environmental Policy

ABB is committed to its environmental policy. We strive continuously to make our products
environmentally more sound by applying results obtained in recyclability and life cycle
analyses. Products, manufacturing process as well as logistics have been designed taking into
account the environmental aspects.
Our environmental management system, certified to ISO 14001, is the tool for carrying out our
environmental policy. However it is on the customer’s responsibility to ensure that local
legislation is followed.

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Millmate Roll Force Systems with Millmate Controller 400, User Manual
Chapter 1 Introduction

1.3.2 WEEE: Waste Electrical and Electronic Equipment

The crossed – out wheeled bin symbol on the product(s) and / or accompanying documents
means that used electrical and electronic equipment (WEEE) should not be mixed with general
household waste.
If you wish to discard electrical and electronic equipment (EEE), in the European Union, please
contact your dealer or supplier for further information.
Outside of the European Union, contact your local authorities or dealer and ask for the correct
method of disposal.
Disposing of this product correctly will help save valuable resources and prevent any potential
negative effects on human health and the environment, which could otherwise arise from
inappropriate waste handling.

1.3.3 Recycling the Transport Material

ABB designs all transport material to be recyclable where practical. The recycling of the
transport material depends on the material type and availability of local recycling programs.
After receiving the system into the site, the package and the transportation locking have to be
removed. Recycle the transport material according to local regulations.

1.3.4 Disposal of the Product

When the product is to be disposed of it should be dismantled and its components recycled
according to local regulations.

1.3.4.1 Dismantling and Recycling of the Product

Dismantle and recycle the components of the product according to local regulations.
• Control Unit and Other Equipment: This includes the various circuit boards, electrical
components, voltage and current transformers, power cables, instrumentation wires, surge
arrestors and capacitors. See avsnitt 1.3.2, WEEE: Waste Electrical and Electronic
Equipment.
• Control Unit and Operator Unit contain lithium batteries

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 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section 1.3.5 Operator Unit HMI differences

1.3.5 Operator Unit HMI differences

This system has been updated with a new Operator Unit.
This manual therefore has not yet been updated with the new HMI layout on all descriptive
figures.
The functions on the system is basically the same, and can be followed as described.

1.4 Safety Information

The safety instructions in this chapter should always be followed to minimize the risk of
personal injury, and also the risk of damaging the equipment, when operating the Millmate Roll
Force Measurement System. However, local regulations, if stricter, always take precedence.

1.4.1 Personal Safety

DANGER
Be careful when working with the measurement system with mains voltage
applied to it. The voltage in the equipment can injure, or even kill.

The following must be observed:

• Everyone working with or around the measurement system must know where the main
circuit breaker for the system is located and how it is operated.
• Safety devices and such like must be checked by a responsible person when parts of the
measurement system have been tested and run. All personnel concerned must be informed
of future test runs.
• A process technician must be present when testing and running the system.
• Never start the system without knowing the effect of start up.
• Remember that the measurement system can be influenced by remote objects via digital
and analog inputs, superior control systems or terminals.

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Millmate Roll Force Systems with Millmate Controller 400, User Manual
Chapter 1 Introduction

1.4.2 Equipment Safety

Observe the following cautions:
• Avoid static discharges by grounding both tools and your-self before handling circuit
boards and other parts of the measurement system.
• Before electrical welding is carried out in the surroundings of the system, switch off the
equipment and disconnect the wires in the terminal blocks.

1.5 About This System

Your Millmate Roll Force Measurement System mainly consists of:
• Control unit Millmate Controller 400, see Table 1-1. Overview of Control Units
• Millmate Excitation Unit PFVI 401
• Millmate Operator Unit 410
• Two or more Pressductor® load cells of type,
PFVL 141 or QGPR 102/104.
• Matching Unit PFVO 142/143
• Junction Box PFXC 141 and PFBC 161
• External Display QDIL 451.
The equipment is intended for use in applications, such as rolling mills and processing lines,
where the roll force has to be continuously measured.

Table 1-1. Overview of Control Units

Control unit Number of Profibus

MC 400 Analog Inputs (AI)
type
PFXA 401 2 no
PFXA 401F 2 yes
MC400 R
PFXA 401S 4 no
PFXA 401SF 4 yes

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 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section 2.1 About This Chapter

Chapter 2 Technical Description

2.1 About This Chapter

This chapter contains:
• A system overview
• Technical description and data for:
– Control unit Millmate Controller 400
Connections
Digital inputs and outputs
Analog inputs and outputs
Optional units, relay board PFVK 128, insulation amplifier PXUB 201 and media
converter PXUB 231
– Millmate Excitation Unit PFVI 401
– Millmate Operator Unit 410
– Matching Unit PFVO 142/143
– Junction Box PFXC 141 and PFBC 161
– External display QDIL 451
• System communication

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Chapter 2 Technical Description

2.2 System Overview

A Millmate Roll Force Measurement System consists of one or more load cells which are
connected via a junction box to a Millmate Controller 400 control unit.
The control unit supplies the load cells with power, processes the signals from the load cells and
transfers measured values to external units.
The control unit can be operated using Millmate Operator Unit 410, external units, a serial
interface or digital inputs.
Measured values are displayed on the operator unit, connected to analog outputs or transmitted
via a serial interface to external displays or other external units.
Status signals and alarms are indicated on the operator unit or connected to digital outputs.

Millmate Controller 400

Matching units
PFVO 142/143

Millmate Controller 400R

Printer
RS-232
RS-485
Fieldbus

Analog External display

inputs

Junction box
PFXC 141 or
PFBC 161
Analog PLC
inputs

Ethernet

Digital inputs Analog

and outputs outputs

Millmate Operator Unit 410

Figure 2-1. Overview Diagram for a Millmate Roll Force System with Millmate Controller 400

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 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section 2.3 Load Cells

2.3 Load Cells

2.3.1 General
The Millmate Roll Force Systems with MC 400 use Pressductor® load cells.

PFVL 141V PFVL 141C PFVL 141R QGPR 102/104

Figure 2-2. Load Cells for Millmate Roll Force Systems

2.3.2 Measuring Principle

The operation of the sensor is based on the fact that the permeability of a magnetic material
changes under mechanical stress.
The sensor consists of a laminated steel block with four holes. Two coils are wound so that they
cross each other at right angles.
The primary winding is supplied with an alternating current which creates a magnetic field
around the primary winding. Since the two windings are at right angles to each other there will
be no magnetic field around the secondary winding, as long as there is no load on the sensor.
When the sensor is subjected to a mechanical force in the direction of measurement, the
propagation of the magnetic field changes so that it surrounds the secondary winding, inducing
an alternating voltage in that winding.
The control unit converts this alternating voltage into a DC voltage proportional to the applied
force.

Figure 2-3. Sensor Element

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Chapter 2 Technical Description

2.4 Millmate Controller 400

2.4.1 Overview
PFVL 141
Matching units
PFVO 142/143

1) Excitation unit
PFVI 401
Load cell
Power excitation
supply
PFVL 141

Mains
85 - 264 V
47 - 63 Hz

Control unit
PFXA 401
Junction box
PFXC 141 or Load cell
QGPR 102/104 Power excitation
PFBC 161
supply
+24 V
1)

AI AO
CPU
(4) (4)

1) Alternative DI DO
depending on (8) (8)
load cell type

2) Serial link
2) 3)
RS-232
RS-485
Operator unit
3) Fieldbus PXAH 411

CPU Display

Voltage Key-
converter board

Figure 2-4. Block Diagram - Millmate Controller 400

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 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section 2.4.2 Technical Data

The Millmate Controller 400 control unit supplies the load cells with power, processes signals
from the load cells and transfers measured values to the operator unit or external units.
The control unit is supplied with mains voltage.
The following additional connections exist:
• Excitation current to the load cells
• 2 or 4 analog inputs for load cells signals
• 4 analog outputs for measured values, voltage or current, insulated as one group.
• 8 digital inputs for control signals, insulated in two groups of four inputs each.
• 8 digital outputs for status signals and alarms, insulated in two groups with four outputs
each.
• +24 V output to power the Millmate Operator Unit 410 and external units, if any.
• Network connection for operator unit, Ethernet 10Base2, 10Base-T and AUI1.
• 2 serial interfaces type RS-232 for external displays, external control, etc.
• 1 serial interface type RS-485 for external displays.
• 1 “SYNC” connection for synchronisation of the load cell excitation frequency of several
control units.
Each Millmate Controller 400 control unit can handle up to four objects. The number of objects
is limited by the number of signal inputs and the power of the load cell power supply unit.
Load cells requiring different types of excitation cannot be mixed in the same control unit.
The control unit is encapsulated according to IP 20 and is intended for vertical mounting in an
external enclosure. The external enclosure is normally required to fulfil the demands for
electrical safety and environmental conditions.

2.4.2 Technical Data

Table 2-1. Technical Data

Type Data
Mains voltage 85 - 264 V AC (100 V –15% to 240 V +10%)
Mains fuses (F1, F2)
in PFXA 401 2 A, slow blow
in PFVI 401 6.3 A, slow blow
Mains frequency 47 - 63 Hz
Power consumption
only PFXA 401 Max. 140 W with QGPR 102/104 load cells
PFXA 401 and PFVI 401 Max. 600 W with PFVL 101/141 load cells
Power factor Min. 0.95 at 140 W / 600 W

1. AUI - Attachment Unit Interface

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Chapter 2 Technical Description

Table 2-1. Technical Data

Type Data
Heat dissipation
PFXA 401 (Control unit) Max. 60 W with QGPR 102/104 load cells
Max. 40 W with PFVL 101/141 load cells

PFVI 401 (Excitation unit) Max. 80 W 170 - 264 V mains voltage

Max. 100 W 105 - 170 V mains voltage
Max. 120 W 85 - 105 V mains voltage

PXAH 411 (Operator unit) Max. 14 W

Load cell excitation PFVL 141 1638 Hz, 2 ARMS, + 5  cable resistance with PFVI 401
QGPR 102/104 330 Hz, 2 ARMS, max. 400 mm core length + 5  cable resistance
(max. 800 mm core length + 5  cable resistance with PFBK 401)
Signal delay
Analog outputs PFVL 141 1 ms (2 - 800 ms with filter)
QGPR 102/104 5 ms (12 - 2000 ms with filter)
Digital outputs 50 ms
Level detectors PFVL 141 5 ms
QGPR 102/104 15 ms
Profibus, measuring signals
PFVL 141 1 ms (2 - 800 ms with filter)
QGPR 102/104 5 ms (12 - 2000 ms with filter)
Profibus, boolean signals 50 ms
Signal filter 8-pole, Bessel type
Refresh rate
Operator unit 2 times / second
External display 1 time / second
Analog outputs PFVL 141 3300 times / second
QGPR 102/104 660 times / second
Profibus PFVL 141 3300 times / second
QGPR 102/104 660 times / second
Analog inputs (4)
Signal level Switchable for 1 - 4 Pressductor® load cells
0 ± 10 V DC
Input impedance Balanced, switchable 10, 20 or 400 k

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 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section 2.4.2 Technical Data

Table 2-1. Technical Data

Type Data
Analog outputs (4)
Output level
Voltage output 0 ± 10 V
Current output 0 ± 20 mA or 4 - 20 mA
Max. load
Voltage output 5 mA
Current output 500 
Rated insulation voltage 50 V AC
Digital inputs (8)
Input level 0 Nominal 0 V, –40 - +6 V
1 Nominal +24 V, +15 - +40 V
Current consumption Max. 5 mA at +24 V
Rated insulation voltage 50 V AC
Digital outputs (8)
Output level 0 Open contact
1 Current driving from external common supply,
protected by a parallel diode
Max. load 0.2 A, over current protection
Max. voltage drop 2 V at 0.2 A
Max. operating voltage (output not active) 50 V
Rated insulation voltage 50 V AC
External outputs (2)
Output, supply to operator unit (X8) +24 V DC (+22 - 28 V) max. 0.5 A (1)
Output, supply to external units (X18) +24 V DC (+22 - 28 V) max. 0.5 A (1)
Clock backup battery
Lithium, 3.6 V, 1.75 Ah, Size R6 SAFT type LS14500 CNA, or equivalent
ABB Ordering No. 3BSC790006R1
4943 013 - 4 (old number)
Environmental data
Degree of protection IP 20, according to IEC 529, EN 60-529
Temperature range 0 to +70°C operation
-40 to +70°C storage
Operating pressure Min. 80 kPa
Storage pressure Min. 70 kPa

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Chapter 2 Technical Description

Table 2-1. Technical Data

Type Data

Mechanical data
Size (l × w × d)
PFXA 401 (Control unit) 380 × 235 × 90 mm
PFVI 401 (Excitation unit) 380 × 235 × 90 mm
Weight
PFXA 401 (Control unit) 5 kg
PFVI 401 (Excitation unit) 7.4 kg
(1) Max total current on X8 + X18 = 0.8 A

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Section 2.4.3 Connections

2.4.3 Connections
Connections to the Millmate Controller 400 control unit with the
Millmate Excitation Unit PFVI 401 are shown in Figure 2-5 and table 2-2.
X31 X23 X27 X26
X29
X22

MC 400 (PFXA 401)

Run Fault
Syserr Profibus
LAN ControlNet
10Base-T
RS-485 RS-232 RS-232:2 RS-232:1
X29
X27 X26
DO1 DO5
DO2 DO6
DO3 DO7
DO4 DO8
X34
X24
X30

AUI Profibus
X34 X35
X22 X31 X25
X24
T2A T2A Digital in Digital out
F1 F2 X35
85-264V~ X21 X30 X23
47-63Hz 140W 10Base2 Profibus RS-485 X25
X21 12 3 4 5 1 2 3 4 5

X13 X15 X16 X18

X18
S1 X2 X3 X5 X6 X8
X1
X8

X1 X2 X3 X13 X5 X15 X6 X16

PFVI 401

RUN EXON OV PL1

SCA CL PL2 X4
X11 SCB UV TEST

X11 X4
Figure 2-5. Millmate Controller 400 - Connections

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Chapter 2 Technical Description

Table 2-2. Millmate Controller 400 - Connections

Unit Connection Type Data

X1 Mains connection 4 pole disconnectable terminal,
max 2.5 mm2
X2 Synchronisation (SYNC) 3 pole disconnectable terminal,
max. 2.5 mm2
X3 Excitation to load cells 4 pole disconnectable terminal,
X13 QGPR 102/104 max. 2.5 mm2
X5 Analog signal from load cells 4 pole disconnectable terminal,
X15 max. 2.5 mm2
X6 Analog output signals 6 pole disconnectable terminal,
X16 max. 2.5 mm2
X8 +24 V DC supply 2 pole disconnectable terminal,
to operator unit max. 2.5 mm2
X18 +24 V DC supply 2 pole disconnectable terminal,
to external units max. 2.5 mm2
X21 LAN, 10Base2 BNC, 50 ohm
PFXA 401
X22 LAN, AUI DB15, female
X23 Serial interface RS-485 2 pole disconnectable terminal,
max. 2.5 mm2
X24 Digital inputs 5 pole disconnectable terminal,
X34 max. 2.5 mm2
X25 Digital outputs 5 pole disconnectable terminal,
X35 max. 2.5 mm2
X26 Serial interface RS-232:1 DB9, male
X27 Serial interface RS-232:2 DB9, male
X29 LAN, 10Base-T RJ45
X30 Profibus 2 pole disconnectable terminal,
max. 2.5 mm2
X31 Profibus DB9, female
X39 External power supply unit 10 pole ribbon cable
X4 Excitation to load cells 4 pole disconnectable terminal,
PFVL 141 max. 2.5 mm2
X11 Mains connection 4 pole disconnectable terminal,
PFVI 401
max 2.5 mm2
X49 Control cable from PFXA 401, 10 pole ribbon cable
connection X39

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 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section 2.4.4 Digital Inputs

2.4.4 Digital Inputs

The eight digital inputs are divided into two insulated groups with four inputs in each group.
The inputs can be activated from an external 24 V supply or from the internal 24 V supply.
Each of the groups DI1 - DI4 and DI5 - DI8 are galvanically insulated from all other parts of the
control unit provided that each group has a separate external 24 V supply.

MC 400

X18
1 +24 V (internal supply)

X34
1
DI1

2
DI2
24 V
external 3
supply DI3

4
DI4
5
X18
2 0V

X18
1 +24 V (internal supply)

X24
1
DI5

2
DI6
24 V
external 3
supply DI7

4
DI8
5
X18
2 0V

Figure 2-6. Principle Diagram - Digital Inputs 1 - 8

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Millmate Roll Force Systems with Millmate Controller 400, User Manual
Chapter 2 Technical Description

2.4.5 Digital Outputs

The eight digital outputs are divided into two insulated groups with four outputs in each group.
The outputs are current driving and can be supplied from an external 24 V supply or from the
internal 24 V supply. Each of the groups DO1 - DO4 and DO5 - DO8 are galvanically insulated
from all other parts of the control unit provided that each group has a separate external 24 V
supply.

MC 400
X18
+24 V (internal supply) 1
X35
5
Output 24 V
DO1 load external
1 supply

DO2
2

DO3
3

DO4
4
X18
0 V (internal supply) 2

X18
+24 V (internal supply) 1
X25
5
Output 24 V
DO5 load external
1 supply

DO6
2

DO7
3

DO8
4
X18
0 V (internal supply) 2

Figure 2-7. Principle Diagram - Digital Outputs 1 - 8

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 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section 2.4.6 Analog Outputs

2.4.6 Analog Outputs

The four analog outputs are insulated as a group. There are separate outputs for voltage and
current, but only one of them can be used at a time.

MC 400

X6
1 +

± 15 V RL
2
Voltage
U –
I 3

AO1 5

AO2 U RL
I 6
D/A- Current
converter
X16
AO3 1
14
bits
AO4 2

0VAO U
I 3

U
I 6

Figure 2-8. Principle Diagram - Analog Outputs 1 - 4

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Millmate Roll Force Systems with Millmate Controller 400, User Manual
Chapter 2 Technical Description

2.4.7 LAN-connections
MC400 uses TCP/IP protocol on Ethernet for communication between control units, operator
units and other systems.
MC400 control and operator units use fixed IP-addresses. How to adjust IP-addresses is
described in Section .
MC400 uses twisted pairs cables from control unit to operator unit or ethernet switch.
External network connection is as an option possible with an opto switch.

10Base-T twisted pair cable

Figure 2-9. Local Network

External network

Opto fiber
Ethernet switch
Opto switch (Optional)

Figure 2-10. Connection to local and external Network with Ethernet switch

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 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section 2.4.8 Optional Units

2.4.8 Optional Units

Relay board PFVK 128, Insulation amplifier PXUB 201 and modem DSTC 562 can be used as
optional units in the measurement system.
• Relay board PFVK 128 is used to switch external loads on and off. See Section 2.4.8.1
Relay Board PFVK 128.
• Insulation amplifier PXUB 201 is used when galvanic insulation between input and
output, or between power supply and input/output, is required. See Section 2.4.8.2
Insulation Amplifier PXUB 201.
• Media converter PXUB 231 is used to connect the local coaxial cable network 10Base2
to Twisted Pair network 10Base-T.

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Chapter 2 Technical Description

2.4.8.1 Relay Board PFVK 128

X1 PFVK 128 X1
13 2

14
3
15 5

16
6
17 8

18
9
19 11

10

20
12

Figure 2-11. Switch Function of Relay Board PFVK 128

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 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section 2.4.8 Optional Units

Table 2-3. Data for Relay Board PFVK 128

Type Data
Dimensions (l × w) 80 × 120 mm
Cable dimensions:
– control signals max 2.5 mm2
– relay outputs max 4 mm2
Weight 200 g
No. of channels 4
Operating voltage, coil 24 V AC or DC
Current consumption, coil 20 mA / relay
Contact function Changeover
Rated voltage, contacts 250 V AC
Breaking current
at 250 V AC max. 8 A
at 48 V DC max. 1.2 A
at 220 V DC max. 0.2 A
Rated insulation voltage 250 V AC
Switch time max. 8.5 ms
Temperature range 0 to +70°C operation
-40 to +70°C storage
Mounting ABB mounting rail

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Chapter 2 Technical Description

2.4.8.2 Insulation Amplifier PXUB 201

+
+
Input Output
–
–

+24VV
+24

Figure 2-12. Insulation Amplifier PXUB 201

Table 2-4. Data for Insulation Amplifier PXUB 201

Type Data
Power supply +24 V (20 - 253 V AC/DC)
Current consumption 10 mA + external load, at 24 V
Signal range Input Output
0 ± 10 V 0 ± 10 V
0-5V 4 - 20 mA
0 - 10 V 4 - 20 mA
0 - 5V 0 - 20 mA
0 ± 10 V 0 ± 20 mA
Input resistance 1 M at 10 V input
500 k at 5 V input
Max. load 10 mA for voltage output
500  for current output
Rise time 50 s or 50 ms, selectable
Ripple 10 mVp-p
Bandwidth (-3 dB) 10 kHz or 10 Hz
Rated insulation voltage 600 V, basic insulation
Insulation test voltage 4 kV
Temperature range -10 to +70°C operation
-40 to +85°C storage
Dimensions (l × w × d) 99 × 12.5 × 111 mm

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Section 2.4.8 Optional Units

Table 2-4. Data for Insulation Amplifier PXUB 201

Type Data
Weight 150 g
Type Data

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Chapter 2 Technical Description

2.4.8.3 Media Converter PXUB 231

10Base2 10Base-T
Coaxial cable Twisted Pair

PXUB 231

+24 V

Figure 2-13. Media Converter PXUB 231

Table 2-5. Data for Media Converter PXUB 231

Type Data
Cable dimension max 2.5 mm2
Power supply +24 V (18-36 V DC)
Current consumption Typical 160 mA at 24 V
Network standards IEEE 802.3, 10Base-T, 10base2
Data rate 10 Mbits/s, half duplex mode
Connectors
Supply Screw terminals
10Base2 BNC
10Base-T RJ-45
Dimensions 10 x 8 x 3 cm
Temperature range -40 to +75°C operation
-40 to +85°C storage
Weight 150 g
Mounting DIN-rail 35 mm

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Section 2.5 Millmate Operator Unit 410

2.5 Millmate Operator Unit 410

Millmate Operator Unit 410 is intended to be used when handling measuring objects.
Several operator units can be used with the same control unit, and each operator unit can handle
different measuring objects in different control units.
The operator units and the control units are interconnected on a common network. This network
can be a separate network for measuring objects, or part of a large area network (LAN).
The Operator units connects to the system with 100Base-T cable. It can be connected direct to
the Controller or via a Ethernet switch.
The communication on the network is in accordance with the IEEE 802.3 standard and uses the
TCP/IP protocol. The operator unit can present menus according to the HTML 3.2 code.
The operator unit is supplied with 24 V DC. This voltage can be supplied from either the control
unit or from another power source. The power supply connection is insulated from the chassis
and other circuits in the operator unit.
Connector X8 on the control unit is used when the operator unit is supplied from the control
unit. If X8 on all the control units are connected in parallel, the operator unit will be supplied as
long as at least one of the control units handled by the operator unit is switched on.
The operator unit is intended for panel mounting, e.g. in a control desk or in a cabinet door. It
can also be mounted, using brackets, inside an enclosure on a mounting plate

Note
This system has been updated with a new Touch screen Operator Unit.
This manual has not yet been updated with the new HMI layout on all descriptive
figures. The functions on the system is basically the same, and can be followed as
described.

New vertical Position

of function buttons

Figure 2-14. Operator Unit for Millmate Controller 400

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Chapter 2 Technical Description

2.5.1 Technical Data

Table 2-6. Technical Data for Millmate Operator Unit 410

Type Data
Power supply voltage +24 V DC (18 - 32 V DC)
Power consumption Max 14 W
Degree of protection Sealing front: IP65, NEMA 4X/ 12 and UL Type
4X/ 12
Sealing back: IP20
Dimensions (l × w × d) 204x143x50 mm
Weight 0.8 kg
Temperature range -10 to +60°C (operation)
-20 to +70°C (storage)

2.5.2 Connections
Table 2-7. Connections for Millmate Operator Unit 410

Connection Type Data

Supply 24 V DC Disconnectable terminal, max. 2.5 mm2
LAN A LAN, 100Base-T Not used
LAN B LAN, 100Base-T RJ45
COM Serial port Not used
USB USB2 Memory stick for softgrade update
SD SDHC Not used

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 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section 2.6 Matching Unit PFVO 142 and PFVO 143

2.6 Matching Unit PFVO 142 and PFVO 143

The matching unit transforms the excitation current from the control unit to the level required
by the load cell. One matching unit is needed per load cell.
The matching unit compensates for the reactive load of the load cell and its cable. The unit is
further used as a junction box for the load cell signals.
Depending on which load cell is to be used, there are two matching units to choose between,
PFVO 142 or PFVO 143. See table 2-8.

Table 2-8. Matching Units PFVO 142 and PFVO 143

Matching unit is intended for: Ratio

PFVO 142 All rectangular load cells PFVL 141V 1.95 A / 25 A
All circular load cells PFVL 141C
Annular load cells PFVL 141R with
nominal load > 8 MN
PFVO 143 Annular load cells PFVL 141R with 1.95 A / 5 A
nominal load  8 MN

1.95 A 5 A / 25 A

To control unit To load cell

Figure 2-15. Block Diagram of Matching Units PFVO 142 and PFVO 143

2.6.1 Technical Data

Table 2-9. Technical Data PFVO 142/ PFVO 143

Type Data
Dimension (h × l × w) 300 × 250 × 150 mm
Weight 8 kg
Temperature range 0 to +55°C operation
-40 to +70°C storage
Degree of protection IP 65 IEC 529, EN 60-529

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Chapter 2 Technical Description

Figure 2-16. Matching Units PFVO 142 / PFVO 143

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Section 2.7 Junction Box PFXC 141

2.7 Junction Box PFXC 141

Junction box PFXC 141 is intended for QGPR 102 and QGPR 104. One junction box per load
cell pair is normally used.

Figure 2-17. Junction Box PFXC 141

2.7.1 Technical Data

Table 2-10. Technical Data for Junction Box PFXC 141

Type Data
Dimensions (l × w × d) 220 × 120 × 80 mm
Weight 2.0 kg
Degree of protection IP 65 IEC 529, EN 60-529

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Chapter 2 Technical Description

2.8 Junction Box PFBC 161

Junction box PFBC 161 is intended for QGPR 102 and QGPR 104. One junction box per load
cell pair is normally used.

[mm]

80
16 37

30 60 90 120

Mounting hole picture

150
D = 8.7 (4 x)

150

110
110

(4 x) D = 10.5 - 13.5
Cable gland PR22.5

Figure 2-18. Dimensions of Junction Box PFBC 161

2.8.1 Technical Data

Table 2-11. Technical Data for Junction Box PFBC 161

Type Data
Dimensions (l × w × d) 150 × 150 × 80 mm
Weight 1.7 kg
Temperature range 0 to +70°C operation
-40 to +70°C storage
Degree of protection IP 65 IEC 529, EN 60-529

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 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section 2.9 External Display QDIL 451

2.9 External Display QDIL 451

The external display is available in two versions:
• 4 digits (red LED type digits)
• 6 digits (red LED type digits)
Max. cable distance with:
• RS-232 is 15 m.
• RS-485 is 500 m.
With RS-485 several displays can be connected to the same RS-485 cable. These displays can
be addressed to show different measuring signals simultaneously.

Figure 2-19. Example of an External Display with six digits

2.9.1 Technical Data

Table 2-12. Technical Data for External Display QDIL 451

Type Data
Supply voltage 24 V DC (18 - 30 V)
Power consumption Max 4 VA
Operation temperature 0 to 50 °C
Degree of protection IP 40 by front
Input interface Serial RS-232 or RS-485
selected from menu

2.9.2 Dimensions
Table 2-13. Dimensions for External Display QDIL 451

Digits Dimensions
Type
No. of height width height depth
4 72 48 68
QDIL 451 14 mm
6 96 48 68

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Chapter 2 Technical Description

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Section 3.1 About this Chapter

Chapter 3 Installation

3.1 About this Chapter

Although the Millmate Roll Force System is a precision measuring system which is intended for
severe operating conditions in a harsh industrial environment, it must be handled with care
when unpacking, during storage and installation.

3.2 General Installation Information

The Millmate controller unit must be installed in a dust proof working environment, to avoid
exposure to conductive dust. It is designed for mounting in a metal enclosure.

3.3 Packaging and Delivery

The wall cabinet, the MNS Select floor cabinet and the control unit are delivered in plywood
boxes. The boxes should be used for transportation to the installation site. If the equipment must
be stored between delivery and installation, this should be done in accordance with the
instructions in Section 3.4, Storage.
The cabinets are equipped to be lifted by an overhead crane. Fenders should be used to prevent
damage during lifting. The weights of the various units of the equipment are given in Table 3-1.
On unpacking, check against the order receipt, dispatch note, etc., that the equipment is
complete. Report any comments immediately to ABB.

Table 3-1. Weight of the Equipment Units

Unit Weight (kg)

Wall cabinet max. 15
MNS Select floor cabinet max. 300
Millmate Controller 400 5
Millmate Excitation Unit PFVI 401 7.4
Millmate Operator Unit 410 0.8
Matching unit PFVO 142/143 8
Junction box PFXC 141 2
Junction box PFBC 161 1.7
Load cell PFVL 141 (depending on size) 10 - 300
Load cell QGPR 102/104 (depending on size) 5 - 100
External display QDIL 451 < 0.5

3BSE023139R0401 Rev A 3-1

Millmate Roll Force Systems with Millmate Controller 400, User Manual
Chapter 3 Installation

3.4 Storage
Limits for various combinations of temperature and humidity when storing electronic
equipment during prolonged periods are shown in Figure 3-1.
If, for any reason, the control unit must be stored prior to the installation, the relative humidity
in the storage area must not exceed the values indicated in Figure 3-1. If the humidity is higher
the units must be stored in air-tight packaging, or in shielded and air conditioned rooms with
filtered air.

Relative
Relativ
humidity (%) (%)
luftfuktighet
100
100

90
90

80
80

70
70
66 months
månader ell
60
60 or longer
längre

50
50 1-2
1 -2 månader
months
40
40

30
30
Best
Bästastorage
20 environment
lagringsmiljö
20

10
10 Unsuitable
Olämplig
storage
lagringsmiljö
environment
-60
-60 -50
-50 -40
-40 -30
-30 -20
-20 -10
-10 00 +10
+10 +20
+20 +30
+30 +40
+40 +50
+50
Temperature (°C)
Temperatur (oC)
Figure 3-1. Permissible Values Regarding Temperature/Humidity at
Prolonged Storage of Electronic Equipment

3.5 Mounting Load Cell Cabling and Accessories

3.5.1 Cable Routing

Apply the following rules to ensure interference free operation:
• Communication cables for communication without modems must be at least 0.1 m away
from all other cables, including MC 400 cables, and at least 0.3 m away from power
supply cables.
• MC 400 cables must be kept at least 0.3 m from power supply cables and cables connected
to inductive non-suppressed loads.
• The incoming mains supply should be routed on the left side of cabinet and I/O cables on

3-2 3BSE023139R0401 Rev A

 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section 3.5.1 Cable Routing

the right side.

Cabinet PFVI 401

MC 400 (PFXA 401) RS-232
X26/X27

Modem
10Base-T
X29
DI DO PFVL 141
RS-485
Mains load cell
Mains X23 X24/X34 X25/X35
voltage excitation
voltage
LC exc. LC signals AO
X3/X13 X5/X15 X6/X16 X11 X4
X1

> 50 mm
Power supply cables >250 V and inductive non suppressed loads

< 50 mm

> 0.3 m > 0.3 m

> 0.3 m
Note:
The 10Base-T cable
is only approved for
Mains
use inside the cabinet
filter

> 0.1 m > 0.1 m

> 0.3 m
RS-232 without modem
RS-232 with modem
Load cell signals
Load cell excitation

Load cell excitation

Mains voltage
110/230 V

10Base-T
RS-485

AO

DO
AI

DI

Figure 3-2. Cable Routing

The cables used and their connections are shown in the cable diagram, circuit diagram and the
installation instructions for all the units included in the application.

3BSE023139R0401 Rev A 3-3

Millmate Roll Force Systems with Millmate Controller 400, User Manual
Chapter 3 Installation

Cables to be connected to control units mounted on rubber dampers must be run to allow for a
degree of movement, e.g. in a loop or a curve, see Figure 3-3.

Figure 3-3. Cable run for Control Unit Mounted on Rubber Dampers

3.5.2 Cable Protection

Each cable should be run in a way which offers the best protection against mechanical damage.
In particularly exposed positions the cable is best run inside a U-channel, see Figure 3-4.
In such cases, an armoured tube does not always provide enough protection.

Figure 3-4. Cable Run in a U-channel

3.6 Installation of Matching Unit PFVO 142 and PFVO 143

The matching units shall be placed as close to the load cells as possible, and well protected
against mechanical damage and heat radiation.
The matching units must be well earthed. It is not enough to earth them through the mounting
lugs. A special earthing cable, connected to the closest possible earthing point, is needed.

NOTE
If the matching unit is earthed at the place of installation, the earth cable must not
be connected between terminal 4 in the matching unit and the earth terminal in the
control unit.

All components in the matching unit are mounted on one plate. This plate is easy to remove and
can be mounted in a locally supplied box, if required
Holes not used must be plugged.

3-4 3BSE023139R0401 Rev A

 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section 3.7 Installing Junction Boxes PFXC 141 and PFBC 161

Figure 3-5. Dimensions of Matching Unit PFVO 142/143

3.7 Installing Junction Boxes PFXC 141 and PFBC 161

Junction boxes PFXC 141 and PFBC 161 are used for connection of Pressductor® load cells,
type QGPR 102/104. The cables fixed to the load cells and the cable to the control unit are to be
connected to the junction box.
The junction box shall be mounted adjacent to the load cells and located in a protected position
easily accessible for service.
The junction box is mounted according to an order-specific drawing.
The dimensions of the junction boxes are shown in Figure 3-6 and Figure 3-7.
Holes not used must be plugged.

3BSE023139R0401 Rev A 3-5

Millmate Roll Force Systems with Millmate Controller 400, User Manual
Chapter 3 Installation

3.7.1 Junction Box PFXC 141

(6 x)
D = 6–12 mm (Cable gland Pg16)

Figure 3-6. Dimensions of Junction Box PFXC 141

3-6 3BSE023139R0401 Rev A

 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section 3.7.2 Junction Box PFBC 161

3.7.2 Junction Box PFBC 161

[mm]

80
16 37

30 60 90 120

Mounting hole picture

150
D = 8.7 (4 x)

150

110
110

(4x) D = 10.5 - 13.5

Cable gland PR22.5

Figure 3-7. Dimensions of Junction Box PFBC 161

3BSE023139R0401 Rev A 3-7

Millmate Roll Force Systems with Millmate Controller 400, User Manual
Chapter 3 Installation

3.8 Electrical Connection of Load Cells

3.8.1 Connecting PFVL 141 Load Cells to MC 400

Connecting two load cells

X1 MC 400 (PFXA 401)

Mains supply 1
85-264 VAC 2 CPU Load cell signals
3 1 2
=
4
X39 X5
1 2 3 4
Ribbon cable
X11 X49
PL 3
1 PL 2
2 = PL 1
3 = UR
4

PFVI 401 X4
1 2 3 4

1
Not connected if the matching units are
properly earthed at the installation site.
1

Matching unit A
1 2 3 4 5 6 7 8 9
PFVO 142
25 A 1.95 A
Load cell A Black
D 11
B Blue
12
A 1
13
C 2
14
15
16 17 18 19 20 21

1
Matching unit B
1 2 3 4 5 6 7 8 9
PFVO 142
25 A 1.95 A
Load cell B Black
D 11
B Blue
12
A 1
13
C 2
14
15

Figure 3-8. Connecting Two PFVL 141V/C Load Cells or Two PFVL 141R 25 A Load Cells

3-8 3BSE023139R0401 Rev A

 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section 3.8.1 Connecting PFVL 141 Load Cells to MC 400

Connecting two load cells

X1 MC 400 (PFXA 401)

Mains supply 1
85-264 VAC 2 CPU Load cell signals
3 1 2
=
4
X39 X5
1 2 3 4
Ribbon cable
X11 X49
PL 3
1 PL 2
2 = PL 1
3 = UR
4

PFVI 401 X4
1 2 3 4

1
Not connected if the matching units are
properly earthed at the installation site. 1

Matching unit A
1 2 3 4 5 6 7 8 9
PFVO 143
5A 1.95 A
Load cell A
D Red 11
B Blue 12
A Black 13
C White 14
15
16 17 18 19 20 21

Matching unit B 1
1 2 3 4 5 6 7 8 9
PFVO 143
5A 1.95 A
Load cell B Red
D 11
B Blue
12
A Black
13
C White
14
15

Figure 3-9. Connecting Two PFVL 141R 5 A Load Cells

3BSE023139R0401 Rev A 3-9

Millmate Roll Force Systems with Millmate Controller 400, User Manual
Chapter 3 Installation

Mains Connecting four load cells

supply
85-264 MC 400 (PFXA 401)
VAC
X1
1
2 CPU Load cell signals Load cell signals
3 1 2 3 4
=
4
X39 X5 X15
1 2 3 4 1 2 3 4
Ribbon cable
X11 X49
PL 3
1 PL 2
2 = PL 1
3 = UR
4

PFVI 401 X4
1 2 3 4
1
Not connected if the matching units are
properly earthed at the installation site. 1
Matching unit A1
1 2 3 4 5 6 7 8 9
PFVO 142
25 A 1.95 A
Load cell A1 Black
D 11
B Blue
12
A 1
13
C 2
14
15
16 17 18 19 20 21

1
Matching unit B1
1 2 3 4 5 6 7 8 9
PFVO 142
25 A 1.95 A
Load cell B1 Black
D 11
B Blue
12
A 1
13
C 2
14
15
1

Matching unit A2
1 2 3 4 5 6 7 8 9
PFVO 142
25 A 1.95 A
Load cell A2 Black
D 11
B Blue
12
A 1
13
C 2
14
15
16 17 18 19 20 21

1
Matching unit B2
1 2 3 4 5 6 7 8 9
PFVO 142
25 A 1.95 A
Load cell B2 Black
D 11
B Blue
12
A 1
13
C 2
14
15

Figure 3-10. Connecting Four PFVL 141V/C Load Cells or Four PFVL 141R 25 A Load Cells

3-10 3BSE023139R0401 Rev A

 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section 3.8.1 Connecting PFVL 141 Load Cells to MC 400

Mains Connecting four load cells

supply
85-264 MC 400 (PFXA 401)
VAC
X1
1
2 CPU Load cell signals Load cell signals
3 1 2 3 4
=
4
X39 X5 X15
1 2 3 4 1 2 3 4
Ribbon cable
X11 X49
PL 3
1 PL 2
2 = PL 1
3 = UR
4

PFVI 401 X4
1 2 3 4
1
Not connected if the matching units are
properly earthed at the installation site. 1
Matching unit A1
1 2 3 4 5 6 7 8 9
PFVO 143
5A 1.95 A
Load cell A1
D Red 11
B Blue 12
A Black 13
C White 14
15
16 17 18 19 20 21

Matching unit B1 1
1 2 3 4 5 6 7 8 9
PFVO 143
5A 1.95 A
Load cell B1
D Red 11
B Blue 12
A Black 13
C White 14
15
1

Matching unit A2
1 2 3 4 5 6 7 8 9
PFVO 143
5A 1.95 A
Load cell A2
D Red 11
B Blue 12
A Black 13
C White 14
15
16 17 18 19 20 21

1
Matching unit B2
1 2 3 4 5 6 7 8 9
PFVO 143
5A 1.95 A
Load cell B2
D Red 11
B Blue 12
A Black 13
C White 14
15

Figure 3-11. Connecting Four PFVL 141R 5 A Load Cells

3BSE023139R0401 Rev A 3-11

Millmate Roll Force Systems with Millmate Controller 400, User Manual
Chapter 3 Installation

3.8.2 Connecting QGPR 102/104 Load Cells to MC 400

See connection between load cell QGPR 102/104 and matching unit QIPZ 127 in Figure 3-23.

Connecting two load cells

Control unit
Load cell A Cable Junction box MC 400 (PFXA 401)
with matching unit No. PFXC 141 X3
1
1 17 1 1 LC EXC
3
2 18 2 2
2 1)
3 19 3
4
4 20 4 LC EXC
Load cell B 6
with matching unit X5
1 21 3 1
LC Signal 1, A
2 22 4 2
3 23 7 3
LC Signal 2, B
4 24 8 4

2)
1) Built-in relays used to disconnect either load cell A or load cell B in Single Cell Operation Mode
2) Copper bar for connecting cable shields (insulated from metal case of junction box)

Figure 3-12. Connecting Two QGPR 102/104 Load Cells with PFXC 141

Control unit
Load cell A Cable Junction box MC 400 (PFXA 401)
with matching unit No PFBC 161 X3
1
1 9 1 1 LC EXC
3
2 10 2 2
2 1)
3 11 3
4
4 12 4 LC EXC
Load cell B 13 3
with matching unit X5
1 14 4 1
LC Signal 1, A
2 15 5 2
3 16 6 3
LC Signal 2, B
4 17 7 4
18 8

1) Built-in relays used to disconnect either load cell A or load cell B in Single Cell Operation Mode

Figure 3-13. Connecting Two QGPR 102/104 Load Cells with PFBC 161

3-12 3BSE023139R0401 Rev A

 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section 3.8.2 Connecting QGPR 102/104 Load Cells to MC 400

Connecting four load cells

Control unit
Load cell A Cable Junction box MC 400
with matching unit No. PFXC 141 X3
1
1 17 1 1 LC EXC
3
2 18 6 2
2
3 19 3
4
4 20 4 LC EXC
Load cell B
with matching unit X5
1 21 1
1 3 LC Signal 1, A
3
2 22 4 2
2 23 3
3 7 LC Signal 2, B
4 4 24 8 4

1)

Load cell A Cable Junction box

with matching unit No. PFXC 141
1
1 17 1
3
2 18 6
2
3 19
4
4 20
Load cell B
with matching unit X15
1 21 3 1
1 LC Signal 3, A
3 22 4 2
2
2 23 7 3
3 LC Signal 4, B
4 4 24 8 4

1)
1) Copper bar for connecting cable shields (insulated from metal case of junction box)

Figure 3-14. Connecting four QGPR 102/104 Load Cells with Two PFXC 141

3BSE023139R0401 Rev A 3-13

Millmate Roll Force Systems with Millmate Controller 400, User Manual
Chapter 3 Installation

Control unit
Load cell A Cable Junction box MC 400
with matching unit No. PFXC 141 X3
1
1 17 1 1 LC EXC
3
2 18 6 2
2
3 19 3
4
4 20 10 4 LC EXC
Load cell B
with matching unit X5
1 1
1 21 3
3 LC Signal 1, A
2 22 4 2
2 3
3 23 7 LC Signal 2, B
4 4 24 4
8

25
26
X15
27 11 1
LC Signal 3, A
28 12 2
31 15 3
LC Signal 4, B
32 16 4
1)

Load cell A Cable Junction box

with matching unit No. PFXC 141
1
1 17 1
3
2 18 6
2
3 19
4
4 20
Load cell B
with matching unit
1
1 21 3
3
2 22 4
2
3 23 7
4
4 24 8

1)

1) Copper bar for connecting cable shields (insulated from metal case of junction box)

Figure 3-15. Connecting four QGPR 102/104 Load Cells with Two PFXC 141 Connected in Series

3-14 3BSE023139R0401 Rev A

 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section 3.8.2 Connecting QGPR 102/104 Load Cells to MC 400

Control unit
Load cell A Cable Junction box MC 400
with matching unit No. PFXC 141 X3
1 17 1 1 LC EXC
1
3 6
2 18 2
2 3
3 19
4 20 14 4 LC EXC
4
Load cell B
with matching unit X5
1 1 21 3 1
LC Signal 1, A
3 22 4 2
2
2 23 7 3
3 LC Signal 2, B
4 4 24 8 4

Load cell A Cable

with matching unit No.
1
1 25
3
2 26
2
3 27
4
4 28
Load cell B
with matching unit X15
1 29 1
1 11
3 LC Signal 3, A
2 30 12 2
2
3 31 15 3
4 LC Signal 4, B
4 32 16 4

1)

1) Copper bar for connecting cable shields (insulated from metal case of junction box)

Figure 3-16. Connecting four QGPR 102/104 Load Cells with One PFXC 141

3BSE023139R0401 Rev A 3-15

Millmate Roll Force Systems with Millmate Controller 400, User Manual
Chapter 3 Installation

Load cell A Cable Junction box MC 400 (PFXA 401)

with matching unit No. PFBC 161 X3
1 1 1 LC EXC
1 9
3
2 10 3 2
2 3
3 11
4 12 4 LC EXC
4
Load cell B 13
with matching unit X5
1 14 4 1
1 LC Signal 1, A
3 15 5 2
2
2 16 6 3
3 LC Signal 2, B
4 4 17 7 4
18 8

Load cell A Cable Junction box

with matching unit No. PFBC 161
1
1 9 1
3
2 10 3
2
3 11
4
4 12
Load cell B 13
with matching unit X15
1 1
1 14 4
3 LC Signal 3, A
2 15 5 2
2
3 16 6 3
4 LC Signal 4, B
4 17 7 4
18 8

Figure 3-17. Connecting Four QGPR 102/104 Load Cells with Two PFBC 161

3-16 3BSE023139R0401 Rev A

 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section 3.8.3 Connecting QGPR 102/104 Load Cells with Phase Matching Board PFBK 401

3.8.3 Connecting QGPR 102/104 Load Cells with

Phase Matching Board PFBK 401
Phase matching board PFBK 401 is delivered with large QGPR 102/104 load cells.
See connection between load cell QGPR 102/104 and matching unit QIPZ 127 in Figure 3-23.

Connecting two load cells

Junction box Matching board Control unit

Load cell A Cable PFXC 141 PFBK 401 MC 400
with matching unit No.
X2 X4 X3
1 3
1 17 1 1 1 LC EXC
3
2 18 2 2 2
2 1)
3 19 3 3
4 4
20 8 4 4 LC EXC
Load cell B 6
with matching unit
X5
1
1 21 3 1
3 LC Signal 1, A
2 22 4 2
2
3 23 7 3
4 LC Signal 2, B
4 24 8 4
2)

1) Built-in relays used to disconnect either load cell A or load cell B in Single Cell Operation Mode
2) Copper bar for connecting cable shields (insulated from metal case of junction box)

Figure 3-18. Connecting Two Large QGPR 102/104 Load Cells with Matching Board PFBK 401 and One PFXC 141

Junction box Matching board Control unit

Load cell A Cable PFBC 161 PFBK 401 MC 400 (PFXA 401)
with matching unit No. X4
X2 X3
1 3
1 9 1 1 1 LC EXC
3
2 10 2 2 2
2 1)
3 11 3 3
4
4 12 8 4 4 LC EXC
Load cell B 13 3
with matching unit X5
1
1 14 4 1
3 LC Signal 1, A
2 15 5 2
2
3 16 6 3
4 LC Signal 2, B
4 17 7 4
18 8

1) Built-in relays used to disconnect either load cell A or load cell B in Single Cell Operation Mode

Figure 3-19. Connecting Two Large QGPR 102/104 Load Cells with Matching Board PFBK 401 and One PFBC 161

3BSE023139R0401 Rev A 3-17

Millmate Roll Force Systems with Millmate Controller 400, User Manual
Chapter 3 Installation

Connecting four load cells individually

Junction box Matching board Control unit

Cable
STAND 1 Load cell A PFXC 141 PFBK 401 MC 400
with matching unit No.
X2 X4 X3
1
1 17 1 1 3 1 LC EXC
3
2 18 6 2 2
2 3
3 19 X4 3
4 6
4 20 4 4 LC EXC
7
STAND 1 Load cell B 8
with matching unit X5
1
1 21 3 1
3 LC Signal 1, A
2 22 4 2
2
3 23 7 3
4 LC Signal 2, B
4 24 8 4

1)

Junction box
STAND 2 Load cell A Cable PFXC 141
with matching unit No.
1
1 17 1
3 6
2 18
2
3 19
4 4
20
STAND 2 Load cell B
with matching unit
1 X15
1 21 3 1
3 LC Signal 3, A
2 22 4 2
2
3 23 7 3
4 LC Signal 4, B
4 24 8 4

1)

1) Copper bar for connecting cable shields (insulated from metal case of junction box)

Figure 3-20. Connecting Four Large QGPR 102/104 Load Cells and Matching Board PFBK 401 with Two PFXC 141

3-18 3BSE023139R0401 Rev A

 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section 3.8.3 Connecting QGPR 102/104 Load Cells with Phase Matching Board PFBK 401

Junction box Matching board Control unit

STAND 1 Load cell A Cable PFXC 141 PFBK 401 MC 400
with matching unit No.
X2 X4 X3
1 1 LC EXC
1 17 1 1 3
3 2
2 18 6 2
2 3
3 19 X4 3
4 4 6
20 4 4 LC EXC
7
STAND 1 Load cell B
with matching unit
14 8
X5
1
1 21 3 1
3 LC Signal 1, A
2 22 4 2
2
3 23 7 3
4 LC Signal 2, B
4 24 8 4

STAND 2 Load cell A Cable

with matching unit No.
1
1 25
3
2 26
2
3 27
4 4
28
STAND 2 Load cell B
with matching unit
1 X15
1 29 11 1
3 LC Signal 3, A
2 30 12 2
2
3 31 15 3
4 LC Signal 4, B
4 32 16 4

1)

1) Copper bar for connecting cable shields (insulated from metal case of junction box)

Figure 3-21. Connecting Four Large QGPR 102/104 Load Cells and Matching Board PFBK 401 with One PFXC 141

3BSE023139R0401 Rev A 3-19

Millmate Roll Force Systems with Millmate Controller 400, User Manual
Chapter 3 Installation

Junction box Matching board Control unit

STAND 1 Load cell A Cable PFBC 161 PFBK 401 MC 400 (PFXA 401)
with matching unit No.
X2 X4 X3
1 1 LC EXC
1 9 1 1 3
3 3 2
2 10 2
2 3
3 11 X4 3
4 4 6 4
12 4 LC EXC
13 7
STAND 1 Load cell B 8
with matching unit X5
1
1 14 4 1
3 LC Signal 1, A
2 15 5 2
2
3 16 6 3
4 LC Signal 2, B
4 17 7 4
18 8

Junction box
STAND 2 Load cell A Cable PFBC 161
with matching unit No.
1 9 1
1
3 10 3
2
2 11
3
4 4 12
13
STAND 2 Load cell B
with matching unit X15
1 14 4 1
1 LC Signal 3, A
3 15 5
2 2
2 16 6 3
3 LC Signal 4, B
4 17 7 4
4
18 8

Figure 3-22. Connecting Four Large QGPR 102/104 Load Cells and Matching Board PFBK 401 with Two PFBC 161

3-20 3BSE023139R0401 Rev A

 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section 3.8.3 Connecting QGPR 102/104 Load Cells with Phase Matching Board PFBK 401

Symbol used for load cell QGPR 102/104

with matching unit QIPZ 127 (see Figures 3-12 to 3-22)

1
2
3
4

Load cell
QGPR 102/104 Matching unit QIPZ 127
A Red X1:1 X2:1
B Blue X1:2 X2:2
C Black X1:3 X2:3
To control unit
D White X1:4 X2:4

Fixed cable n.c.

Figure 3-23. Connection between Load Cell QGPR 102/104 and Matching Unit QIPZ 127

3BSE023139R0401 Rev A 3-21

Millmate Roll Force Systems with Millmate Controller 400, User Manual
Chapter 3 Installation

3.9 Installing Millmate Controller 400

3.9.1 Mounting MC 400 Control Unit

The control unit is delivered with or without a wall cabinet or mounted in a floor cabinet.
See dimension drawings for cabinets in Appendix C, Drawings.

NOTE
The incoming mains voltage must be provided with fuses and a means outside the
control unit for disconnection.

3.9.2 Installing Wall Cabinet

When choosing a place for installation, the following aspects must be considered:
• It must be possible to open the cabinet door fully.
• There must be enough work space in front of the cabinet.
• The wall cabinet should be fitted at a convenient
height for commissioning and service.
Cable glands are supplied with every wall cabinet.
The following work steps are recommended:
1. Drill the holes in the wall according to the drilling template.
See Appendix C, Drawings.
2. Mount the rubber dampers (vibration isolators).
See Appendix C, Drawings.

NOTE
Vibration isolators shall be used when mounting the control unit
in a harsh environment.

3. Mount the control unit at its intended location.

4. Pull the cables through.
5. Make the necessary electrical connections and tighten the
screw terminals and cable glands.

3-22 3BSE023139R0401 Rev A

 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section 3.9.3 Installing MNS Select Floor Cabinet

3.9.3 Installing MNS Select Floor Cabinet

3.9.3.1 Mounting Cabinets Together

If cabinets are to be mounted to each other use the included screw/bolt kit. The four M8 screws,
with washers and nuts, in the angle hinges and six M6 screws at about Z1=500, Z2=1000,
Z3=1500 mm height from the floor, see Figure 3-24. Tighten the M8 screws to 20 Nm
maximum and the M6 screws to 10 Nm maximum.

Figure 3-24. Mounting Cabinets together - Screw Position

3.9.3.2 Mounting Cabinets to the Floor

When fixing the cabinet to the floor use four or six M12 screws where Figure 3-25 indicates,
one at each corner in the first left hand cabinet in a row of cabinets and screw the following
cabinets with two screws each at the right hand side. The bottom angle hinges features holes,
14 mm (0.6”) in diameter. These holes permit you to adjust the cabinet location after holes are
drilled in the floor. If drilling is necessary, make sure that no dust or other foreign matter enters
the equipment in the cabinet. Please notice the minimum distances from cabinet to walls and
ceiling. Use washers between the floor and the cabinet bottom to level the cabinet floor into a
horizontal position.

3BSE023139R0401 Rev A 3-23

Millmate Roll Force Systems with Millmate Controller 400, User Manual
Chapter 3 Installation

Figure 3-25. Position of the Holes for fixing the Cabinet(s) to the Floor

Table 3-2. Distances in Figure 3-25

Symbol Distance
X 69 mm (2.7”)
W3 602 mm (23.7)
W 700 mm (27.6”)
Y 56 mm (2.2”)
D3 544 mm (21.4”)
Dtot 655 mm (25.8”)

3.9.3.3 Space Requirements

The overall dimensions of the cabinet are shown in a dimension diagram in
Appendix C, Drawings, page A-3.
The following rules apply to locating and positioning of the cabinet:
• The distance between the top surface of the cabinet and the roof, soffit of a beam or
ventilation duct etc. must be at least 250 mm. If cables enter from above, this distance is
increased to 1000 mm.
• There must be a clearance of at least 40 mm between the rear of the cabinet and the wall,
and between the sides of the cabinet and the wall.
• To permit a frame with hinge, or a door to an outer encapsulation to open fully without
catching on the adjacent wall, the distance to the wall must be increased to 500 mm on the
hinge side (left) of the frame, or 300 mm on the hinge side (right) of the door.
• There must be at least 1 meter of free space in front of the cabinet. It must be possible to
open the door completely, in order not to restrict access for check-out and servicing.

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 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section 3.9.4 Connecting Cables

3.9.4 Connecting Cables

3.9.4.1 Power Supply Cables

Detailed information about the cables is given in Table 3-3.

X34 X35
X24 X25
T2A T2A MC 400 (PFXA 401) Digital in Digital out
F1 F2
85-264V~ X21 X30 X23
47-63Hz 140W 10Base2 Profibus RS-485

1 2 3 4 5 1 2 3 4 5

X13 X15 X16 X18

S1 X2 X3 X5 X6 X8
X1

1) 12) 3) 11)
Mains SYNC Load cell excitation External supply
(X1) (X2) to junction box +24 V DC
(X13, X3) (X18, X8)

PFVI 401

X11 X4

1) 3)
Mains Load cell excitation
(X11) to matching units
(X4)
3) 4)
3) 4)
Matching units
Junction
box

Load cell signal

and excitation
13) 13)
2) 2)

QGPR 102/104 PFVL 141

Figure 3-26. Power Supply Cables

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Chapter 3 Installation

3.9.4.2 Signal Cables

Detailed information about the cables is given in Table 3-3.

RS-232
Ethernet to (X27, X26)
9)
Operator unit
(X29) 5)
Run Fault
10Base-T Syserr Profibus
LAN C
X29 RS-485 RS-232 RS-232:2 RS-232:1
X27 X26
DO1 DO5
DO2 DO6
DO3 DO7
DO4 DO8

AUI
X22
Profibus
X31
X34 X35 6) Digital in
X24 X25
T2A T2A Digital in Digital out (X34, X24)
F1 F2
85-264V~ X21 X30 X23
47-63Hz 140W 10Base2 Profibus RS-485
Digital out
1 2 3 4 5 1 2 3 4 5 7)
(X35, X25)
X13 X15 X16 X18

S1 X2 X3 X5 X6 X8
X1

10) 4) 8)

RS-485 Analog out

(X23) (X16, X6)

Load cell signal

from junction box or matching unit
(X15, X5)

Figure 3-27. Signal Cables

3.9.4.3 Cable Specifications

To ensure that the equipment functions correctly ABB recommends the following cable types.

Table 3-3. Recommended Cable Types

No. (1) Cable route Description

1 Mains 3 × 0.75 - 2.5 mm2
2 Load cell - matching unit ABB special cable for both supply and
PFVL 141 signal.

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 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section 3.9.4 Connecting Cables

Table 3-3. Recommended Cable Types

No. (1) Cable route Description

3 *) Junction box - control unit, Pressductor® load cells:
load cell excitation 2 - 4 × 0.5 - 2.5 mm2 with screen.
Rated insulation voltage 250V.
*)
Millmate Controller 400R

For
PFVL 141:

Load cell excitation circuit (in 1.95 A loop) - max. 5 ohm cable
resistance. 5 ohm corresponds to approx. 350 m of 2.5 mm2 cable.

Millmate Controller 400R

For
QGPR 102/104:

Load cell excitation - max. 5 ohm cable resistance.

5 ohm corresponds to approx. 350 m of 2.5 mm2 cable.

4 Junction box - control unit, n × 2 × 0.25 - 2.5 mm2 with screen.

load cell signal Twisted pairs.
5 Control unit - operator unit, Twisted pairs 10Base-T
Ethernet
6, 7 Digital inputs and outputs n × 0.25 - 2.5 mm2 with common screen
8 Analog outputs n × 0.25 - 2.5 mm2 with screen.
9 RS-232 0.25 - 0.5 mm2 with screen.
DB9-connector.
10 RS-485 2 × 0.25 - 0.5 mm2 with screen.
Twisted pair.
11 +24 V DC supply 0.5 - 2.5 mm2.

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Chapter 3 Installation

Table 3-3. Recommended Cable Types

No. (1) Cable route Description

12 SYNC 3 × 0.25 - 2.5 mm2 with screen.
13 Load cell - junction box Two types of cables can be used:
a) Symmetrical 4 core cable with common
screen. Measuring signal and excitation
Signal Load cell pairs are to consist of diagonally
excitation opposite cores to keep crosstalk to a
minimum. See the figure to the left.
4 × 0.5 - 2.5 mm2
b) Cable with twisted pairs and common
screen. Use one pair for excitation and
one for measuring signal.
2 × 2 × 0.5 - 2.5 mm2
(1) The number in this column refers to the corresponding number in Figure 3-26 and Figure 3-27.

3.9.4.4 Connection of Excitation Unit

Excitation unit PFVI 401 is controlled by control unit PFXA 401 via a ribbon cable.

Ribbon cable

X39 X49
PFXA 401 PFVI 401
control unit excitation unit

3.9.4.5 Mains Connection

MC 400 R operates on any mains voltage within a range from 85 V to 264 V. However, heat
dissipation varies the mains voltage, see Table 2-1, and may be considered if a choice of mains
voltage is possible.
Mains voltage shall be connected to terminal groups X1 (PFXA 401) and X11 (PFVI 401).

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Section 3.9.4 Connecting Cables

PFXA 401 PFVI 401

X1 X11
1 2 3 4 1 2 3 4

Mains voltage connection for PFXA 401 and PFVI 401

85 - 264 V AC
Figure 3-28. Mains Connection

3.9.4.6 Synchronisation (SYNC)

The purpose of the synchronisation is to eliminate the beat frequency, which may occur if the
load cell excitation from one MC 400 interferes with the load cell signal to another MC 400.
If the control units are not synchronised the interference will sometimes be in phase and
sometimes in opposite phase with the signal and thus cause a slow drift up and down with a
frequency equal to the difference between the excitation frequencies of the two control units.
When the control units are synchronised the interference becomes a fixed signal which can be
removed by zero setting.
The synchronising is achieved by connecting all corresponding terminals of the X2 terminals in
parallel on all control units which are using the same excitation frequency.

X2
1 2 3

From To
previous next
unit unit

Figure 3-29. Synchronisation

3.9.4.7 Connecting Millmate Operator Unit 410 to LAN.

The Operator unit PXAH411 is connected to LAN by using LAN B. See Table 2-7.

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Chapter 3 Installation

3.9.4.8 Connecting Redundant +24 V Supply to Millmate Operator Unit 410 and Network
switch
One Millmate Operator Unit can be redundantly supplied with +24 V DC from several Millmate
Controller 400 control units, see Figure 3-26.

MC 400 (1) Millmate Operator

Unit 410
0V

+24 V + -

X8 1 2

MC 400 (2)

0V
The Operator Unit and the Network switch
+24 V will be supplied if at least one of the control
units is switched on.

X8 1 2

+ –
MC 400 (n)
Network
Switch
0V

+24 V

X8 1 2

Figure 3-30. Connection of Redundant +24 V Supply to Millmate Operator Unit 410
and Network switch

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 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section 3.10 Installing Optional Units

3.10 Installing Optional Units

3.10.1 Connecting Insulation Amplifier PXUB 201

Insulation amplifier PXUB 201 is intended to be installed on a mounting rail at the rear of the
cabinet. PXUB 201 is connected by screw terminals.
PXUB 201 is normally supplied from the +24 V DC supply in the control unit.
If PXUB 201 is mounted close to the terminal group, it is not necessary for the cable between
the control unit and PXUB 201 to be screened.

MC 400 PXUB 201

X6/16
3
Signal +
4 – 5
0V +
6
–

+24 V X18:1 7
+

X18:2 8 –
0V

Figure 3-31. Typical Connection of Insulation Amplifier PXUB 201

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Chapter 3 Installation

3.10.2 Connecting Relay Board PFVK 128

Relay board PFVK 128 is intended to be installed on a mounting rail at the rear of the cabinet.
PFVK 128 is connected by screw terminals.
Relay board PFVK 128 is normally supplied from the +24 V DC supply in the control unit.

PFVK 128

MC 400
X18
+24 V (internal supply) 1

X25
5
PFVK 128
DO5
X1 X1
1 13 2

1
14
DO6 3

2 15 5

4
16
DO7 6

3 17 8

7
18
DO8 9

4 19 11

X18 10
0 V (internal supply) 2 20

12

Figure 3-32. Typical Connection of Relay Board PFVK 128

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 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section 3.10.3 Mounting External Display QDIL 451

3.10.3 Mounting External Display QDIL 451

External display QDIL 451 can be mounted in cabinet doors or panels.
The external display is available in two versions:
• 4 digits (red LED type digits)
• 6 digits (red LED type digits)
Max. cable distance with:
• RS-232 is 15 m.
• RS-485 is 500 m.
With RS-485 several displays can be connected to the same RS-485 cable. These displays can
be addressed to show different measuring signals simultaneously.

Figure 3-33. Example of an External Display with Six Digits

3.10.3.1 Dimensions
Table 3-4. Dimensions for External Display QDIL 451

Digits Dimensions
Type
No. of height width height depth
4 72 48 68
QDIL 451 14 mm
6 96 48 68

3.10.4 Connecting External Display QDIL 451

3.10.4.1 General
External display QDIL 451, mounted in cabinet doors or panels, can be connected either to the
RS-232 or RS-485 outputs.
RS-485 is normally recommended since longer communication cables can be used.
• RS-485, max 500 m
• RS-232, max 15 m

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Chapter 3 Installation

Another advantage with RS-485 is that several external displays indicating different measured
signals simultaneously can be connected to the same RS-485 cable (max cable area 0.75mm2).

3.10.4.2 Terminating RS-485 Cable Connected to QDIL 451

The transmitting end of the RS-485 cable is terminated in the control unit and the other end
must be terminated by connecting a resistor, 120 , 0.5 W. This is done by connecting RX- and
ZR together. See Figure 3-34.

MC 400 External display External display

X23 RX+ RX- RX+ RX- ZR

1 2
Connection of
RS-485 cable internal
Termination
120 
Figure 3-34. Termination of External Display QDIL 451

3.10.4.3 Power Supply for QDIL 451

External display QDIL 451 can be supplied from the 24 V DC terminals X18:1 and 2 at the
control unit, or from an external supply.

3.10.5 Connecting Serial Ports

DB 9
Male

Signal Ground (GND) Common, 0 V (5)

(9) N.C. Not Connected
Data Terminal Ready, DTR (4)
(8) CTS, Clear To Send
Transmitted Data, TXD (3)
(7) RTS, Request To Send
Received Data, RXD (2)
(6) N.C. Not Connected
Data Carrier Detected, DCD (1)
MC 400 X26 or X27

Figure 3-35. Signals on Serial Ports

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 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section 4.1 About This Chapter

Chapter 4 Commissioning

4.1 About This Chapter

This chapter contains necessary information for commissioning your Roll Force System.
It is assumed that the Roll Force System has been installed according to the instructions given in
Chapter 3 Installation and Appendix C Drawings.
You must know the following data before starting commissioning:
1. Load cell type and nominal load
2. Type of measuring object, see Section 4.5.9
3. Maximum applied roll force on the load cells
4. Desired output data at given roll force
5. Communication data.

4.2 Recommended Equipment

The following equipment is required for commissioning:
• Circuit diagrams
• Cable diagram
• Inspection and test record
• Multimeter
• Service tools (screwdriver, wire cutter etc.)
• Installation drawings of the load cells

4.3 Actions Before Mains Supply is Switched On

Perform the following checks before the mains supply is switched on:
• Visual inspection
• Connection check
• Power supply check
When this is done, the measuring system is ready to be switched on.
The detailed actions are described in sections in the following.

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Millmate Roll Force Systems with Millmate Controller 400, User Manual
Chapter 4 Commissioning

4.3.1 Visual Inspection

Ensure that the equipment has not been damaged in transit.
Check:
• that the cabinet door can be opened and closed.
• that no short circuits or breaks have occurred by displacement of units,
e.g. they have been subject to impact or shocks.
• that no cables or conductors have been subject to abrasion or other damage.
• that no units or connectors have been damaged.
Also check:
• that the control unit fulfills the installation instructions given in the manual
“Environmental Immunity” (Doc. No. 3BSE040398Rxx01).

4.3.2 Checking Connections

Before switching on, check:
• that external fuse for mains voltage is correct.
• that all cables have been installed in accordance with the cable diagram.
• that all cables have been installed in order to minimize the risk of interference.
• that the load cells have been connected correctly.
Incorrect connections can damage load cells.

NOTE
Check that the load cells are connected to give a positive output signal change for
increased roll force. See cable diagram for actual type of load cell in Appendix C
Drawings.

• that the operator unit is connected.

• that any V24 units are connected.
• that any external units are correctly connected.
• that all screw terminals are tightened.
• that all cable grommets seal properly and that strain relief devices do take up the strain.
• that, if network switches or the operator unit are power supplied from a separate 24 V DC
supply, it is properly connected to terminal X1 on the operator unit.

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 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section 4.3.3 Checking Power Supplies

4.3.3 Checking Power Supplies

4.3.3.1 Millmate Controller 400

Check that the mains supply is 85 - 264 V, 47 - 63 Hz.

4.3.3.2 Millmate Operator Unit 410

If the network switches or the operator unit power are supplied from a separate 24 V DC supply,
check that it is switched on.

4.3.3.3 Additional Supplies

Check any additional power supplies that are used for the measurement system.

4.4 Starting the Equipment

4.4.1 Starting Millmate Controller 400

Start the control unit with the mains switch on the front.
Check that:
• the green LED “Run” on the front is lit.
• the red LED “Fault” remains off.

4.4.2 Starting Millmate Operator Unit 410

The operator unit is normally powered from the control unit.
Check the supply from the control unit (or separate supply) to the operator unit.
It should be 24 V DC. Also check that the polarity is correct.
The Operator Unit starts up automatically at power up. The unit will display Home menu or
other menu set as start menu.

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Millmate Roll Force Systems with Millmate Controller 400, User Manual
Chapter 4 Commissioning

4.5 Commissioning the Control Unit

4.5.1 Menu Map for Millmate Controller 400

This is an overview of main menus for operation and service in MC 400.

Home menu

Press Object Select measuring

MC400 Service Press Network/Display object in list

Settings in operator unit View measuring values

IP-address, Brightness, Zero set
Start menu LC exc. on/off
See 4.5.4 Single cell

Service menu 1 Service menu 2 Service menu 3

System Error Lc exc Next Settings Check Next Define Comm. MC 400 Next
test inspect ON/OFF I/O system setup data

Test system Switch load Level detectors Set time

See 4.5.27 cell excitation Single cell Set identity
on/off See
See 4.5.20
Print data
Simulate lc See 4.5.29
Clear errors Set DI/DO
See 7.4 Check lc-exc

Setup I/O Trim LAN Serial FieldBus

object sensit. ports

Modify or Modify or set up Adjust measuring Settings Settings for Settings for
add new analog and digital sensitivity for LAN RS-232, and VIP and Profibus
measuring inputs/outputs See 4.5.24 See 4.5.16 RS-485 comm. See 4.5.17 and 4.5.18
objects See 4.5.14 Zero adjustment See 4.5.19
See 4.5.8 or See 4.5.25
4.5.13

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 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section 4.5.2 Overview of Service Menus for the Control Unit

4.5.2 Overview of Service Menus for the Control Unit

Select Control unit label

Service menu 1 111
in Home menu
ABB225
Service menus 1, 2 and 3 are start menus for
or Date 12 jan 2004, 12:00 the control unit settings. From these three
For current control unit Load cell excitation off
menus all necessary settings can be entered
when in object menu select for the control unit and the objects.
MC400 service

System Error Lc exc Next

test inspect ON/OFF

Service menu 2 112

ABB225
Date 12 Jan 2004, 12:00

Load cell excitation off

Settings Check Next

I/O

Service menu 3 113

ABB225
Date 12 jan 2004, 12:00
Serial number SE9808A123
Software release 3.2-2
Software type MC400 R
Options 4 load cell ports
Profibus

Define Comm. MC400 Next

system setup data

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Millmate Roll Force Systems with Millmate Controller 400, User Manual
Chapter 4 Commissioning

4.5.3 Actions During the Commissioning

Commissioning of the control unit is best done using the operator unit, which is assumed in this
description. It is also assumed that no measuring objects are set up. Carry out the following
actions during the commissioning:

Actions See section

Setting up the operator unit 4.5.4
Establishing communication between 4.5.5
the operator unit and the control unit
Setting up the basic data in the control unit 4.5.7
Defining a measuring object in the control unit 4.5.8, 4.5.13
Configuring digital inputs and outputs 4.5.14
Setting up the external communication 4.5.15
Switching on the load cell excitation 4.5.20
Select start object for the operator unit 4.5.26
Performing a system reference test (self test) 4.5.27
Store reference test 4.5.27

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 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section 4.5.4 Setting Up the Operator Unit

4.5.4 Setting Up the Operator Unit

4.5.4.1 Set screen saver

From the Home menu, press Display

After selecting screen saver, it will automatically start when your computer is idle for the time
interval specified in Wait. Select one of the specified wait intervals and press Save. The
available wait intervals are 5 seconds up to 10 hours. It is also possible to set the screen saver to
OFF, this disables the screen saver.

To clear the screen saver after it has started, touch the screen.
A screen that is continuously updated will redirect to Startup Object on Home menu when
screen saver has been activated to avoid data traffic during time out. If Startup Object has not
been activated, the Home menu is shown.

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Chapter 4 Commissioning

4.5.4.2 Set Backlight Brightness

From the Home menu, press Display

Set Backlight brightness level. Intensity is set in levels 10 (brightest) to 1 (dullest). When
approaching level 1 backlight, changes in brightness level may no longer be noticeable in the
panel.
Complete dimming (to level 0) is not possible. Backlight brightness level is maintained after
reboot of panel.

4.5.4.3 Touch Screen Calibration

Presssing Touch Calibration starts a Touch Screen Calibration setting procedure. Follow the
instructions on the screen to calibrate the touch screen.

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 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section 4.5.5 Establishing Communication Between the Operator Unit and the Control Unit, Millmate Controller 400

4.5.5 Establishing Communication Between the Operator Unit and

the Control Unit, Millmate Controller 400
Communication must first be established between the operator unit and control unit, Millmate
Controller 400 before the control unit can be set up.
Ethernet is the physical connection between the operator unit and the control unit. The network
can consist of either one operator unit and one control unit, or form part of a wide area network,
see Section 3.8.1.

NOTE
If the units are to be used in a wide area network where other equipment is
present, the IP addresses in the operator unit and the control unit must be adapted
to the network address range. To accomplish this, the IP address in the control
unit must be altered first. This is best done using an operator unit in a temporary
local area network where no other equipment is present. When the IP address in
the control unit is altered, the IP address in the operator unit can be changed.
After that, the units can be connected in the wide area network.

Connect the panel to the network using LAN B port.

To find a control unit:
• Press Scan LAN to do a network search for available control unit (Millmate controller).
Each control unit is equipped with a label which is set to “ABB XXX” from the factory.
XXX equals the three last digits in the control unit IP address.
If the operator unit and the control unit are within the same subnetwork, the control unit is
automatically localized.
Press Controllers and press Scan LAN

Listing of control units, adds the designated controller device (Millmate controller or other) for
this particular operator unit. It is also a way to see if a particular controller is off line.
To save a control unit to the list:
• Slide the toggle switch “In List” to the right and press “Apply”
To set an object as Startup menu see Section 4.5.26.

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Chapter 4 Commissioning

4.5.6 Setting Up Network Data For the Operator Unit

For setting up network data for the operator unit, there are two alternatives:
1. All units in the network are Millmate Controller 400 (MC 400).
Action: No settings are necessary. Factory settings can be used.
2. The operator unit and the control unit (MC 400) are parts of a wide area network
containing equipment of other types.
Action: The IP addresses must be adapted (by a network responsible person) to fit in the
wide area network address range.
Use Obtain IP address automatically or manually set IP address, Subnet mask, default gateway
and DNS server. Configuring to obtain an IP address automatically allows the networking
device to assign a dynamic IP address to it.
Normally a fixed IP address is used

From the Home menu, press Network

“
Subnet Mask” is used to decide if the connection
should be done within the local network or through
a router. Default is ffff0000.

The address “Default gateway” shall be set when a

router is used to switch over to the external network.
This is not used on a closed network.

DNS 1 and DNS 2 are normally not used.

Use “Apply” to save the modified settings and

terminate.

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 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section 4.5.7 Setting Up Basic Data in the Control Unit

4.5.7 Setting Up Basic Data in the Control Unit

In the “MC400 data” menu you can change the control unit name, set time, select language and
access the internal database.

MC400 data 115 Date / Time

Service The clock and calendar are set in a sub menu
MC400 label ABB225
Date 12 jan 2004, 12:00 which is accessed by pressing “Set time”.
Latest startup 12 jan 2004, 10:18 The set time becomes active when the sub menu
Service Language English
Svenska is exited with “End”.
Deutsch
MC400 label
Next Set Data Print End
time base data The control unit name is changed by entering the
new name in the field.
Next
Data base
Pressing “Data base” gives access to the internal
MC400 database stored in the control unit.
data

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Millmate Roll Force Systems with Millmate Controller 400, User Manual
Chapter 4 Commissioning

4.5.8 Defining a Measuring Object

This page shows a simplified step by step instruction on how to define a measuring object. Each
step is also described in detail later in this section, (see references).
Setup object 301
Service
Menu 301. Select a free object. See 4.5.9
1 Not defined
2 Not defined
3 Not defined
Menu 309. This menu
4 Not defined Select application 309 appears in an empty
Multi view
Service MC 400R
Not defined
Tensiometer system (no objects
Roll Force Meter
Setup Remove End Strip scanner
defined).
Next Select type of
application.
Select type 310 Next

Next Single input measurement

Standard measurement
Menu 310. Select ob-
3 input measurement ject type. See 4.5.9
4 input measurement
Define Select load cell type 324
PFVL 141
PFVL 101
system QGPR 102 (d)
QGPR 102 (c)
Next QGPR 102 (b)
Setup QGPR 102 (a)
QGPR 104 (d)
QGPR 104 (c)
object See 4.5.10 QGPR 104 (b)
QGPR 104 (a)
Next
Menu 320. Enter load
Object parameters 320 cell size. Select load
Name Std1@ABB225
Options - cell type. See 4.5.10.
LC type PFVL 141 See 4.5.11.2
LC size 20.00 MN
Select unit 338
Port No of LC/port Newton (N)
Load cell A 1 1
kiloNewton (kN) Note
Load cell B 2 1 (MN)
306
MegaNewton
(kp) Main menus (always in-
Pending object setup kiloPond
tons (t)
Change Change Next
US pound (lb) cluded in the object setup)
Name Std1@ABB225 lc name lc type (T)
Application Standard measurement
US Tons
are connected with thick
Lc type PFVL 141
See 4.5.11
Next ( ) arrows.
Lc size 20.00 MN
Lc at port 1, 2
Load division 0.05 MN Measurement parameters 330
See 4.5.11.1 See 4.5.12.3
Name Std1@ABB225
Setup step detector 353
Modify Discard Check Filter response time 1 ms Set filter response time 336 Active
changes object Measuring range 20.00 MN 0 - 90% Label SD
Load unit MegaNewton 1 ms Unfiltered H1 Step up height 1.0000 MN
2 ms D1 Step up time 0.10 s
5 ms D2 Step up hold time 0.10 s
12 ms D3 Step up lock time 0.10 s
24 ms H2 Cut-off offset -0.1000 MN
50 ms D4 Step down hold time 0.10 s
Object checked 307 100 ms D5 Step down lock time 0.10 s
200 ms Step counter 0 times
Change Change Next 400 ms
Next
Std1@ABB225 filter unit Next
Result SUCCESSFUL
See 4.5.12.2
Analog output 355
See 4.5.12 Port 1
Measurement value
Tot Diff A B

Indication parameters 351 Fixed value

Store Level detectors 800 ms Filter
Modify Discard
1 Not defined Low High
changes 10.00 MN
2 Not defined Measurement 0.00
3 Not defined Output 0.000 10.000 V
4 Not defined Limit -11.000 11.000 V
Analog OUT Volt or Default Default Next
New measuring object 1 Fixed value 0V Ampere All AO
2 Fixed value 0V
Setup object 301 3 Fixed value 0V
4 Fixed value 0V See 4.5.12.1
1 Std1@ABB225 Level Analog Step Next Setup level detector 352
2 Not defined detect. OUT detect. Active
Not defined Label
3 Level MN
0.00
4 Not defined Hysteresis 0.00 MN
Multi view Counter 0 times
Digital out port 0 Invert
Not defined
High Low
Tot Diff A B
Measurement value
Setup Remove End
Next
Press “End” to finish the setup

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 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section 4.5.8 Defining a Measuring Object

4.5.8.1 Modifying an Existing Measuring Object

An object that has been setup can be modified by using the “Modify” command as shown in this
overview.

See 4.5.10
Service Object parameters 320
Name Std1@ABB225
Options -
LC type PFVL 141
LC size 20.00 MN
Service Port No of LC/port Select load cell type 324
Load cell A 1 1 PFVL 141
Load cell B 2 1 PFVL 101
QGPR 102 (d)
QGPR 102 (c)
QGPR 102 (b)
Change Change Next QGPR 102 (a)
Next lc name lc type QGPR 104 (d)
QGPR 104 (c)
QGPR 104 (b)
QGPR 104 (a)
Next
See 4.5.11
Next Measurement parameters 330
Name Std1@ABB225
See 4.5.11.2
Filter response time 1 ms
20.00 MN
Define Measuring range
Load unit MegaNewton Newton
Select unit
(N)
338
(kN)
system kiloNewton
MegaNewton (MN)
kiloPond (kp)
tons (t)
Setup US pound (lb)
(T)
object Change Change
filter unit
Next US Tons

Next
Select object
See 4.5.11.1
Setup See 4.5.12 Set filter response time 336
0 - 90%
Indication parameters 351 1 ms
2 ms
Unfiltered
Level detectors 5 ms
1 Not defined 12 ms
24 ms
Object information 305 2 Not defined
3 Not defined 50 ms
100 ms
4 Not defined 200 ms
Name Std1@ABB225 Analog OUT 400 ms
Application Standard measurement 1 Fixed value 0V Next
Lc type PFVL 141 2 Fixed value 0V
Lc size 20.00 MN 3 Fixed value 0V
Lc at port 1, 2 4 Fixed value 0V
Load division 0.005 MN Level Analog Step Next
detect. OUT detect. See 4.5.12.3
Setup step detector 353
Modify End Active
Label SD
H1 Step up height 1.0000 MN
D1 Step up time 0.10 s
D2 Step up hold time 0.10 s
Pending object setup 306 D3 Step up lock time 0.10 s
H2 Cut-off offset -0.1000 MN
Name Std1@ABB225 D4 Step down hold time 0.10 s
D5 Step down lock time 0.10 s
Application Standard measurement Step counter 0 times
Lc type PFVL 141 Next
See 4.5.12.2
Lc size 20.000 MN Analog output 355
Lc at port 1, 2 Port 1 Tot Diff A B
Load division 0.005 MN Measurement value
Fixed value
800 ms Filter
Modify Discard Check Low High
changes object Measurement 0.00 10.00 MN
Output 0.000 10.000 V
Setup object 301 Limit -11.000 11.000 V
See 4.5.12.1 Volt or Default Default Next
1 Std1@ABB225 Object checked 307 Ampere All AO
2 Not defined
Setup level detector 352
Active
3 Not defined Std1@ABB225 Label
4 Not defined Result SUCCESSFUL
Level 0.00 MN
Hysteresis 0.00 MN
Multi view Counter 0 times
Not defined Digital out port 0 Invert
High Low
Tot Diff A B
Setup Remove End Measurement value

Next
Modify Discard Store
changes

Press “End” to finish.

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Millmate Roll Force Systems with Millmate Controller 400, User Manual
Chapter 4 Commissioning

4.5.9 Objects Types

Up to five objects can be defined in each control unit.
Use the arrow keys and “Select” and then “Setup”
Setup object 301
Service to select a free object in the list. Free objects are
1 Std1@ABB225
2 Not defined
marked with “Not defined”. The object name is
3 Not defined shown for a defined object.
Service 4 Not defined
Multi view
Not defined If the object is already defined, settings are shown
Next Setup Remove End by pressing “Setup”, see 4.5.12.4.

Four standardized object types can be selected,

Next Select type 310 see Figure 4-1. For each object type, adapted op-
Single input measurement eration menus are created. Operation parameters
Standard measurement
Define 3 input measurement
and functions are preset depending on the select-
system 4 input measurement ed object type.
Setup
object
Next

Standard measurement Single input measurement

Two load cells with separate signals Two load cells connected together Using only one load cell
to one signal

+
MC 400 MC 400 MC 400

Signal input Signal input

Signal input
A A
A
B
Note.
Measured force is half of total force.
Enter 2 X Fnom as Nominal size
of load cell to get correct reading.
Figure 4-1. Standardized Object Types

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 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section 4.5.10 Changing Load Cell Data

4.5.10 Changing Load Cell Data

This menu has one main menu and two sub menus. See details in Table 4-1.

Object parameters 320 This menu is prepared with suggested default

Service
Name Std1@ABB225 values when an object is set up for the first time.
Options -
LC type PFVL 141
LC size 20.00 MN
Service Port No of lc/port
Select load cell type 324
Load cell A 1 1 PFVL 141
Load cell B 2 1 PFVL 101
QGPR 102 (d)
QGPR 102 (c)
Next Change Change Next
QGPR 102 (b)
lc name lc type QGPR 102 (a)
QGPR 104 (d)
QGPR 104 (c)
Next See Table 4-1 QGPR 104 (b)
QGPR 104 (a)
Next

Define
system

Setup Define own lc names 321

object See Table 4-1 Active
Load cell A Drive Side
Setup Load cell B Operator Side

Continue the object

Modify setup with “Next”.

Next

Table 4-1. Load Cell Data to be Entered

Parameter Description
Name Enter an object name. This object name will be shown in the
headline of the operation menus.
Lc name Select sub menu “Change lc name” to change the load cell
names.
Enter a load cell name for each load cell. The names will be
shown in operation menus.
For the load cell names to be displayed, this function must be
activated.
Lc type Select sub menu “Change lc type” to alter the load cell type. A
list of load cells which can be selected is shown.
Load cells QGPR 102/104 exist in four types, depending on
size; a, b, c and d. Check the calibration certificate for the load
cells for correct gain setting.

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Millmate Roll Force Systems with Millmate Controller 400, User Manual
Chapter 4 Commissioning

Table 4-1. Load Cell Data to be Entered

Lc size The nominal load of the load cell in MegaNewton. If more than
one load cell is connected, enter the measuring range for the
individual load cell, not the total.
Lc at port Load cell inputs (port numbers) connected to the object.
No of Lc / port The number of load cells connected to the same input port is
stated here.

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 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section 4.5.11 Setting Force Measurement Parameters

4.5.11 Setting Force Measurement Parameters

This menu is used for defining the measurement parameters. Some sub menus belong to this
main menu.

Measurement parameters 330

Service Name Std1@ABB225
Filter response time 1 ms
Measuring range 40.00 MN
Load unit MegaNewton

Service

Change Change Next

filter unit
Next

Next
Select unit 338
Newton (N)
kiloNewton (kN)
MegaNewton (MN)
Define See Table 4-2 and 4.5.11.2 kiloPond (kp)
(t)
system tons
(lb)
US pound
US Tons (T)
Setup
object Next

Setup

Set filter response time 336

0 - 90%
Modify 1 ms Unfiltered
2 ms
5 ms
See Table 4-2 and 4.5.11.1 12 ms
24 ms
Next 50 ms
100 ms
200 ms
400 ms
Next

Menu 351

Table 4-2. Measurement Parameters to be Defined

Parameter Description
Filter response time The filter response time is set in sub menu 336 “Set filter
response time”. All presentation and indication will be filtered
with the selected filter. The time corresponds to 0-90% step
response.
Load unit The load unit is selected in sub menu “Select unit”.

Note.
1 US ton = 2000 US pound
1 ton (metric) = 2205 US pound

Measuring range The nominal measuring range for the object is stated here.

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Millmate Roll Force Systems with Millmate Controller 400, User Manual
Chapter 4 Commissioning

4.5.11.1 Setting Filter Response Time

Signals can be filtered prior to presentation, to avoid unstable readings.

Use “Select” to select the desired time constant,

Set filter response time 336
Service and exit with “Next” to save the modifications.
0 - 90%
1 ms Unfiltered
2 ms
5 ms All presentations of values are filtered with the
12 ms
Service 24 ms
50 ms
selected time constant.
100 ms
200 ms
400 ms
Next Next
Note!
The filter should be used to avoid anti-aliasing phe-
nomena if MC 400 is connected to a sampling sys-
Next tem without a matching input filter. This is valid for
both analog signals and communication via Profib-
Define us or VIP.
system Tip!
A good compromise is to select an MC 400 filter re-
Setup
sponse time to be 1-2 times the sampling time of a
object
connected unit.
Setup

Modify

Next

Change
filter

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 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section 4.5.11 Setting Force Measurement Parameters

4.5.11.2 Selecting Load Unit

Select unit 338 Use “Select” to mark the desired unit, and exit
Service Newton (N) with “Next”.
kiloNewton (kN)
MegaNewton (MN) Note.
kiloPond (kp)
tons (t) 1 US ton = 2000 US pounds
Service
US pound (lb) 1 ton (metric) = 2205 US pounds
US Tons (T)

Next Next

Next

Define
system

Setup
object

Setup

Modify

Next

Change
unit

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Millmate Roll Force Systems with Millmate Controller 400, User Manual
Chapter 4 Commissioning

4.5.12 Setting Indication Parameters

This menu defines how measurement values are presented. Some sub menus belong to this main
menu.

Indication parameters 351 Setup step detector 353

Service Level detectors Active
1 Not defined Label SD
2 Not defined H1 Step up height 1.0000 MN
3 Not defined D1 Step up time 0.10 s
4 Not defined D2 Step up hold time 0.10 s
Service Analog OUT D3 Step up lock time 0.10 s
1 Fixed value 0V H2 Cut-off offset -0.1000 MN
2 Fixed value 0V D4 Step down hold time 0.10 s
3 Fixed value 0V D5 Step down lock time 0.10 s
4 Fixed value 0V Step counter 0 times
Next Level Analog Step Next Next
detect. OUT detect.

Next See 4.5.12.3

Analog output 355
Port 1 Tot Diff A B
Measurement value
Fixed value
Define See 4.5.12.2 800 ms Filter
system Low High
Measurement 0.00 10.00 MN
Setup Output 0.000 10.000 V
Limit -11.000 11.000 V
object
Volt or Default Default Next
Ampere All AO
Modify

Setup level detector 352

Next Active
Label
Level 0.00 MN
Hysteresis 0.00 MN
See 4.5.12.1 Counter 0 times
Next Digital out port 0 Invert
High Low
Tot Diff A B
Measurement value

Next

Continue the object

setup with “Next”.
See 4.5.8, menu 306 “Pending object setup”.

Parameter Description See section

Level detectors Use “Select” to mark a level detector. Press “Level 4.5.12.1
detect.” to modify settings.
Analog out Use “Select” to mark an analog output port. Press 4.5.12.2
“Analog OUT” to modify settings.

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 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section 4.5.12 Setting Indication Parameters

4.5.12.1 Setting Up Level Detectors

Each object has four level detectors which can be used, for example, as overload protection.

Indication parameters 351 Use “Select” to select the desired level

Level detectors
Service 1 Not defined detector to set-up, and then press “Level de-
2 Not defined
3 Not defined
tect.”.
4 Not defined
Analog OUT
Service
1 Fixed value 0V Level detectors not activated are indicated
2 Fixed value 0V
3 Fixed value 0V with “Not defined”.
4 Fixed value 0V
Next Level Analog Step Next
detect. OUT detect.

Next
Setup level detector 352
Active
Label
Define Level 0.00 MN See Table 4-3.
Hysteresis 0.00 MN
system Counter 0 times
Digital out port 0 Invert
Setup High Low
object Tot Diff A B
Measurement value

Setup Next

Modify
Indication parameters 351
Level detectors
1 LABEL VALUE
Next 2 Not defined
Activated level detectors for the current object
3 Not defined are shown with set level and label.
4 Not defined
Analog OUT
Next 1 Fixed value 0V
2 Fixed value 0V
3 Fixed value 0V
4 Fixed value 0V
Level Analog Step Next
detect. OUT detect.

To menu 306

Example of level detector indications:

Entry 720 MC 400 front panel

Total 50.0 MN
Side A 26.0 MN Run Fault
Syserr Profibus
Side B 24.0 LAN C
Difference 2.0 MN RS-485 RS-232
The level detector Digital OUT
indicates on the set to 1.
DO1 DO5
OVERLOAD DO2 DO6
display when the DO3 DO7
set level is reached. Zero System LC-exc Settings DO4 DO8
set test ON/OFF

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Millmate Roll Force Systems with Millmate Controller 400, User Manual
Chapter 4 Commissioning

Table 4-3. Level Detector Settings

Parameter Description
Label The label is shown on the object operation menu when the set
level for the level detector is reached.
Level Trigger level for the level detector.
Hysteresis Hysteresis for the trigger level.
Digital OUT Enter the desired digital output number (1 - 8), or 0 if no digital
out is used.
Counter Counts the number of times the level detector has been active.
To zero set the counters (max. 4) for one object:
Press “Service”, “Service”, “Next” and “Settings”.
Select object and press “Level detect.”
Press “Zero set” in menu 172 “Level detector counter”.
This command zero sets all displayed level detector counters
for the selected object.
Active / Not active Use “Select” to state if the level detector should be activated or
not. An activated level detector is shown with its label on higher
menu levels, where a not activated level detector is shown as
“Not defined”.
High / Low Use “Select” to state whether the level detector should respond
to high or low level. This affects the hysteresis function.

Load

High
Hysteresis

Time
LD ON LD OFF
Load
LD = Level detector

Hysteresis
Low
Time
LD ON LD OFF

Tot, Diff, A or B Use “Select” to state if the level detector should be connected to
Total (Tot), Difference (Diff), A or B signals. The level detector
for “Diff “ works on the absolute value A – B .

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 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section 4.5.12 Setting Indication Parameters

4.5.12.2 Setting Analog Output

Indication parameters 351 Use “Select” to select desired analog output

Level detectors
Service 1 Not defined port, and then press “Analog OUT”.
2 Not defined
3 Not defined
4 Not defined – Select measurement signal Total tension,
Analog OUT
Service
1 Fixed value 0V Difference, Side A or Side B.
2 Fixed value 0V
3 Fixed value 0V – Select, if a 500 ms filter should be used.
4 Fixed value 0V
Next
– Press “Volt or Ampere” for voltage or current
Level Analog Step Next
detect. OUT detect. output.
– Insert Low and High values on “Measure”
Next and “Output”, see Figure below.
Analog output 355
Port 1 Tot Diff A B – Set output “Limit”, High and Low.
Measurement value
Define Fixed value
system 800 ms Filter Exit with “Next”.
Low High
Setup Measurement 0.00 10.00 MN
Output 0.000 10.000 V
object
Limit -11.000 11.000 V The key “Default” will set up the selected analog
Setup Volt or Default Default Next
Ampere All AO
output according to the table below, depending
on selected signal.
Modify

Next

Next
MR is the Measuring Range choosen on Ten-
sion Parameter menu 330.

The key “Default All AO” will set up all four ana-
Output log outputs according to the table above. This
V/A
only works for a standard object.
High limit
High

Low
Low limit
Low High Measurement value
MN (t, T, lb., kp)

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Millmate Roll Force Systems with Millmate Controller 400, User Manual
Chapter 4 Commissioning

4.5.12.3 Setting Up Step Detector

Indication parameters 351 Use “Select” to select the desired level

Level detectors
Service 1 Not defined detector to set-up, and then press “Step detect.”.
2 Not defined
3 Not defined
4 Not defined Level detectors not activated are indicated
Analog OUT
Service
1 Fixed value 0V with “Not defined”.
2 Fixed value 0V
3 Fixed value 0V
4 Fixed value 0V
Next Level Analog Step Next
detect. OUT detect.

Next
Setup step detector 353
Active See Table 4-4.
Label SD
Define H1 Step up height 1.0000 MN
system D1 Step up time 0.10 s
D2 Step up hold time 0.10 s
D3 Step up lock time 0.10 s
Setup H2 Cut-off offset -0.1000 MN
D4 Step down hold time 0.10 s
object D5 Step down lock time 0.10 s
Step counter 0 times
Setup Next

Modify
Indication parameters 351
Level detectors Activated level detectors for the current object
1 Not defined
Next 2 Not defined
are shown with set level and label.
3 Not defined
4 Not defined
Analog OUT
Next 1 Fixed value 0V
2 Fixed value 0V
3 Fixed value 0V
4 Fixed value 0V
Level Analog Step Next
detect. OUT detect.

To menu 306

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 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section 4.5.12 Setting Indication Parameters

Table 4-4. Step detector Settings

Parameter Description
Label The label is shown on the object operation menu when the set
level for the step detector is reached.
H1 Step up height Trigger level for activating step detector output.

The output of the step detector is activated (SD=ON) when the

sum signal (A+B) for roll force increases more than a set value
(H1) faster than a stated amount of time (D1), and remains on,
or exceeds the achieved level (L1) during a period longer than
(D2). When the signal has accomplished such a step,
deactivation of the step detector is prohibited during a set
amount of time (D3). See also Figure 4-2
D1 Step up time The sum signal has to increase to H1 within the time D1 to
initiate the step detector.
D2 Step up hold For activating step detector output, signal level must remain
time above L1 for the set time period D2.
D3 Step up lock If step detector output is activated, deactivation is prohibited
time during the time D3.
H2 Cut-off offset Deactivation of the step detector output depends on the setting
of H2. If H2 is set as a:
negative value (H2 < 0),
the step detector output is deactivated (SD=OFF) when the
signal level falls below the level L2 = L1 + H2, and remains
below this level during the time interval (D4). Further activation
of the step detector is prohibited during the time interval (D5).
positive value (H2 > 0),
the step detector output is deactivated (SD=OFF) when the
signal level falls below the level H2, and remains below this
level during the time interval (D4). Further activation of the step
detector is prohibited during the time interval (D5).
D4 Step down hold The sum signal has to stay below level L2 for the time D4 to
time deactivate step detector. See also Figure 4-2
D5 Step down lock If step detector output is deactivated, activation is prohibited
time during the time D5.
Step counter The step detector has a counter which counts the combination
of up and down going steps. When both an up and a down
going step have occurred, the counter is incremented by 1. The
counter can count up to 9999 combinations of steps, and can
also be set to zero.
The counter is reset by entering the value zero.
Digital in- and Digital inputs and outputs for step detector are set on digital in-
outputs and output menus, see section 4.5.14.1 and 4.5.14.2

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Millmate Roll Force Systems with Millmate Controller 400, User Manual
Chapter 4 Commissioning

.
Signal level

Signal H2 < 0 H2 > 0

L1 L1 L1
L2 H2 L2
H1
H2

Time Time
D1 D2 D3 D4 D5 D4 D5

SD=ON
SD=OFF SD=OFF

Figure 4-2. Time intervals and levels for adjusting the step detector
An alternative type of step down function of the step detector was introduced in release 3.3-2. It
works as the step detector in the 1986-1988 version of PFVA101 using processor board
PFVK105.
It reacts on fast step down only.
To switch between the standard step detector of PFVA401 and this additional type a negative
sign of D4 is used.

Signal

U1 } h2

Time
}
}

D4 D5 (S)

A step down is detected when the signal has decreased the force H2 in a time less than D4 and
stayed below the value U1 the time D5.
The input parameters at the Step detector meny 351 will have different meaning depending on
the sign in front of D4. Note that the menu will always show the text for the standard step
detector function.
Parameter 3.3-0 logic PFVK105 logic (minus sign on D4)
H2 Cut-off offset/Level Step down height (=h2 in PFVK105)
D4 Step down hold time Step down time (=t3 in PFVK105)
D5 Step down lock time Step down hold time (=t4 in PFVK105)
E.g:
D4= 0.1s ->standard logic with step down hold time of 0.1s
D4= -0.1s -> logic from PFVK105 with a step down time of 0.1s

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 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section 4.5.12 Setting Indication Parameters

4.5.12.4 Object Information

This menu shows some actual object settings.

Object information 305 The settings shown in this menu can be altered
Service or accepted.
Name Std1@ABB225
Application Standard measurement
Lc type PFVL 141 “Modify” changes to the first setup menu for al-
Service Lc size 20.00 MN
Lc at port 1, 2 tering the settings, see Section 4.5.8.1.
Load division 0.05 MN

Next
Detailed settings about inputs, outputs and level
Modify End
detectors will still remain.

Next Load division is the internal resolution that will

be used on fieldbus. It is calculated automatical-
Define ly and depends on the set measuring range.
system
“End” accepts all settings and stores the data.
Setup
object

Setup

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Millmate Roll Force Systems with Millmate Controller 400, User Manual
Chapter 4 Commissioning

4.5.13 Defining a Multi View Object

This is a simplified step by step instruction on how to define a multi view object. Up to 8
measuring objects/rolls can be displayed in one menu.

Setup object 301

Service
1 Std1@ABB203
2 Std2@ABB203
3 Not defined
4 Not defined
Service Multi view
Select “Multi view”.
Not defined See 4.5.13.1
Setup Remove End

Next

Multiview objects 312

Next Name: MultiView5@ABB203 Enter a name of the object.
Std1@ABB203
Std2@ABB203
Select objects to be included.

Define
system
Select Order in Next
Setup MC 400 menu
object

Select MC 400 314 View order in menu 315 Mark the desired
Mark MC 400 that has presentation order
Name: MultiView5@ABB203 Active 1 2 Combined objects
the desired objects. ABB226 Entry x Std1@ABB203
for the multi view
Std2@ABB203
objects in the op-
eration menu.
Search for
Search Next Next
more MC 400. MC 400

Multi view objects 312

Name: MultiView5@ABB203
Std1@ABB203
Std2@ABB203 Select objects to be
ABB226
Entry included.

Select Order in Next

MC 400 menu

Pending object setup 306 Object checked 307

Name MultiView5@ABB203 MultiView5@ABB203
Application Multi view Result SUCCESSFUL
Combined objects Standard 1@ABB203
Standard 2@ABB203
Entry

Modify Discard Check Modify Discard Store

changes object changes

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 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section 4.5.13 Defining a Multi View Object

4.5.13.1 Combined Object Type (Multi View Object)

The figure shows a multi view object, where the measurement results from up to eight
measuring objects in one or more MC 400 control units are presented on the same operation
menu.

Rougher
Rougher 720
Total 38 MN
Side A 20 MN
Side B 18 MN
Difference 2 MN

MC 400 MC 400

A
B

Stand F2
F2 720
Total 6.0 MN
Side A 3.5 MN
Side B 2.5 MN
Difference 1.0 MN
Operation menu for
multi view object

Hot Mill 1 750

MC 400 Rougher 38 MN
F2 6 MN
F3 2 MN
A F4 20 MN
B F5 22 MN
F6 18 MN
F7 24 MN
F8 20 MN
Stand F3
F3 720
Total 2 MN
Side A 1 MN
Side B 1 MN
Difference 0 MN

MC 400

A
B

Figure 4-3. Multi View Object

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Millmate Roll Force Systems with Millmate Controller 400, User Manual
Chapter 4 Commissioning

4.5.14 Configuring Analog and Digital Inputs and Outputs

The control unit is equipped with:
• 2 or 4 analog inputs for load cells and compensating signals
• 4 analog outputs for presenting measured values
• 8 digital inputs for process control
• 8 digital outputs for status indication and alarm signals.
All of these inputs and outputs can be freely configured. Some are configured as standard when
defining certain object types.
See the overview of the menus for analog and digital inputs and outputs on next page.

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 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section 4.5.14 Configuring Analog and Digital Inputs and Outputs

4.5.14.1 Configuring Digital Inputs

Digital & analog I/O 201

Service Setup ports

Digital OUT connection 260
Port Invert Signal Object
1 - -
2 - - Digital OUT connection 262
3 - - Select object
4 - - Std1@ABB225
Service 5 - - Std2@ABB225
Analog Digital End 6 - -
I/O I/O 7 Ready all
8 Sys. error

Menu 200 Signal Select End

Define system list object
Next Next
Digital I/O 205
Setup ports
Digital OUT connection 261
Not active Not active
Next Healthy
ReadyA
Healthy
Ready all
LCEXON Lc exitation
SYSERR Sys.error
Locked Sts. locked
TEST Test mode

Define SIMU Simulation mode

Digital Digital End READY Ready
IN OUT LD1 Level det. 1

system End

Digital IN connection 250

I/O Port Invert Signal Object
See Section 4.5.14.2 1 - -
2 - - Digital IN connection 252
3 - - Select object
4 - - Std1@ABB225
5 - - Std2@ABB225
See Section 4.5.14.1 6 - -
7 - -
8 - -
Signal Select End
list object

End

Analog I/O 203

Digital IN connection 251
Setup ports Not active Not active
EXON Lc exc on
EXOFF Lc exc off
LOCK Lock sys
SYTEST Sys. test
ZS Zero set
SCCA Single cell A
SCCB Single cell B
SDON Step det on
SDOFF Step det off
Analog Analog End
IN OUT End

Analog output 240

Port
1 Std1@ABB225 0-10 V
Side A Analog output 242
2 Std1@ABB225 0-10 V Select object
See Section 4.5.14.4 Side B Std1@ABB225
3 Fixed value 0V Std2@ABB225

4 Fixed value 0V

Change Select End

output object

End

Analog output 241

Port 1 Tot Diff A B
Std2@ABB225
Measurement value
Fixed value
800 ms Filter
Low High
Measurement 0.00 10.00 MN
Output 0.000 10.000 V
Limit 0.000 10.000 V
Volt or Default Next
Ampere

Analog IN ports 230

Port NoOf LC type LC size
1 1 PFVL 141 20 MN Analog IN load cell 231
See Section 4.5.14.3 2 1 PFVL 141 20 MN
Port 1
PFVL 141
3 - Not connected - PFVL 101
4 - Not connected - QGPR 102 (d)
QGPR 102 (c)
QGPR 102 (b)
QGPR 102 (a)
QGPR 104 (d)
Change End QGPR 104 (c)
QGPR 104 (b)
LC type QGPR 104 (a)
End

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Millmate Roll Force Systems with Millmate Controller 400, User Manual
Chapter 4 Commissioning

The eight digital inputs can be configured for a number of signals in the control unit.
See Table 4-5.

Digital I/O 205

Service
Setup ports

Service
Digital Digital End
IN OUT

Next Enter the function to be executed when

the selected input port is activated.
Digital IN connection 250
Port Invert Signal Object – The selected digital input port is dis-
Next 1 Zero set Inlet
2
connected if “Signal” is set to “-”.
- -
3 - - – The input function can be inverted
4 - -
Define 5 - - by marking the “Invert” column.
system 6 - -
7 - - Return to the main menu and save the
8 - -
I/O modifications with “End”.
Signal Select End
list object

Digital
I/O

Digital IN connection 252

Select object
Std1@ABB225
Std2@ABB225 Select the object that the signal belongs
to. For signal types that control the entire
control unit, the object name doesn’t
matter.
End

Digital IN connection 251

Not active Not active
EXON Lc exc on
EXOFF Lc exc off
LOCK Lock sys
SYTEST Sys. test
ZS Zero set
Select desired input signal to be con-
SCCA
SCCB
Single cell A
Single cell B
nected to the digital input port.
SDON Step det on
SDOFF Step det off “Not active” disconnects the input port,
End selected in menu 250.

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 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section 4.5.14 Configuring Analog and Digital Inputs and Outputs

Table 4-5. Functions That Can Be Activated by Digital Input Signals

Signal name Description

Not active Used to disconnect an input port
EXON Switch on load cell excitation
EXOFF Switch off load cell excitation
LOCK Lock System
SYTEST Start System test
ZS Zero set
SCCA Change to Single Cell Operation with load cell A
SCCB Change to Single Cell Operation with load cell B
SDON Set stepdetector
SDOFF Reset stepdetector

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Millmate Roll Force Systems with Millmate Controller 400, User Manual
Chapter 4 Commissioning

4.5.14.2 Configuring Digital Outputs

The eight digital outputs can be configured for a number of signals in the control unit.
See Table 4-6.

Service Digital I/O 205

Enter the function to be executed when
Setup ports
the selected output port is activated.

Service – Output 7 is preset to the signal

“Ready all”.
Digital Digital End
IN OUT – Output 8 is preset to the signal
Next “sys.error (System error)”.
– Outputs 7 and 8 can be changed to
Digital OUT connection 260 other functions.
Next Port Invert Signal Object
1 - - – The selected digital output port is
2 - -
3 - -
disconnected if “Signal” is set to “-”.
Define 4 - - – The output function can be inverted
system 5 - -
6 - - by marking the “Invert” column.
7 Ready all
I/O 8 Sys. error – Non-inverted outputs are closed
Signal Select End when activated.
list object
Digital Return to the main menu and save the
I/O modifications with “End”.

Digital OUT connection 262

Select object Select the object that the signal be-
Std1@ABB225 longs to. For signals that belong to the
Std2@ABB225
entire control unit, the object name
doesn’t matter.

Next

Digital OUT connection 261

Not active Not active
Healthy Healthy
Select desired output signal to be con-
ReadyA
LCEXON
Ready all
Lc exitation
nected to the digital output port.
SYSERR Sys.error
Locked Sts. locked “Not active” disconnects the output
TEST Test mode
SIMU Simulation mode port, selected in menu 260.
READY Ready
LD1 Level det. 1

End

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 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section 4.5.14 Configuring Analog and Digital Inputs and Outputs

Table 4-6. Functions on Digital Outputs

Signal name Description

Not active Disconnects the output port, selected in menu 260.
Healthy No unconfirmed system errors in system.
ReadyA* All objects in the control unit are working.
LCEXON Load cell excitation is working.
SYSERR A system error has been detected.
Locked System is locked by input “Lock system”.
TEST System test is now running.
SIMU System is running in Simulation Mode.
VIP_Est VIP link is established
READY One per object. Object is working.
LD 1-4 Four per object. Outputs for level detectors 1-4.
SD Output for step detector.
SC One per object. The object is running in Single cell A or
B mode.
SCA One per object. Object is running in Single cell A mode.
SCB One per object. Object is running in Single cell B mode.

* ReadyA is recommended output for indication of working system.

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Millmate Roll Force Systems with Millmate Controller 400, User Manual
Chapter 4 Commissioning

4.5.14.3 Configuring Analog Inputs

This menu is normally only used for disconnection of load cells. Setup and changing of load
cells should be done via Defining a measuring object, Section 4.5.8.

Analog I/O 203

Service
Setup ports

Service
Analog Analog End
IN OUT

Next

Analog IN ports 230

Next Port NoOf Lc type Lc size Change number of load cells and load
1 1 PFVL 141 20 MN cell size with “No Of” and “Lc size”.
2 1 PFVL 141 20 MN
3 - Not connected -
Define 4 - Not connected -
system To change load cell type, select “Port”
and press “Change Lc type”.
I/O
Change End
lc type
Press “End” to save the settings.
Analog
I/O
Analog IN load cell 231
Port 1
PFVL 141
PFVL 101
QGPR 102 (d)
QGPR 102 (c) Select load cell type and press “Next”.
QGPR 102 (b)
QGPR 102 (a)
QGPR 104 (d)
QGPR 104 (c)
QGPR 104 (b)
QGPR 104 (a)
Next

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 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section 4.5.14 Configuring Analog and Digital Inputs and Outputs

4.5.14.4 Configuring Analog Outputs

Analog I/O 203

Service
Setup ports

Service
Analog Analog End
IN OUT

Next

Analog output 240

Next Port Select port.
1 Std1@ABB225 0-10 V
Side A Press “Change output” or
2 Std1@ABB225 0-10 V “Select object”.
Define Side B
3 Fixed value 0V
system
4 Fixed value 0V
I/O
Change Select End
output object

Analog Press “End” to save the settings.

I/O
Analog output 242
Select object
Std1@ABB225 Select object.
Std2@ABB225

Next

Analog output 241

Port 1 Tot Diff A B
Std1@ABB225
Measurement value Setting up analog output, see Section
Fixed value
4.5.12.2.
800 ms Filter
Low High
Measurement 0.00 10.00 MN
Output 0.000 10.000 V
Limit 0.000 10.000 V
Volt or Default Next
Ampere

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Millmate Roll Force Systems with Millmate Controller 400, User Manual
Chapter 4 Commissioning

4.5.15 Setting Up External Communication

External communication is made via Ethernet LAN, serial ports or on a fieldbus.
The following external communications can be used:
• Ethernet LAN (see Section 4.5.16)
• Profibus (see Section 4.5.17)
• VIP (Vendor Internet Protocol) (see Section 4.5.18)
• Serial ports (see Section 4.5.19)
– External display (see Section 4.5.19.1)
– Serial communication (see Section 4.5.19.2)
– Printer, no further settings necessary
– Console, no further settings necessary

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 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section 4.5.16 Setting Up Ethernet LAN

4.5.16 Setting Up Ethernet LAN

Ethernet LAN is mainly used for communication between the control unit and the operator unit.
However, it can also be used for communication with a superior control system using VIP.

Press “End” to store the changed address.

Net addresses 122
Service
IP address 172.16.1.225 An altered address does not become valid until
Subnet mask ffff0000
Gateway address 172.16.1.1 a restart is performed. Carry on with other alter-
Ethernet address 0000230001E1 ations before a restart is performed using the
Service
New IP address mains switch.
New subnet mask
New gateway address The Ethernet address cannot be changed.
Next Apply End

Note
Next Double-check that the correct IP address has
been entered before pressing “End”. It will be
impossible to get contact with the control unit if
Comm.
the two first parts of the address are incorrect.
setup

LAN
Default values are:
IP address: 172.16.x.y (x and y are between 1
and 255 and y is decimal value from the two last
digits from the hexadecimal value of the Ether-
net address).
NOTE
The IP-address is included in the startup message Subnet mask:ffff0000
from port RS232:1. But only If this port is
set up as “Printer”, the default setting. It is sent Gateway address: 172.16.1.1
with 9600 Baus, 8 databits, No parity, 1 stop bit.

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Chapter 4 Commissioning

4.5.17 Setting Up Profibus

Communication 120
Service Setup
Local area network,
Serial port or
FieldBus
Service

Next LAN Serial Fieldbus End

ports

Next
Fieldbuses 121
Comm. Profibus Active - 123
Address

setup Vip Active

IP address 172.16.1.50
Port 5001
Send id 1
Receive id 2
Time out 1000

Profibus VIP ... End

Profibus 270
None Profibus Address 123 Enter unit Address.
Output Object Signal
1 Entry Load cell A
2 Entry Load cell B
3 Not defined -
4 Not defined -
Input
1 Not defined -
2 Not defined -

Input Output Signal End

Boolean Boolean values

Select value

Set up Booleans Set up Booleans Signal values 271

from PLC to MC 400. to PLC from MC 400.
Measurement value Tot. Diff. A B C D
Use the menus for digital inputs. Use the menus for digital outputs. Entry

See 4.5.14.1. See 4.5.14.2.

End

Valid GSD-file can be dumped from MC 400 directly. See Section 4.5.29.2.
For more information about Profibus, see Appendix B Profibus-DP Fieldbus Communication.

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 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section 4.5.18 Setting up Vendor Internet Protocol (VIP)

4.5.18 Setting up Vendor Internet Protocol (VIP)

Communication 120
Service Setup
Local area network (LAN),
Serial port or
Fieldbus
Service

Next LAN Serial Fieldbus End

ports

Next
IP address is the IP address of
Fieldbuses 121 the PLC.
Comm. Profibus Not active - -

setup Vip Active Port is the TCP port number.

IP address 172.16.1.50
Port 5001
Send id 1
Receive id 2 Send id and Receive id
Time out 1000 are id-numbers for the
Profibus VIP ... End VIP-message (telegram).

Time out is set in ms.

Vip interface 290
Output
1 Std1@ABB225 Load cell A
2 Std1@ABB225 Load cell B
3 Std2@ABB225 Load cell A
4 Std2@ABB225 Load cell B
Input Object Signal
–
–
–
–
Apply ... ... End

Read more about VIP in Appendix A Vendor Internet Protocol (VIP)

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Millmate Roll Force Systems with Millmate Controller 400, User Manual
Chapter 4 Commissioning

4.5.19 Setting Up Serial Ports

Serial ports are mainly used for presenting measuring values on external displays and printers.
They can also be used for communication with a superior system.
The desired serial port is chosen in the menu “Select serial ports” by pressing “Select”. The sub
menu for setting up the communication parameters is then accessed by pressing “Setup port”.
Selecting the unit to connect to, including the protocol to be used, is accessed by pressing
“Change device”.

Setup serial ports 280

Service
Serial ports Device
RS232:1 Printer
RS232:2 Serial comm.
RS485 -
Service

Next Change Setup Setup End

device device port

Next Setup port 283

RS232:1
Baud rate 9600
Data bits 7
Comm. 8
setup Parity No parity
Odd parity
Even parity
Serial Stop bits 1
2
ports
Apply End

Change device 281

RS232:1
None
External display
Printer
Console
Serial comm.
Note.
“Setup device”
is valid only for Setup End
device
“External display”

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 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section 4.5.19 Setting Up Serial Ports

4.5.19.1 Setting Up External Display

Setup serial ports 280

Service
Serial port Device
RS232:1 Printer
RS232:2 Serial comm.
RS485 -
Service

Next Change Setup Setup End

device device port

Next
Change device 281
RS232:1
Comm. None
Printer
setup
External display
Console
Serial Serial comm.
ports
Setup End
device

Note.
Setup device 282
“Setup device”
Display type QDIL 410/430/450 5d
is valid only for Addressing mode
“External display” Leading zeroes
Object / Signal Tot Diff A B C D
Object name 1
Object name 2
Object name 3
Object name 4
Protocols for External Displays Setup End
(QDIL 410/420/430/440/450) display
NOTE: Select QDIL 450 for QDIL 451
Protocol in: Setup display 284
- Unaddressed mode: <STX>VALUE<ETX> Digits
4 5 6
- Addressed mode: <STX> ADDRESS VALUE<ETX> QDIL 410/430/450
QDIL 420/440

Example: Total (tension) is 0.346 kN for Object 1

(Total for object 1 has address 05, see Table 4-7)
Unaddressed mode: <STX>0.346<ETX> Setup End
port
Addressed mode: <STX> 050.346<ETX>

Setting decimal point for QDIL 410/430/450: Setup port 285

RS232:1
The decimal point is transmitted. Baud rate 1200
Data bits 7
The position of the decimal point is determined by the 8
setting of the load division in menu 306, see Section 4.5.8 Parity Even
Odd
Setting decimal point for external display QDIL 420/440: None
Stop bits 1
QDIL 420/440 has a fixed decimal point. 2
A yellow-colored tape has to be attached in the position Default End

for the decimal point.

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Millmate Roll Force Systems with Millmate Controller 400, User Manual
Chapter 4 Commissioning

Table 4-7. Addresses with Corresponding Displayed Values

Address (1) Value

01 Value A for object 1
02 Value B for object 1
03 Value C for object 1
04 Value D for object 1
05 Total for object 1
06 Difference for object 1
07 Value A for object 2
08 Value B for object 2
09 Value C for object 2
10 Value D for object 2
11 Total for object 2
12 Difference for object 2
13 Value A for object 3
14 Value B for object 3
15 Value C for object 3
16 Value D for object 3
17 Total for object 3
18 Difference for object 3
19 Value A for object 4
20 Value B for object 4
21 Value C for object 4
22 Value D for object 4
23 Total for object 4
24 Difference for object 4
(1) The addresses are fixed and sent as two figures.

4.5.19.2 Setting up Serial Communication

This function is intended for communication with superior computers via RS-232.
Data can be read in MC 400 and commands and parameters can be set.
All exchange is made through the internal data base in MC 400.
Syntax:

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 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section 4.5.19 Setting Up Serial Ports

?XX.YY <CR> Read data XX.YY

!XX.YYV123 <CR> Send value 123 to data XX.YY
XX.YY is the address in MC 400 data base
Contact ABB for further information of the data base.

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Millmate Roll Force Systems with Millmate Controller 400, User Manual
Chapter 4 Commissioning

4.5.20 Switching On Load Cell Excitation

Load cell excitation 119 Switch on the load cell excitation

Service
by pressing “YES”.
Verify excitation ON

Service

Lc exc YES NO
ON/OFF

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 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section 4.5.21 Adjusting Load Cell Excitation

4.5.21 Adjusting Load Cell Excitation

Power range has to be selected for optimum operation of the excitation unit PFVI 401.
Start values:

Number of load cells Load cell size, Fnom Cable length Power range
1 x x 1
2 35 MN 2x10 m 2
2 > 35 MN x 3*
2 x > 2x10 m 3*
3 or 4 x x 3*
* For operation in Power range 3, additional phase compensation should be
performed, see Section 4.5.21.2.

4.5.21.1 Checking of Load Cell Excitation in PFVI 401

Check load cell exc. 164 – If “Excitation level” with both load cell sections
Service Excitation level 138 V selected is between 80 and 140 V, no further
Power range 2 adjustment is necessary.
Load cell excitation on – Changing of Power range is done by entering
Service
a new range (1, 2 or 3) and pressing “Apply”.
Excitation, 1st Lc sect On
Excitation, 2nd Lc sect On
The excitation level corresponds to the internal
Next Apply Change Lc exc End
section ON/OFF voltage “UR”, see Section 3.8.1.

Check
Excitation of lc sect 166
I/O
Excitation, 1st Lc sect On
First load cell section (1st Lc sect): Excitation
Check Excitation, 2nd Lc sect On circuit connected to X4, terminals 1-2.
lc-exc
Second load cell section (2nd Lc sect): Excitation
circuit connected to X4, terminals 3-4.
End

As low power range as possible is preferred as it gives lower power losses in the excitation unit.
The excitation level should not exceed 150 V.
Additional phase compensation is introduced in the load cell excitation circuit by connecting the
additional capacitor C2 of 3 F in series with the capacitor C1 of 1 F in the PFVO 142
matching unit.
In the PFVO 143 matching unit the capacitor C3 of 3 F is connected in series with the
capacitors C1 and C2.
Phase compensation should be adjusted for minimum excitation level.

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Chapter 4 Commissioning

4.5.21.2 Procedure for Phase Compensation

Turn on load cell excitation

Power range = 3, All load cells connected Lc sect = Load cell section

Over voltage No
Alarm?

Yes

Disconnect
2nd Lc sect.

No Over voltage Over voltage No

Alarm? Alarm?
Yes Yes

Check load cell

cabling.

Add phase compensation Add phase compensation Add phase compensation

in one matching unit in one matching unit in one matching unit.
in 1st Lc sect. in 2nd Lc sect.

Is new Is new No Is new

No No
excitation level excitation level excitation level
lower? lower? lower?
Yes Yes Yes

Is there a Add phase

Is there a
No No second matching unit compensation
second matching unit
unit in 2nd Lc sect? in one more
unit in 1st Lc sect?
matching unit.

Yes Yes
Add phase compensation Add phase compensation
in 2nd matching unit in 2nd matching unit
Disconnect latest
in 1st Lc sect. in 2nd Lc sect.
added phase
compensation.
Is new Is new
No No
excitation level excitation level
lower? lower? Is
No
Yes Disconnect latest Yes Disconnect latest excitation level
added phase added phase <80 V?
compensation. compensation.
Yes

Change to
Connect 2nd Lc sect and Connect both Lc-sections.
Power range 2
disconnect 1st Lc sect.

End

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 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section 4.5.22 Adjusting Phase Matching Board PFBK 401

4.5.22 Adjusting Phase Matching Board PFBK 401

Phase Matching Board PFBK 401 is used to compensate the inductance in large QGPR 102/104
load cells only. It consists of an adjustable capacitor, that is connected in series with the load
cells. Normally the board is factory adjusted and no further adjustment should be necessary.
The capacitance is adjusted by changing jumpers on S1, see Table 4-8.

Table 4-8. Adjusting Phase Matching Board PFBK 401

S1
Capacitor value 1-2 3-4 5-6 7-8
16 F - - X X
24 F X - - X
32 F X X - -

Adjust the capacitor value based on the excitation level presented in menu 164, “Check load cell
excitation”. Use the following procedure:

Check load cell exc. 164

Service Excitation level 138 V – If “Excitation level” with both load cell sec-
Power range 2 tions selected is less than 40 V, no further
Load cell excitation on adjustment is necessary.
Service
Excitation, 1st Lc sect On
– Adjust capacitance by means of S1 to min-
Excitation, 2nd Lc sect On imize excitation level. Levels up to 50 V are
acceptable.
Next Apply Change Lc exc End
section ON/OFF – If no matching can be achieved, the sec-
tion impedance is too high.
Check Check load cell sections separately:
I/O
First load cell section (1st Lc sect).
Excitation of lc sect 166
Check
Excitation should be able to work with only
lc-exc Excitation, 1st Lc sect On section 1, regardless of the S1 position. If
Excitation, 2nd Lc sect On
not, check cables and resistance.
Second load cell section (2nd Lc sect).
Excitation should be able to work with only
section 2. Compensation capacitor is not
End
in use when section 2 only is run.

Resistance between X2:1 and 8 on

PFBK 401 must be less than 6 ohms. Re-
sistance can be measured if load cell exci-
tation is switched off.

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Millmate Roll Force Systems with Millmate Controller 400, User Manual
Chapter 4 Commissioning

4.5.23 Simulate Load Cells

This function is used at commissioning to simulate load cell signals for:
• checking indication outputs
• checking signal transfer to superior systems.

Press “Simulate lc”.

Check IO 160
Service
ABB225
Date 12 jan 2004, 14:15 By pressing “Default” the following load val-
ues are simulated and the text “Simulation in
Load cell excitation on
Service progress” is displayed:
Port 1: 52.5% of capacity
Next Simulate Set Check End
Port 2: 47.5%
lc DI/DO lc-exc
Port 3: 38.0%
Check Port 4: 42.0%
I/O Capacity (total nominal load per port)
Simulate load cells 161
Port Lc type Capacity Value = Number of load cells per port × nominal
1 PFVL 141 20.00 MN 15.25 MN
2 PFCL 411 20.00 MN 15.75 MN
load cell size.
3 Not connected
4 Not connected
Lc exc on If the port is a DC-input, total nominal load is
Process values
equal to 10 V DC. The default value is 50%
Change Default Reset End (5 V) for all ports.
value

Press “Change value” to go to menu 162

Simulate load cells 161 where other values can be set for simulation.
Port Lc type Capacity Value
1 PFVL 141 20.00 MN 10.50 MN
Simulated default values 2 PFVL 141 20.00 MN 9.50 MN
3 Not connected Set simulated values (in this case 8.50 MN).
(port 1 = 10.50 MN = 52.5%) 4 Not connected
(port 2 = 9.50 MN = 47.5%) Lc exc on
Simulation in progress By pressing “Apply” the set values are activat-
Change Default Reset End ed and the text “Simulation in progress” is dis-
value
played.
Terminate simulation, without leaving the
Simulate load cells 162 menu, by pressing “Reset”.
Port Lc type Capacity Value Terminate simulation and return to menu 160
1 PFVL 141 20.00 MN 8.50 MN
2 PFVL 141 20.00 MN 8.50 MN
by pressing “End”.
3 Not connected
4 Not connected
After 30 minutes the text “Time out” is shown,
Lc exc on if simulation has not been terminated.
Values simulated
Simulation in progress
by using “Apply”
Apply Default Reset End

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 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section 4.5.24 Performing Manual Sensitivity Adjustment

4.5.24 Performing Manual Sensitivity Adjustment

Trim factors 220

Service
1 Rougher
2 1. Select object to be adjusted.
3
Service 4

Next Manual Zero End

2. Press “Manual trim”.
trim adjust
3. Enter an adjustment factor, e.g. 1.0013,
Next Manual trim 222 if the presented value should be in-
Rougher creased by 0.13%. Press “Apply”.
Trim factor Corr. fact
Total value 1.000 1.000
If all inputs are to be changed, enter the
Define
Balance value for total.
system Load cell A 1.000 1.000
Load cell B 1.000 1.000 If the balance of the load cells are to be
Trim changed, enter the value for one of the
sensit. Apply Factory End load cells. In this case the total sensitivity
calib.
will be kept, only the relation between the
load cells will be affected.
Factory values 229
Example: Load cell A should be 2% larger
Rougher than Load cell B. Enter 1.02 for A and
press “Apply”. The trim factor for A will
Verify
now be 1.01 and for B 0.99.
4. The factory setting of the calibration value
can be restored by pressing “Factory
YES NO
calib.”.
5. Exit with “End”.

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Chapter 4 Commissioning

4.5.25 Performing Zero Adjustment

Trim factors 220

Service
1 Rougher
2 1. Select object to be adjusted.
3
Service 4

Next Zero End

2. Press “Zero adjust”.
adjust

Next Zero adjust 223

Rougher
Present offset Set value
Load cell A -1,23 0.00 MN 3. Enter new zero values, one for each load
Define Load cell B -2,21 0.00 MN cell. If the load cells are preloaded with a
system
force, this force should be entered here.
Trim 4. Press “Apply” to make entered values ac-
sensit. Apply Zero Exit tive.
set
5. Press “Exit” to leave the menu without
more changes.

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 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section 4.5.26 Selecting a Start Object for the Operator Unit

4.5.26 Selecting a Start Object for the Operator Unit

The operator unit can be set to start with a predefined object at power on.
The object to be selected must be defined in a control unit within the same network as the
operator unit.
Press Controllers

A list control units and objects to control units is displayed.

The “Start up” function sets an object of a control unit as a start up menu at power on.
To set an object as start up menu:
• Press “Startup” at the object. The text “Startup” now becomes bold.

To remove an object from the start up menu:

• Slide the toggle switch “In list” to the left and press “Apply”.

Object as Start menu

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Millmate Roll Force Systems with Millmate Controller 400, User Manual
Chapter 4 Commissioning

4.5.27 Performing a System Reference Test (Self Test)

The Roll Force System must be tested at commissioning, and the test result must be stored, in
order to be used for comparing later test results.
When a load cell is replaced, a system test must be carried out in order to store the new load cell
data.
It is highly recommended that the Self Test is performed on a regular basis as preventive
maintenance. Regular Self Tests reduces downtime in cases of fault tracing and are able to
indicate future errors and bottlenecks in the system before they will have a negative effect on
the measurement performance. A Self Test will also provide a good view of the overall health of
the system, with its 64 testpoints.

4.5.27.1 Starting the Self Test

System test 140 1. Press “Run tests” to start the system

Service
Start sequence or do test manually
test. It takes approximately 20 sec-
onds.
Reference never saved
“Reference never saved” means that
Service
no previous test result has been saved.

System Run Manual Save as End

tests test ref. “Result SUCCESSFUL” is shown when
test
the system test is completed, provided
no errors are detected.
System test running 141
“Result FAILURE” means that an error
Test sequence running has been detected during the system
Test 12 of 64 completed
test.
If an error is detected, the error is
shown.
To display the errors, press “Service”
Stop
test twice and then “Error inspect”.
2. If a printer is connected to the system,
the test results can be printed out by
System test finished 143
pressing “Print result”.
3. Store approved test results as
Test 64 of 64 completed.
Result SUCCESSFUL reference values by using
“Save as ref.” in the main menu (140).
Any faulty test results must be
Run Print Error End corrected. See 4.5.27.2.
tests result inspect

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Section 4.5.28 Setting Up System Lock

4.5.27.2 System Test Errors

When the system test is performed for the first time with a new control unit the test values from
the actual installation will be compared with default values set in factory tests. Some of the test
values can differ from the default values. If the test values and the default values are not the
same the system test will not be approved. Tests resulting in an error message must be
performed with a manual test (see Section 7.6.2) and then evaluated to see if the test values
seem to be correct.
If the test values seem to be correct they must be stored using the function “Save as ref.” Future
system test values will be compared with previously approved and saved reference values and
this test procedure ensures reliable fault detection.

4.5.28 Setting Up System Lock

System lock is a function, that when active, blocks all commands on the system to guarantee a
safe system.
System lock is controlled by a digital signal “Lock sys”.
When system lock is activated, the system generates a message “System locked”, that is
displayed in operation menus.
The message “System locked” remains until the digital signal “Lock sys” is deactivated.
An attempt to use a blocked command generates an error message,
“ERROR 501 System locked”, that is displayed in the actual menu.
Ongoing system tests and simulations will be interrupted, if system lock is activated, and the
system automatically switches back to the operation menu or service menu where the action was
started.
How to set up a digital input for “Lock sys” is described in Section 4.5.14.1.
A digital output can be used to indicate that the system is locked, see Section 4.5.14.2.

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Chapter 4 Commissioning

4.5.29 Printing Out Data

MC 400 can send out some internal data on a serial port as ASCII-strings for external use, for
example to a PC or a printer. The same data can also be viewed in a web browser. See Section
7.6.2.
Data that can be sent out is:
• A complete list of the valid setup information in MC 400 See Section 4.5.29.1
• GSD-file for Profibus use See Section 4.5.29.2
• System test results. See Section 4.5.29.3

Use “Select” to choose type of print-out.

Print out data 118
Service
Setup For printing out system test results:
Profibus GSD file
One test Test no 1 Select “One test” and insert “Test no”.
Service
All tests Current Reference or
“All tests”
Next
Print to Print to ... End Select “Current” to print latest test results
RS232 Browser or
Next
Select “Reference” to print saved reference
test.
MC400 Not shown on
PXAH411
data Press “Print”.
Print
data Exit with “End”.

Note.
The selection “Reference” is available, when the
reference test has been saved the first time.

All data are sent as plain ASCII-text and can be handled in a terminal program as a text file for
later processing.
Serial port RS-232:1 (X26) is set up as default printer port, with 9600 Baud, 8 data bits, no
parity and 1 stop bit. No handshake is used.
For connection to a PC a standard crossed RS-232 cable (“Null modem cable”) should be used.

NOTE
Line ends are sent as <CR> (ASCII 0D16) only and some terminal programs work
better if they are set up to add <LF> (ASCII 0A16) to incoming <CR>.

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Section 4.5.29 Printing Out Data

4.5.29.1 Printing Out Setup Information

A complete list of all setup information in MC 400 is sent. See example below:

4.5.29.2 Printing Out Profibus GSD-file

The valid GSD-file for MC 400 is sent out and can directly be imported to the Profibus Master
in use.

4.5.29.3 Printing Out System Test Results

Select “One test” and insert test number to print out all data of a specific system test.
Select “All tests” to get a table including all test results.
Select “Current” to have the latest test results
or select “Reference” to have values from the saved reference test.

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Chapter 4 Commissioning

4.5.30 Setting up Load and Dump

To load or dump complete object setups in MC 400 you can use a web browser run on a
personal computer (PC) or similar. See Section 5.7.2 for instructions on how to setup the
communication.
The following menu is presented:

201

ABB201
Language

Figure 4-4. Start Page in Millmate Controller 400

4.5.30.1 Saving a Backup Copy (Dump) of a Complete Object Setup

To save a backup copy of the complete object setup for one object, do the following:
• Open the start page in MC 400 as described in Section 4.5.30

201

ABB201
Language

• Click “Backup” to go to the next menu.

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Section 4.5.30 Setting up Load and Dump

• Select object and click “Show” to display the complete object setup.

• Store a backup copy of the complete object setup (for example, use the Internet Explorer
command “Save as”).
• Click “End”.

4.5.30.2 Loading a Complete Object Setup

The complete object setup for one object at a time can be loaded. Do as follows:
• Open the start page in MC 400 as described in Section 4.5.30.
201

ABB201
Language

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Chapter 4 Commissioning

• Click “Backup” to go to the next menu.

• Select type of application (Roll Force Meter) and object and click “Store”.

• Open your earlier stored html file, (for example,

use the Internet Explorer command “Open”).

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Section 4.5.30 Setting up Load and Dump

The complete object setup to be loaded is displayed.

• Scroll down to the end of the object list.

• Change to the correct IP address (172.16.1.201) for this MC 400.
• Click “Store” to load the complete object setup for Rougher.

This menu appears when the object (Rougher) is loaded successfully.

Otherwise an error message is displayed near the bottom of the menu.
• Click “End”.

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Chapter 4 Commissioning

4.5.31 Removing An Object

Setup object 301 1. Use “Select” and then “Setup” to select the
Service object to remove.
1 Rougher
2 Not defined
3 Not defined
4 Not defined
Service Multi view
Not defined

Next Setup Remove End

Next
Object remove 302 2. Verify the removal of the object.

Define Rougher
NOTE
system Verify Detailed settings about inputs and outputs
Setup will still remain.
object To remove all settings, see Section 4.5.32.
Remove NO

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Section 4.5.32 Removing All Setup

4.5.32 Removing All Setup

Service menu 3 113

Service ABB225 All setup data in the control unit can be removed.
Date 12 Jan 2004, 12:00
Serial number SE9808A123 Only the IP address and the MC 400 label will re-
Software release 3.2-2
Software type
Options
MC400 R
4 load cell ports main.
Service Profibus

Define Comm. MC400 Next

system setup data
Next Press “MC 400 data”.
MC400 data 115

MC400 label ABB225

Next Date 12 jan 2004, 12:00
Latest startup 12 jan 2004, 10:18
Language GB
SE
User defined

Set Data End

time base Press “Data base”.
Data base service 117
ABB225
Date 12 jan 2004, 12:00
Latest startup 12 jan 2004, 10:18
Serial number
Software release 3.2-2
Software type MC400 R
Options 4 load cell ports
Profibus
Value ***

Insp. Local ABB End

DB DB setup Press “Insp. DB”.

Inspect database 135

Database version 3.2-3.0
Block 0
Field 0
Value
Text
Integer
Float
Boolean
Press “Init flash” (Clear memory).
Init Set Get End
flash value value

Clear memory 138 Press “YES” to verify.

Verify
The unit will clear the memory and restart the program.
It will take several seconds and communication with the
operator unit will be lost.
YES NO Check indications on control unit MC 400:
When the clearing function is going on, indication “Run”
is switched OFF and indications “Fault”, “Syserr”, “LAN”
Wait for.... 139
and “Profibus are switched ON.
Clearing the memory
When clearing is finished, “Run” is switched ON and
and
the restart “Fault”, “Syserr”, “LAN” and “Profibus” are switched
OFF.
Check that “Run” is ON (lit).
MC 400
service Press “MC 400 service” to continue.

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Chapter 4 Commissioning

4.6 Commissioning Optional Units

4.6.1 Insulation Amplifier PXUB 201

The insulation amplifier is normally connected to one of the outputs of the control unit.
S1 is normally set for voltage 1:1 ratio.
The output is selected to generate a voltage or current output by means of switch S1 and S2.
Slower response is selected by means of switch S2, position 3.
The switches are located inside the unit.

Pull out the top lid,

after you released
the snap-locks.
Top lid

S2
ON

1 2 3

Snap-lock Snap-lock

S1
ON

1 2 3

To release Spring lock

Figure 4-5. Location of Switches on the Insulation Amplifier Board

You must open the insulation amplifier to be able to set the switches S1 and S2.
1. Demount the insulation amplifier from the DIN rail.
Use a screw driver to unload the spring at the bottom of the insulation amplifier.
2. Press down the snap-locks on both sides of the insulation amplifier.
3. Pull the top lid open, until you see both the switches S1 and S2.
4. Set the switches S1 and S2.
5. Slide back the top lid to locked position.
6. Remount the insulation amplifier on the DIN rail.

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Section 4.6.1 Insulation Amplifier PXUB 201

PXUB 201
3 Output: 0 to ± 10 V
Signal +
0V 4 - Input: 0 to ± 10 V
5
7 +
+ S1 S2
+24 V
0V 8 - – 6
ON ON

1 2 3 1 2 3

Earth

PXUB 201 Output: 4 to 20 mA

3 5 Input: 0 to 10 V
Signal + +
0V 4 -
S1 S2
6
7 – ON ON

+24 V + 1 2 3 1 2 3
0V 8 -
Earth

Figure 4-6. Typical Connection of the Insulation Amplifier

Table 4-9. Setting of Input and Output Range

Range S1 S2
Default
Input Output 1 2 3 1 2 3

× 0 to ±10 V 0 to ±10 V × ×

0 to 5 V 4 to 20 mA ×

0 to 10 V 4 to 20 mA ×

0 to 5 V 0 to 20 mA × ×

0 to 10 V 0 to 20 mA ×

0 to ±10 V 0 to ±20 mA x

Table 4-10. Setting of Bandwidth

S2, position 3
Default Bandwidth
(× = ON)

× 10 kHz

10 Hz ×

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Chapter 4 Commissioning

4.6.2 Media Converter PXUB 231

The Media Converter PXUB 231 is used to connect local MC 400 10Base2 Ethernet network to
external 10Base-T network.

Table 4-11. Switches

Switch Position Usage

 Standard
• For external termination
Internal Termination Switch
50  Internal termination
Standard
• Straight cable to hub, switch
or router
• Cross-over cable to PC
Uplink (Cross-over) Switch
• Cross-over cable to hub,
switch or router
• Straight cable to PC

PWR

Link / L / LK

Figure 4-7. PXUB 231, Switches and Indicators

Table 4-12. Indicators

Indicator Function
PWR (Power) Indicates power applied
Link / L / LK Indicates proper connection on 10Base-T segment

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Section 4.7 Commissioning External Units

4.7 Commissioning External Units

4.7.1 External Display QDIL 451

Setting up the control unit is described in Section 4.5.19. The corresponding setups must also be
carried out in the external display.
The display setup is accessed by pressing both the menu keys for one second.
The left key is used for stepping the settings forward, and the right key is used for changing the
settings.
If a menu key is double-clicked, the menu setting is stepped backwards.

Table 4-13. Settings for QDIL 451

Position Parameter Recommended settings

1 Interface 485, for RS 485
2 Data format 7 data bits
3 Parity 0, no parity
4 Baud rate 12 for 1200Bd
5 Protocol S-E for STX/ETX
6 Protocol answer 0, no protocol answer
7 Character ignore 00, no characters ignored
8 Address length 2 if addressing is selected, else 0
9 Address Select address according to Section
4.5.19 if addressing is selected, else 0
t Time out 4, the display is extinguished after 4
seconds if updating ceases
A Decimal point 0, no fixed decimal point
C Leading zeros 0000 if leading zeros are desired, else 0.0
F Segment test 888 segments are tested at power-on
U Saving SEt for saving parameters
ESC for not saving

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Chapter 4 Commissioning

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 Millmate Roll Force Systems with Millmate Controller 400,
Section 5.1 About This Chapter

Chapter 5 Operation

5.1 About This Chapter

This chapter describes how to operate the Millmate Roll Force System with
Millmate Controller 400.
Millmate Controller 410 is intended to be handled by the operator from
Millmate Operator Unit 400 or from a web browser run on a personal computer or similar.
The control unit can also be operated from a superior system.
In this chapter operation from the operator unit or from a web browser is described.
Your measurement system does not need any attention during normal operation. Measurement
runs continuously as long as the system is switched on. However, you need to know how to start
up and shut down the system, see Section 5.4 and Section 5.6.
To obtain the best possible measuring results the measuring equipment should be switched on
even when it is not being used in production. This is to ensure that the electronics system is
warmed up to operational temperature when the measuring equipment is put back into
production.

5.2 Safety
The safety instructions given in Section 1.4 should always be followed to minimize the risk of
personal injury, and also the risk of damaging the equipment when operating the measuring
objects. However, local regulations, if stricter, always take precedence.

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Millmate Roll Force Systems with Millmate Controller 400,
Chapter 5 Operation

5.3 Indications
Status for the measurement equipment is indicated by LEDs on the control unit, the operator
unit and the excitation unit through messages on the operator unit display, or via the RS-232 and
RS-485 serial ports.

5.3.1 LED Indications

Control unit LEDs Marking Color Indicates when lit that ...
Run green the control unit is working normally.
Run Fault
Syserr Profibus a serious fault in the control unit has
LAN C Fault red been detected, see Chapter 7, Fault
RS-485 RS-232 Tracing.
a system fault is detected by the self
DO1 DO5 Syserr red test, or by the continuous monitoring
DO2 DO6 function, see Chapter 7, Fault Tracing.
DO3 DO7
DO4 DO8 communication in progress on the
Profibus yellow
fieldbus.
LAN yellow communication in progress on Ethernet.
C yellow Not used.
communication in progress on the
RS-485 yellow
RS-485 port.
communication in progress on any of
RS-232 yellow
the RS-232 ports.
activity in progress on the digital outputs
DO1 - DO8 yellow
DO1 - DO8.
Operator unit LEDs Marking Color Indicates when lit that ...
Power supply voltage is present in the
blue
Operator Unit
purple Command to Control Unit on Ethernet
.

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 Millmate Roll Force Systems with Millmate Controller 400,
Section 5.3.2 Fault Indications During Run

Excitation unit LEDs Marking Color LED indicates ...

RUN green Mains voltage ON.
EXON green Load cell EXcitation ON.
yellow Single Cell A mode active.
RUN SCA
EXON OV PL1 (load cell B by-passed)
SCA CL PL2
SCB UV TEST yellow Single Cell B mode active
SCB
(load cell A by-passed)

Error. Over Voltage in excitation circuit.

OV red
See Chapter 7, Fault Tracing
UV Error. Under Voltage in excitation circuit.
red
See Chapter 7, Fault Tracing

red Error. Current Limitation activated.

CL
See Chapter 7, Fault Tracing

PL1 yellow “Power range 1” set.

PL2 yellow “Power range 2” set.
PL1 and PL2 yellow “Power range 3” set.
TEST yellow Load cell test in progress.

5.3.2 Fault Indications During Run

Faults detected by the continuous monitoring function are indicated in the following way:
• A fault message is shown in the operator unit display.
• The LED “Syserr” is lit on the control unit.
• The digital output DO8 is activated.
(default setting, can be altered or disconnected)
A fault message is shown in the operator unit display when a communication
problem between the control unit and the operator unit exists.

NOTE
Serious faults, which cannot be detected by the normal fault handling in the
control unit are indicated by illuminating the LED “Fault” on the control unit.

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Millmate Roll Force Systems with Millmate Controller 400,
Chapter 5 Operation

5.4 Start-up
1. Switch the mains switch on the front of the control unit to position “1”.
a. The green LED “Run” on the control unit should be lit,
indicating that the equipment is powered.
b. The red LED “Fault” should be extinguished..

Millmate Controller 400R

Fault (red)

Run (green)

Mains switch
in position “1”

The operation menu for the pre-selected object is shown when measurement is started.
Example of an operation menu:

ROUGHER 720

Total 15 MN
Side A 8 MN
Side B 7 MN
Difference 1 MN

Zero set System Lc exc Single

test ON/OFF cell

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 Millmate Roll Force Systems with Millmate Controller 400,
Section 5.5 Measurement During Normal Operation

5.5 Measurement During Normal Operation

The Millmate Controller 400 is intended for continuous operation. Normally, the control unit
should be switched on to allow the load cells to maintain a constant working temperature.

5.6 Shutdown
1. Switch the mains switch to position “0” to switch off the control unit and the
operator unit.

Millmate Controller 400R

Mains switch
in position “0”

Normally, the operator unit is powered from the control unit, and is shut-down automatically
when the control unit is shut-down.

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Millmate Roll Force Systems with Millmate Controller 400,
Chapter 5 Operation

5.7 Operation

5.7.1 Operation from the Operator Unit

5.7.1.1 General

Corresponding
old HMI function
buttons

P1

P2

P3

P4

Figure 5-1. Operator Unit for Millmate Controller 400

The operator unit menus are divided into four types:

• Operation menus for different type of objects
– Handling the object and showing measuring results.
• List of connected objects (Home menu)
– Changing selected object or entering a new object.
• Service menus for the operator unit
– Settings for the operator unit.
– Connecting to another control units.
• Service menus for the control unit
– Settings for the control unit.

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 Millmate Roll Force Systems with Millmate Controller 400,
Section 5.7.1 Operation from the Operator Unit

5.7.1.2 Operator Unit Buttons

The Operator Unit is a industrial high-resolution touch screen panel. The row of buttons on the
right side is divided in two sections. The top section is buttons that lead to the functions that are
described in respective button.
The lower consist of buttons that re-directs the operator in the menu tree.
See table below.

Table 5-1. Operator Unit Buttons

Button Function

Start Go to start object

Control lers Go to Home menu

Escape One step back to previous menu

Home Go to Controller menu from Service menu

MC400 service Go to Service menu 1 of the applicable selected controller

Next Selects next service menu from current

<- One step back to previous menu

http;//
Connection to other device than MC400.
Operator unit works as a standard web browser.

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Millmate Roll Force Systems with Millmate Controller 400,
Chapter 5 Operation

5.7.1.3 Operator Unit Display

Millmate Operator Unit 400

S ROUGHER 720 1 2 3
abcd efgh ijkl
C
Total 15 MN
F Side A 8 MN 4 5 6
Side B 7 MN mnop qrst uvwx
Difference 1 MN
Select 7 8 9
yz%& åäöü ()<>

Clear - 0 +
Zero set System Lc exc Single
+=/* _#@‘ ,:;$
test ON/OFF cell

Esc Service Operation

P1 P2 P3 P4

Menu number

ROUGHER 720 Headline area

Total 15 MN
Side A 8 MN
Side B 7 MN Menu area
Difference 1 MN

Message area
Zero set System Lc exc Single
test ON/OFF cell Function line

P1 P2 P3 P4

Figure 5-2. The Operator Unit Display. The Example Shows the Operation Menu for a Standard Object

The operator unit display is divided into four parts:

• The headline shows the name and the number for the current menu.
• The menu area shows the operation menus and the service menus.
• The message area shows fault messages, when faults occur,
and messages during operation.
• The function line shows the meaning of the function keys
P1 - P4 for the current menu.

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 Millmate Roll Force Systems with Millmate Controller 400,
Section 5.7.2 Operation from an Optional Web Browser

5.7.2 Operation from an Optional Web Browser

The operator unit can be substituted by a web browser run on a personal computer or similar.
Refer to Section 4.5.16 to obtain the IP-address and Subnet mask used by the MC400. The
Subnet mask is in hexadecimal form, where ff = 255. So e.g. "ffff0000" is equivalent to
"255.255.0.0".

NOTE
It is not possible to use the X29/X22 and X21 connectors at the same time. X29 has priority
over X22. X22 has priority over X21.
If the operator unit uses a LAN 10Base2 cable, connected to X21, this cable will be
disconnected when X22 or X29 is used.

If the MC400 is connected to a local area network (LAN):

• Connect the PC via a standard Ethernet cable to a socket belonging to the LAN to obtain
access to the LAN automatically.

If the MC400 is not connected to a local area network (LAN):

1. Make sure that there is a free Ethernet port on your PC. Connect a crossover Ethernet cable
to socket X29 on the MC400.
2. On the PC, select “Start”, “Settings”, “Network Connections”, and then the "Local Area
Connection" belonging to the free Ethernet port.
3. Select “Properties”, "Internet Protocol (TCP/IP)", “Properties”.
4. Select "Use the following IP address".
5. Enter an IP-address close to the one for MC400, or use “172.16.1.10”. This will work with
all MC400 that have the factory set IP-address.
6. Enter the Subnet mask “255.255.0.0”. The default setting for “Gateway” is blank.

Ethernet switch

Figure 5-3. Examples for connecting a PC directly to the MC400.

When network connection is established:
1. Start a web browser (e.g. Internet Explorer).
2. Select “Tools”, “Internet options”, “Connections”, “LAN Settings”.
3. Temporarily disable the use of a proxy server for the LAN if it is enabled.

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Millmate Roll Force Systems with Millmate Controller 400,
Chapter 5 Operation

4. Select “OK“ and then “OK”.

5. Write the MC400 IP address in the navigator field, followed by port 8080, e.g.
http://172.16.1.225:8080/
The following menu is then presented.

CU name

Select language

• Select the language from the “Language” scroll down list,

before pressing the “MC 400 service” or the “Operation” button.
• Activate the service menu by pressing the “MC 400 Service” button.
• The actual menus are handled in the same way from a
web browser as from the operator unit.

To activate the operation menu for an object:

1. Click “Operation” in menu 101.

2. Select an object from the list in menu 410.

3. Click “Operation”.

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 Millmate Roll Force Systems with Millmate Controller 400,
Section 5.7.3 Selection List (List of Connected Objects)

5.7.3 Selection List (List of Connected Objects)

Press Home

The connected objects is can be seen

under Millmate control unit.The con-
troller and objects name is written in
blue text. That means it is a button
that can be pressed.

All active and objects are shown in

the window by pressing “Scan LAN”.

Objects can be stored by using In List

toggle switch, they are then displayed
Control unit name Object name

5.7.4 Service Menus

The service menus are used for carrying out settings and maintenance on the operator unit and
the control unit. The operator unit can also be connected to another control unit connected on
the same network from the service menus.

Press Home to get to the Home menu. Click the name of desired Millmate

controller in the list.

If you are in the object menu and want to reach the control unit, click MC400 service .

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Millmate Roll Force Systems with Millmate Controller 400,
Chapter 5 Operation

5.7.4.1 Service Menu Settings for the Control Unit

Service menus 1, 2 and 3 are start menus for

Service menu 1 111
Service the control unit settings. From these three
ABB225 menus all necessary settings can be entered
Date 12 jan 2004, 12:00
Load cell excitation On
for the control unit and the objects.
Service

Functions such as system test and fault

inspection are accessed from the
System Error Lc exc Next
test inspect ON/OFF control unit service menu.

Service menu 2 112

ABB225
Date 12 jan 2004, 12:00
Load cell excitation On

Settings Check Next

I/O

Service menu 3 113

ABB225
Date 12 jan 2004, 12:00
Serial number SE9808A123
Software release 3.2-2
Software type MC400 R
Options 4 ports
Profibus

Define Comm. MC400 Next

system setup data

5.7.5 Settings for the Operator Unit

5.7.5.1 Set Screen saver

From the Home menu, press Display

After selecting screen saver, it will automatically start when your computer is idle for the time
interval specified in Wait. Select one of the specified wait intervals and click Save. The
available wait intervals are 5 seconds up to 10 hours. It is also possible to set the screen saver to
OFF, this disables the screen saver.

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 Millmate Roll Force Systems with Millmate Controller 400,
Section 5.7.5 Settings for the Operator Unit

To clear the screen saver after it has started, touch the screen.
A screen that is continuously updated will redirect to Startup Object on Home screen when
screen saver has been activated to avoid data traffic during time out. If Startup Object has not
been activated, the Scan Controller screen is shown.

5.7.5.2 Set Backlight Brightness

From the Home menu, press Display

Set Backlight brightness level. Intensity is set in levels 10 (brightest) to 1 (dullest). When
approaching level 1 backlight, changes in brightness level may no longer be noticeable in the
panel. Complete dimming (to level 0) is not possible. Backlight brightness level is maintained
after reboot of panel.

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Millmate Roll Force Systems with Millmate Controller 400,
Chapter 5 Operation

5.8 Connecting to a Measuring Object

5.8.1 Selecting an Object from the Selection List

Press Control lers

Press the wanted object name listed under the se-

lected control unit.
The object will now be presented in the object
menu.

Object name

5.8.2 Changing to an Object in Another Control Unit

Press Home

The operator can be connected to another object

on the same network.
Press “Scan LAN” to see the List of Control Units.
Press the name of the Control Unit.
Press the name of the Object.
The object will now be presented in the object
menu.

New control unit name New object name

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 Millmate Roll Force Systems with Millmate Controller 400,
Section 5.9 Operation Menus for Roll Force Measurement

5.9 Operation Menus for Roll Force Measurement

5.9.1 Standard Measurement (720, 730, 740)

Rougher 720
Total 15 MN
Side A 8 MN
Side B 7 MN
Difference 1 MN

Zero set System Lc exc Single

test ON/OFF cell

To menu 761 To menu 775 or 776

(See Section 5.13.1) (See Section 5.13.2)

If there are more than four function keys, settings are moved to a separate menu.

Rougher 720 Settings 760

Total 15 MN Rougher
Side A 8 MN
Side B 7 MN LC set number 2
Difference 1 MN

Zero set System Lc exc Settings Set Single End

test ON/OFF number cell

To menu 761
(See Section 5.13.1)

To menu 775 or 776

(See Section 5.13.2)

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Millmate Roll Force Systems with Millmate Controller 400,
Chapter 5 Operation

5.9.1.1 Key Functions

Roll functions chosen at installation determine some of the operation menu function keys that
can be available. Other desired function keys can be selected separately.

Table 5-2. Meaning of Function Keys for Standard Measurement

Function
Description See section
key
Zero sets measuring signals from both load cells. The
Zero function must be acknowledged before it is executed.
set

System Starts system test. The function must be acknowledged

5.11.1
test before it is executed.
Lc exc Switches load cell excitation ON/OFF. The function must
ON/OFF be acknowledged before it is executed.
Single Disconnects one load cell.
cell 5.11.2

Set
number Changing load cell set number in menu 760. 5.11.3

Switches to sub menu 760, where settings can be

Settings 5.9.1
performed.

End Stores entered settings.

5.9.1.2 Operation Messages

The messages are shown beneath the measuring values during operation.

Table 5-3. Operation Messages for Standard Measurement

Operation message Description See section

Load cell excitation is switched off and
Load cell EXC off
measurement is interrupted.
The system is locked and cannot be
System locked
affected.
The measuring roll operates with only one
Single cell A (B)
active load cell.
Error XXX The system has detected an error with No
7.4
(XXX=Error No) XXX.

The name of the level detector that has

“Level detector”
been activated is shown here.

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 Millmate Roll Force Systems with Millmate Controller 400,
Section 5.9.2 Single Input Measurement (710)

5.9.2 Single Input Measurement (710)

ROUGHER 710 ROUGHER 710

Total 15 MN Total 15 MN
Passline deviation: -45.0 Passline deviation: -45.0

Zero set System Lc exc Zero set System Lc exc Settings

test ON/OFF test ON/OFF

To menu 760
(See Section 5.13.3)

5.9.2.1 Key Functions

Table 5-4. Meaning of Function Keys for Single Input Measurement

Function key Description See section

Zero sets measuring signals from both load cells.
Zero
set
The function must be acknowledged before it is
executed.

System Starts system test. The function must be

5.11.1
test acknowledged before it is executed.
Lc exc Switches load cell excitation ON/OFF. The function
ON/OFF must be acknowledged before it is executed.
Settings Switches to sub menu 760, where settings can be
5.9.1
performed.

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Millmate Roll Force Systems with Millmate Controller 400,
Chapter 5 Operation

5.9.2.2 Operation Messages

The messages are shown beneath the measuring values during operation.

Table 5-5. Operation Messages

Operation message Description See section

Load cell excitation is switched off and
Load cell EXC off
measurement is interrupted.
System locked The system is locked and cannot be affected.
Error XXX The system has detected an error with No
7.4
(XXX=Error No) XXX.

The name of the level detector that has been

“Level detector”
activated is shown here.

5.10 Multi View (750)

In this menu values from several measuring objects can be shown but the measuring objects
cannot be operated. To operate a certain measuring object it must be selected separately.

Hot Mill 1 750

Rougher 38 MN
F2 2 MN
F3 6 MN
F4 20 MN
F5 22 MN
F6 18 MN
F7 24 MN
F8 20 MN

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 Millmate Roll Force Systems with Millmate Controller 400,
Section 5.11 Sub Functions for Operation Menus

5.11 Sub Functions for Operation Menus

Some service functions that can be accessed directly from an operation menu are described in
this section.

5.11.1 System Test (761, 762, 763)

Activation of the system test starts a sequence for testing the complete measurement system.
The measurement is interrupted when the test is in progress (about 30 seconds). After the test is
finished, the system returns to normal operation (measurement) and switches back to the
previous operation menu after 20 seconds delay.

System test 761 System test running 762

Verify start of the system test sequence. Test sequence running
This will interrupt all measurements Test 12 of 64 completed
in this unit.
Name roll/stand 1 Name object 5
Name roll/stand 2
Name roll/stand 3
Name roll/stand 4 Error message
Reference values never saved
(or reference values saved 2002-01-14)
Error Yes No
inspect

After
completed
System test finished 763 test
Test completed successfully
Reference saved: 12 feb 2004, 10:45

(or test completed with error)

Previous
operation
menu

Error Print End

inspect result

After the test is finished, detected errors can be read and acknowledged by pressing “Error
inspect”. The result of the tests can be printed by pressing “Print result”, see 4.5.29.

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Millmate Roll Force Systems with Millmate Controller 400,
Chapter 5 Operation

5.11.2 Changing to Single Cell Operation (775, 776, 777)

If one load cell (in a system with two load cells) is not connected or is suspected to be faulty, the
signal from the other load cell can be connected to both load cell inputs. The connection is made
internally in the control unit and simulates a complete measurement system.

ROUGHER 720
Total Actual operation menu (example)
15 MN
Side A 8 MN
Side B 7 MN
Difference 1 MN

Zero set System Lc exc Settings

test ON/OFF

Settings 760
ROUGHER

LC set number 2

Set Single End

number cell

Double cell operation active Single cell operation active

Single cell operation 775 Double cell operation 776

ROUGHER ROUGHER

Verify Verify
Single cell operation Double cell operation

Single Single No Double No

cell A cell B cell

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 Millmate Roll Force Systems with Millmate Controller 400,
Section 5.11.3 Setting Load Cell Set Number

5.11.3 Setting Load Cell Set Number

This menu is used for setting number of load cell sets.

Settings 760
ROUGHER

LC set number 2
Previous
operation
menu

Set Single End

number cell

5.11.3.1 Key Functions

Table 5-6. Function Keys for Setting Load Cell Set Number

Function key Description

Set Used for setting or changing load cell set number.
number

End
Stores the entered value and leaves the menu.

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Millmate Roll Force Systems with Millmate Controller 400,
Chapter 5 Operation

5.11.4 Error Inspection

Errors can be viewed and acknowledged.

ROUGHER 720
Total 15 MN
Side A 8 MN
Side B 7 MN
Difference 1 MN

Zero set System Lc exc Settings Press “System test”.

test ON/OFF

System test 761

Verify the start of the system test sequence.
This will interrupt all measurements
in this unit.

Std1@ABB225

Reference saved: 12 feb 2004, 10:45

Error YES NO Press “Error inspect”.

inspect

The latest detected error is viewed. The er-

Stored errors 781
Error id (No) received at (Date,Time) rors can be viewed and acknowledged
Type of error (confirmed) one at time by pressing “Con-
firm”.

“No errors” is shown, when all errors are

confirmed.
Confirm End Exit with “End”.

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 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section 6.1 About This Chapter

Chapter 6 Maintenance

6.1 About This Chapter

Millmate Roll Force Systems with Pressductor® load cells are very reliable and require no daily
service.
Preventive maintenance should be carried out especially on parts which are subject to
mechanical stress.
Recommended maintenance intervals for different parts of the system are given in Table 6-1.

6.2 Periodical Maintenance

A summary of recommended maintenance intervals for Millmate Roll Force Systems are given
in Table 6-1.

Table 6-1. Recommended Maintenance Intervals

Maintenance interval
Equipment Action 3 6 1
months months year
Enclosures and Cleaning x
cabinets
Checking cables x
Operator unit Cleaning x
Load cells Cleaning x
Visual inspection x
Cabling Visual inspection x
Junction box Check terminals x
Matching Units Check terminals x

It is also recommended that the System Reference Test (Self Test) is performed on a regular
basis, see Section 4.5.27, Performing a System Reference Test (Self Test).

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Millmate Roll Force Systems with Millmate Controller 400, User Manual
Chapter 6 Maintenance

6.3 Operator Unit

The operator unit contains no parts requiring maintenance by the user. Apart from cleaning the
enclosure and the keyboard, no routine maintenance is required for the operator unit.

CAUTION
Only use a damp cloth when cleaning the operator unit.

6.4 Cabinets
Check that:
• all screw terminals are well tightened.
• all units are securely fastened.
• no cables or conductors are damaged.

6.5 Load Cells

Check that:
• the polished and unpainted surfaces on the load cells are not corroded.
Protect against corrosion if necessary.
• the load cell installation is not covered with dirt, which could cause partial overloading
and poor load distribution.
• the load cell cabling is not damaged.

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 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section 6.6 Changing Battery in the Control Unit

6.6 Changing Battery in the Control Unit

The control unit is equipped with a lithium battery for powering the internal clock when the
equipment is switched off. The battery is expected to last for 10 years. A continuous monitoring
function in the control unit detects if the battery should be changed and generates an alarm.
NOTE
Use only batteries recommended by ABB
For battery data, see Section 2.4.2, Technical Data. Replacing the battery requires that the
control unit is switched off and disassembled.
Follow these instructions:
1. Switch off the control unit using the S1 mains switch.
2. Disconnect the mains voltage by separating X1.
3. Remove all connections to the control unit.
4. Loosen the four mounting screws holding the control unit in place. Do not remove them
completely.
5. Push up the control unit to make it free from the screws and remove it.
6. Remove the eight screws holding the cover lid on the control unit.
7. Lift the lid carefully and disconnect the ribbon cable connector from the lower circuit
board.
8. Turn the lid upside down to access the circuit board on the lid.
9. Unplug the connectors X23 and X30 and remove the ESD protection cover from the 10-
pole ribbon cable connector at the top edge of the lid.
10. Loosen the nine M4 screws holding the circuit board to the lid.
11. Remove the circuit board carefully from the lid.
12. Cut off the straps holding the battery in place.
13. Carefully, unsolder the battery.
14. Place and solder a new battery in position. Fix it with straps.
15. Replace the circuit board in the lid and fix it with the nine M4 screws.
16. Reinsert X23 and X30 connectors and the ESD protection cover.
17. Reconnect the ribbon cable connector to the lower circuit board.
18. Replace the lid over the main unit.
19. Re-fit the eight screws holding the lid. Do not fully tighten them until all screws are in
position.
20. Replace the control unit on its four mounting screws.
21. Re-tighten the mounting screws.
22. Reconnect all connections to the control unit.
Finally connect the mains connection X1.
23. Switch on the control unit using the S1 mains switch.
24. Use the operator unit to set the clock and calendar from the service menu.
See Section , Setting Up Network Data For the Operator Unit.

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Millmate Roll Force Systems with Millmate Controller 400, User Manual
Chapter 6 Maintenance

6.7 Replacing Battery in the Operator unit

The Operator unit holds a lithium battery. The battery is not used in any function and is
therefore in no need of replacement.

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 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section 7.1 About This Chapter

Chapter 7 Fault Tracing

7.1 About This Chapter

Millmate Controller 400 has a continuous monitoring function for the control unit function and
the load cell excitation circuit.
Fault messages can be read and acknowledged from the control unit service menu.
Fault inspection is described in 7.4.
The control unit contains a system test which checks the system and its connected units. The
system test shall not be started when measurement is in progress. It must be started manually.
This is because the measurement is interrupted when cabling and load cells are checked.
The system test is described in 7.6.

7.2 Interchangeability

7.2.1 Load Cells

The load cells are interchangeable with load cells of the same type and measuring range.
A system test must be performed and new reference values must be stored.
The storing of reference values is described in 7.6.

7.2.2 Matching Units

Matching units are interchangeable with units of the same type. PFVO 102 is also
interchangeable with PFVO 142 and PFVO 201 is interchangeable with PFVO 143.
The setting of phase compensation capacitors C1–C3 has to be changed to the setting of the
replaced unit.

7.2.3 Millmate Controller 400

The control unit Millmate Controller 400 (MC 400) is interchangeable with a control unit of the
same type. Replacement can also be done according to Table 7-1. All settings must be reentered,
a system test must be performed and new reference values must be stored.

Tabell 7-1. Choosing Replacement Control Unit MC 400

Replaced Replacement control unit MC 400

control unit type
MC 400, type PFXA 401 PFXA 401F PFXA 401S PFXA 401SF
PFXA 401 MC 400R x x x x
PFXA 401F x x
PFXA 401S x x
PFXA 401SF x

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Millmate Roll Force Systems with Millmate Controller 400, User Manual
Chapter 7 Fault Tracing

7.3 Fault Indications

An alarm is given in one of the following ways when the Millmate Controller 400 detects a
fault:
• The LED “Syserr” on the control unit front panel is lit.
• The digital output DO8 is activated (default setting, can be altered or disconnected).
• A fault message is shown on the operator unit display which is connected to the control
unit in question.

7.4 Fault Inspection

Fault messages can be acknowledged from the control unit service menu.

Service menu 1 111

Service
ABB225
Date 12 jan 2004, 12:00
Load cell excitation on
Latest error 23 12 jan 2004, 11:12
Service Load cell configuring ports

System Error Lc exc Next

test inspect ON/OFF

Stored errors 130

This is an example of a fault message.
Error id 23
Received at 12 jan 2004, 11:12
Load cell configuring ports

Confirm End

Fault (error) inspection can also be done from operation menus, see 5.11.4.

7.4.1 System Error List

The system errors are divided into three groups:
1. Errors in operator unit (due to improper use of the operator unit)
Error types No 1-99
2. Errors detected at commissioning or during normal operation
Error types No 101-198 and No 301-349 See 7.4.1.1
3. Errors detected when running the system test
Error types No 201-264 See 7.4.1.2

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 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section 7.4.1 System Error List

7.4.1.1 Errors Detected at Commissioning or During Normal Operation

Reading error messages can be done in different ways:
• From operation menu See 5.11.4 and 5.11.1
• From service menu See 7.6.1
Press “Error inspect”, read error messages in menu “Stored errors” and take necessary actions to
correct detected faults.
Error types No 101-198 affect signals Healthy, Ready, Ready all and Syserr (System error)
Error types No 301-349 affect signals Healthy and Syserr (System error). Ready and Ready
all are not affected. They are to be considered warnings as the measurement values are not
directly affected.
as described in Table 7-2.
Before using the system error list in Table 7-3, check in your system to which digital outputs
system status signals Healthy, Ready (one per object) and Ready all have been connected.
Syserr = System error (fault) that must be corrected
Healthy = No unconfirmed system errors in the system
Ready = The object connected to the Ready signal is working (measuring).
Ready all = All objects in the control unit are working (measuring).

Tabell 7-2. Error Indication Alternatives

Errors No errors. No errors.

Indications on MC 400 System status Errors confirmed Unconfirmed error System
control unit front panel signal detected but messages in menu running
remaining “Stored errors” normally
“Healthy” Off Off Off On
Run Fault “Ready” (one per Off Off On On
Syserr Profibus object) (For faulty (For faulty
LAN C
RS-485 RS-232 object) object)
“Ready all” Off Off On On
(connected as default
DO1 DO5 to DO 7)
DO2 DO6
“Syserr” (also On On On Off
DO3 DO7
DO4 DO8 connected as default
to
DO 8)

“Healthy” and “Ready” can be connected to any digital output if desired.

“Ready all” and “Syserr” are connected as default to DO 7 and DO 8 respectively, but can be
changed or removed if desired.

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Millmate Roll Force Systems with Millmate Controller 400, User Manual
Chapter 7 Fault Tracing

Tabell 7-3. List of Errors

Error
Fault Description Measures
Code
101 +5V supply voltage supervision alarm Replace control unit PFXA 401
102 +15V supply voltage supervision alarm
103 -15V supply voltage supervision alarm
104 +24V supply voltage supervision alarm
105 Analog in 1 offset voltage, supervision alarm If the system has been running:
• Replace control unit PFXA 401
106 Analog in 2 offset voltage, supervision alarm Error detected at commissioning:
• Try to restart the control unit.
• If error remains, remove all setup, see 4.5.32.
107 Analog in 3, offset voltage, supervision alarm
• Load the complete object setup, see 4.5.30, or do
the object setup manually.
108 Analog in 4, offset voltage, supervision alarm • Start the system. If not OK, replace control unit.

109 AD1 reference voltage supervision alarm Replace control unit PFXA 401
110 AD2 reference voltage supervision alarm
112 Load cell excitation loop impedance too high Check excitation circuit, see 4.5.21
114 Excitation unit under voltage alarm These alarms interrupt load cell excitation:
• Run system test, see 7.6, to check if error
diagnostics identifies cause of error.
116 Excitation unit loop impedance too high
• Use “Checking of load cell excitation in
PFVI 401”, see 4.5.21, for fault tracing.
117 Excitation unit over current alarm Note. Intermittent cable break in excitation circuit
can cause both error 116 and error 117.
121 Digital output 1 overload
122 Digital output 2 overload
123 Digital output 3 overload
124 Digital output 4 overload
Check wiring on Digital output
125 Digital output 5 overload
126 Digital output 6 overload
127 Digital output 7 overload
128 Digital output 8 overload
129 Analog in 1 amplification alarm If the system has been running:
• Replace control unit PFXA 401
130 Analog in 2 amplification alarm Error detected at commissioning:
• Try to restart the control unit.
• If error remains, remove all setup, see 4.5.32.
131 Analog in 3 amplification alarm
• Load the complete object setup, see 4.5.30, or do
the object setup manually.
132 Analog in 4 amplification alarm • Start the system. If not OK, replace control unit.

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 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section 7.4.1 System Error List

Tabell 7-3. List of Errors

Error
Fault Description Measures
Code
136 Analog in 1 signal overflow
137 Analog in 2 signal overflow
Check setting on analog input
138 Analog in 3 signal overflow
139 Analog in 4 signal overflow
141 Analog in 1 voltage overload
142 Analog in 2 voltage overload
Check wiring on analog input
143 Analog in 3 voltage overload
144 Analog in 4 voltage overload
145 Analog inputs transient voltage overload Check wiring on analog input
149 Excitation unit PFVI401 power supply Excitation unit PFVI 401 is not working.
Check fuses and mains voltage connections.
If error remains, replace PFVI 401.
150 Excitation unit PFVI401 not connected Check ribbon cable between PFXA 401 and
PFVI 401. If error remains, replace PFVI 401.
151 Communication failure to the other MC 400 Check LAN wiring
152 Illegal system configuration Check settings
181 DSP communication failure
182 DSP to excitation synchronisation error
185 CPU bus error
186 CPU address error
188 Illegal instruction
189 Divide by zero detected Contact ABB
191 Other exception type
192 Boot sector memory checksum fault
195 Application checksum error
197 DSP interrupt missing
198 Watchdog time out
1 Load cell excitation level supervision warning Excitation level is changed compared to reference
301 )
test. The current is however still correct so meas-
urement is working correctly.
This indicates a change in excitation wiring and
matching units. Check wiring and matching unit.
3031) Saving on Boot FLASH fault Contact ABB

3041) Saving on PXAK401 FLASH fault Replace control unit PFXA 401

3051) Memory fragmentation Contact ABB

3061) Task overload Contact ABB

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Millmate Roll Force Systems with Millmate Controller 400, User Manual
Chapter 7 Fault Tracing

Tabell 7-3. List of Errors

Error
Fault Description Measures
Code
3071) Low battery voltage Replace battery, see 6.6
Battery only supplies clock. Control unit works well
as long as it is switched on. Date and time will be
wrong after next power down if battery has not
been changed.
3201) Cannot setup IP-port for http communication

3301) Vip comm. cannot allocate memory

3311) Vip comm. cannot release memory

3321) Vip comm. cannot create the link Contact ABB.

3361) Vip comm. server isn't activated

3381) Vip comm. cannot delete the task

3391) Vip comm. cannot delete the link

3491) Excitation unit PFVI 401 cooling fan Cooling fan is not working. Replace PFVI 401
or make sure that ambient temperature around
PFVI 401 is lower than 30°C.
1) Does not affect Ready and Ready all

7.4.1.2 Errors Detected when Running the System Test, (Error Types No 201-264)
The system test can be activated in different ways.
• From operation menu See 5.11.4 and 5.11.1
• From service menu See 7.6.1

NOTE
Measurement is interrupted when running the system test.

Press “Error inspect”, read error messages in menu “Stored errors” and take necessary actions to
correct detected faults.
Error types No 201-264 affect system status signals Healthy and Syserr (System error).
Syserr = System error (fault) that must be corrected.
Healthy = No unconfirmed system errors in the system

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 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section 7.4.1 System Error List

Tabell 7-4. Errors Detected by the System Test

Error code Fault description Measures

201 +5V supply voltage faulty
202 +15V supply voltage faulty
203 -15V supply voltage faulty
Replace control unit PFXA 401
204 +24V supply voltage faulty
205 AD1 reference voltage faulty
206 AD2 reference voltage faulty
207 Analog in 1 offset voltage faulty
If the system has been running:
208 Analog in 2 offset voltage faulty
• Replace control unit PFXA 401
209 Analog in 3 offset voltage faulty
Error detected at commissioning:
210 Analog in 4 offset voltage faulty
• Try to restart the control unit.
211 Analog in 1 amplification faulty • If error remains, remove all setup, see 4.5.32.
212 Analog in 2 amplification faulty • Load the complete object setup, see 4.5.30,
or do the object setup manually.
213 Analog in 3 amplification faulty • Start the system.
If not OK, replace control unit.
214 Analog in 4 amplification faulty
215 Load cell input 1 signal circuit break
216 Load cell input 2 signal circuit break
Check load cell wiring
217 Load cell input 3 signal circuit break
218 Load cell input 4 signal circuit break
219 Load cell input 1 signal circuit short circuit
220 Load cell input 2 signal circuit short circuit
Check load cell wiring
221 Load cell input 3 signal circuit short circuit
222 Load cell input 4 signal circuit short circuit
223 Load cell input 1 isolation resistance faulty
224 Load cell input 2 isolation resistance faulty
Check load cell wiring
225 Load cell input 3 isolation resistance faulty
226 Load cell input 4 isolation resistance faulty
227 Load cell input 1 zero voltage check A faulty load cell has been replaced.
Run system test and store new reference value.
228 Load cell input 2 zero voltage check
Load cell is faulty. Replace load cell. Run test and
229 Load cell input 3 zero voltage check store new reference value.
230 Load cell input 4 zero voltage check Load cell is not unloaded. Check that load cell is
unloaded before running the test.

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Millmate Roll Force Systems with Millmate Controller 400, User Manual
Chapter 7 Fault Tracing

Tabell 7-4. Errors Detected by the System Test

Error code Fault description Measures

231 Load cell input 1 overload damage • Check that the test is carried out under the
same conditions.
232 Load cell input 2 overload damage
The test indicates that something has happened to
233 Load cell input 3 overload damage the load cell.
234 Load cell input 4 overload damage • Measure the resistance in the signal circuit.
• Check if the load cell is damaged.
If so, replace the load cell.
235 Load cell input 1 polarity faulty
236 Load cell input 2 polarity faulty Check if the cabling to the load cell is in accordance
237 Load cell input 3 polarity faulty with the cable diagram.

238 Load cell input 4 polarity faulty

239 Load cell input 1 calibration altered
240 Load cell input 2 calibration altered Load cell sensitivity, compared to saved ref. value,
241 Load cell input 3 calibration altered has been changed. Setting sensitivity, see 4.5.24.

242 Load cell input 4 calibration altered

243 Load cell excitation installation faulty Check phase compensation, see 4.5.24.
244 Load cell excitation circuit break, loop 1
245 Load cell excitation circuit break, loop 2 Check load cell wiring
246 Load cell excitation circuit break, total loop
247 Load cell excitation unit faulty Check connection of PFVI 401.
248 Load cell excitation unit faulty If error remains, replace PFVI 401.

249 Excitation level changed, loop 1

250 Excitation level changed, total loop 2
251 Excitation level changed, total loop
Check load cell wiring
252 Load cell excitation short circuit, loop 1
253 Load cell excitation short circuit, loop 2
254 Load cell excitation short circuit, total loop
261 Excitation under voltage, loop 1
Replace PFVI 401.
262 Excitation under voltage, loop 2
264 PFVI 401 missing Check ribbon cable between PFXA 401 and
PFVI 401. If error remains, replace PFVI 401.

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 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section 7.5 Fault Tracing Procedure

7.5 Fault Tracing Procedure

The measuring equipment can be divided into four parts:
• The mechanical installation (see the load cell manual)
• The load cell (see the load cell manual)
• Junction boxes and cabling
• The control unit
The fault symptoms indicate in which part the fault lies.
• Faults in the mechanical installation often result in an unstable zero point or incorrect
sensitivity. If a fault follows something else in the process, such as temperature, or can be
linked to a particular operation, it probably originates from something in the mechanical
installation.
• Load cells are extremely robust and can withstand several times their nominal load. If a load
cell has nevertheless been so overloaded that its data have been altered, this is probably due
to an event in the mill, such as strip breakage. On excessive overload the first thing that
happens is that the zero point shifts.
• Problems such as interference or unstable zero point may be caused by wiring faults. Some
malfunctions may be due to the proximity of cables that cause interference. Incorrect
installation, such as imbalance in a cable or screens earthed at more than one end may cause
the zero point to become unstable. Cables are subject to mechanical wear, and should be
checked regularly. The junction box should also be checked, especially if it is subjected to
vibration.
• A fault in the control unit usually causes intermittent loss of a function. It is unusual for the
control unit to cause stability problems. Faults in connected units may affect the operation of
the control unit.

7.6 System Test

Millmate Controller 400 contains a system test which checks the measuring object and its
connected units. The system test cannot be started when measurement is in progress. It must be
started manually. This is because the measurement is interrupted when cabling and load cells are
checked.
The system test consists of 64 part tests - these can be run one at a time or in sequence.

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Chapter 7 Fault Tracing

7.6.1 Starting the System Test

System test 140 1. Press “Run tests” to start the system

Service
Start sequence or do test manually
test. It takes approximately 2½ min-
utes.
Reference never saved
“Reference never saved” means that
Service
no previous test result has been saved.

System Run Manual Save as End

tests test ref.
test

System test running 141

Test sequence running “Result SUCCESSFUL” is shown when

Test 12 of 64 completed
the system test is completed, provided
no errors are detected.
“Result FAILURE” means that an error
has been detected during the system
Stop
test test.
If an error is detected, the error is
shown.
System test finished 143 To display the errors, press “Service”
twice and then “Error inspect”.
Test 64 of 64 completed.
Result SUCCESSFUL
2. If a printer is connected to the system,
the test results can be printed out by
pressing “Print result”.
3. If the test results are correct they must
Run Print Error End
tests result inspect be stored as reference values.
Use “Save as ref.” in the main menu
(140) to store the test result.
Any faulty test results must be correct-
ed. See 4.5.27.2.

NOTE
The System Test can also be run from the operation menus, see 5.9 and
5.11.

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 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section 7.6.2 Starting a Part Test

7.6.2 Starting a Part Test

Manual test 150 1. Enter the part test number and press “Start
Service Test no 1 test”. The part test is run continuously.
+5V Supply During the test, the previously stored test re-
Previous 5.03 V sults and approved limits are shown.
Service Reference 5 V
Low limit 4.75 V 2. Terminate the part test by pressing “Stop
High limit 5.25 V
Not performed test” - otherwise the part test is automatically
System Start Check Next End terminated after 30 minutes.
test values test
test 3. Press “Check values” to show all stored val-
ues without starting a part test.
Manual Repeated test 151
test Test no 1
4. Press “Next test” to step to the next part test.
+5V Supply 5. Analog outputs and digital inputs/outputs can
Value 5.03 V
Previous 5.03 V be tested manually using “Check I/O”.
Reference 5 V
Low limit 4.75 V
High limit 5.25 V
Running, OK
Stop Next
test test

Example of a menu for part test

7.6.3 System Test List

Tabell 7-5. System Test List

Test
Description
No.
1 Power supply + 5 V
2 Power supply +15 V
3 Power supply –15 V
4 Power supply +24 V (for internal use and for external equipment)
5 Offset voltage, analog input 1
6 Offset voltage, analog input 2
7 Offset voltage, analog input 3
8 Offset voltage, analog input 4
9 Internal reference voltage, A/D-converter 1
10 Internal reference voltage, A/D-converter 2
11 Relative gain, analog input 1
12 Relative gain, analog input 2

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Chapter 7 Fault Tracing

Tabell 7-5. System Test List

Test
Description
No.
13 Relative gain, analog input 3
14 Relative gain, analog input 4
15 Insulation in the signal circuit connected to analog input 1.
16 Insulation in the signal circuit connected to analog input 2.
17 Insulation in the signal circuit connected to analog input 3.
18 Insulation in the signal circuit connected to analog input 4.
19 Resistance in the signal circuit connected to analog input 1.
The measured value is compared with the reference test value.
20 Resistance in the signal circuit connected to analog input 2.
The measured value is compared with the reference test value.
21 Resistance in the signal circuit connected to analog input 3.
The measured value is compared with the reference test value.
22 Resistance in the signal circuit connected to analog input 4.
The measured value is compared with the reference test value.
23 Output level of load cell supply for the first half of load cell excitation circuit.
The measured value is compared with the reference test value.
24 Over voltage alarm for supply of the first half of load cell excitation circuit.
25 Over current alarm for supply of the first half of load cell excitation circuit.
26 Under voltage alarm for supply of the first half of load cell excitation circuit.
27 Not in use.
28 Not in use.
29 LC sensitivity on load cells connected to analog input 1
30 Zero voltage, load cells at analog input 1.
The measured value is compared with the reference test value.
The test is only performed if load cells are connected.
31 Output level of load cell supply for the second half of load cell excitation circuit.
The measured value is compared with the reference test value.
32 Over voltage alarm for supply of the second half of load cell excitation circuit.
33 Over current alarm for supply of the second half of load cell excitation circuit.
34 Under voltage alarm for supply of the second half of load cell excitation circuit.
35 Not in use.
36 Not in use.
37 LC sensitivity on load cells connected to analog input 2

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Section 7.6.3 System Test List

Tabell 7-5. System Test List

Test
Description
No.
38 Zero voltage, load cells at analog input 2.
The measured value is compared with the reference test value.
The test is only performed if load cells are connected.
39 LC sensitivity on load cells connected to analog input 3
40 Zero voltage, load cells at analog input 3.
The measured value is compared with the reference test value.
The test is only performed if load cells are connected.
41 LC sensitivity on load cells connected to analog input 4
42 Zero voltage, load cells at analog input 4.
The measured value is compared with the reference test value.
The test is only performed if load cells are connected.
43 Output level of load cell supply for the entire load cell excitation circuit.
The measured value is compared with the reference test value.
44 Over voltage alarm for the supply of the entire load cell excitation circuit.
45 Over current alarm for the supply of the entire load cell excitation circuit.
46 Under voltage alarm for the supply of the entire load cell excitation circuit.
47 Not in use.
48 Not in use.
49 Not in use.
50 PFVI 401 presence check.
51 Analog in 1, calibration check.
52 Analog in 2, calibration check.
53 Analog in 3, calibration check.
54 Analog in 4, calibration check.
55 Not in use.
56 Not in use.
57 Not in use.
58 Not in use.
59 Not in use.
60 Not in use.
61 Not in use.
62 Not in use.
63 Not in use.
64 Not in use.

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Chapter 7 Fault Tracing

7.6.4 Fault Tracing Diagram

This fault tracing diagram assumes a fault has occurred during normal running.

Check that the

mains switch on the
control unit is in
position 1.

Check the operator F is lit

Is the Contact service.
Any text shown unit LEDs: C is off
“Run” LED on Yes Yes
on the operator
the control unit
unit display?
lit?
S is lit, C is flashing and F is off
No No

Is the
“Syserr” LED on Yes Carry out a system test.
the control unit Correct any faults according
lit? to the fault list.
Carry out a new system test.
No

The fault remains

Is the
“Fault” LED on Yes
Contact service.
the control unit
lit?

No

Check the cabling. Check that the operator unit

is powered on (LED S is lit).
Check that values for illumination
Check the mechanical and contrast are correct.
installation.

Carry out a
system test.

The fault remains The fault remains

The operator unit may be faulty.

Contact service. Contact service.

Figure 7-1. Fault Tracing Diagram

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 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section 7.7 Single Cell Operation

7.7 Single Cell Operation

If one load cell (in a system with two load cells) is not connected or is suspected to be faulty, the
signal from the other load cell can be connected to both inputs. The connection is made
internally in the control unit and simulates a complete measurement system.

ROUGHER 720
Operation Total Actual operation menu (example)
15 kN
Side A 8 kN
Side B 7 kN
Difference 1 kN
Operation

Zero set System Lc exc Settings

test ON/OFF

Settings 760
ROUGHER

LC set number 50.0

Set Single End

number cell

Double cell operation active Single cell operation active

Single cell operation 775 Double cell operation 776

ROUGHER ROUGHER

Verify Verify
Single cell operation Double cell operation

Single Single No Double No

cell A cell B cell

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Chapter 7 Fault Tracing

7.8 Checking Matching Units PFVO 102/142 and PFVO 201/143

Matching units are often exposed to vibrations, heat and cooling liquids.
Points to check are:
• Screw terminals, especially terminals 11 and 12 can be damaged by overheating if they
have not been properly tightened.
• Capacitor C1 in PFVO 102/142.
This 1 µF capacitor can fail because of aging and heat. The capacitance can be checked
with a capacitance meter or by measuring the voltage across it during operation. The
voltage should be 190 V AC.
The capacitor should be replaced if the capacitance is lower than 0.85 µF or if the voltage
is higher than 223 V AC.
Replacement capacitor has to be of industrial grade designed for continuous operation.
The 3 µF capacitors, C2 in PFVO 102/142 and C1 – C3 in PFVO 201/143, are less critical.
They work with lower load and fail rarely.

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 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section A.1 About This Chapter

Appendix A Vendor Internet Protocol (VIP)

A.1 About This Chapter

This chapter describes the Vendor Internet Protocol (VIP)
for communication between a PLC (or equivalent) and:
• Millmate Strip Tensiometer Systems (MST) with Millmate Controller 400 (MC 400)
• Millmate Roll Force Systems (MRF) with MC 400
• Millmate Strip Scanner Systems (MSS) with MC 400.

A.1.1 Terminology

Table A-1. Terminology

Term Definition
VIP Vendor Internet Protocol
IP Internet Protocol
TCP Transmissions Control Protocol
Retransmission of lost or damaged data packages.
MC 400 Control unit Millmate Controller 400
MST Millmate Strip Tensiometer Systems with MC 400 (PFCA 401/PFXA 401)
MRF Millmate Roll Force Systems with MC 400 (PFXA 401 only)
MSS Millmate Strip Scanner Systems with MC 400 (PFXA 401 only)

A.2 General Description

The communication between a PLC or equivalent and the MC 400 systems uses the VIP
application protocol.

A.2.1 VIP Implementation in MC 400

The VIP implementation in the MC 400 uses TCP/IP. MC 400 acts as a server.

A.2.2 Communication Establishing

The VIP client connects to the MC 400 VIP server, which has a given IP-address and port
number.

A.2.3 Communication Procedure

Messages are sent in both directions. The sending procedure is normally cyclic, but the
receiving procedures react on incoming events.

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Millmate Roll Force Systems with Millmate Controller 400, User Manual
Appendix A Vendor Internet Protocol (VIP)

A.2.4 Message Configuration

The configuration is defined in the MC 400 setup.

A.2.5 Supported Data Types

The main characteristics for the VIP protocol are:
• Predefined telegrams are sent and received
• TCP/IP peer-to-peer connection in full duplex mode
• Automatic handling of connection reestablishment
• Big Endian byte order format.
Below is a list over the data types supported by the MC 400 VIP implementation which is used
in the interface with MC 400:

Table A-2. Supported Data Types

Data type Description

packed bool 16 16 bit value were each bit represents a boolean value
Int16 16 bit integer value

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 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section A.2.6 General VIP Telegram Structure

A.2.6 General VIP Telegram Structure

Two main parts compose a VIP telegram:
• Header part (4 bytes)
• Data part (0 to n bytes)
Maximum telegram length is 65535 (No. of bytes).

4 bytes 0 - n bytes
Header Data

Telegram length Telegram Id

2 bytes 2 bytes
Figure A-1. General VIP Telegram Structure

A.2.6.1 Header Part

The header is composed of two 16 bit integers:
1. Total telegram length (No. of bytes), including the header.
2. Telegram identity, a system unique integer which is used to distinguish between telegrams
in the same network.
See an example of a telegram in Table A-3.

A.2.6.2 Data Part in MC 400

The data part of a VIP telegram consists of a number of data blocks.
The VIP telegram in MC 400 has one data block.
The order of data types in the data block is shown below.

Header Data

packed packed
int16 int16 int16 int16 int16 int16 int16 int16 bool 16 bool 16
1 2 3 4 5 6 7 8 1 2
Figure A-2. Order of Data Types in the Data Block

See an example of a telegram in Table A-3.

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Appendix A Vendor Internet Protocol (VIP)

Table A-3. Example of a VIP Telegram in MC 400

Data Byte Type of information Part of telegram

24 01 Telegram length Telegram header
02
1 03 Telegram Id
04 Send id = 1, Receive id = 2

Value1 int16 05 Measurement values Data

06 Parameters
Settings
Value2 int16 07
Status information
08
Value3 int16 09
10
Value4 int16 11
12
Value5 int16 13
14
Value6 int16 15
16
Value7 int16 17
18
Value8 int16 19
20
Status1 21
packed bool 16
22
Status2 23
packed bool 16
24

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Section A.3 Specific Functions

A.3 Specific Functions

A.3.1 Overview
Millmate Strip Tensiometer (MST), Millmate Roll Force Meter (MRF) and
Millmate Strip Scanner (MSS) are based on a common platform designated
Millmate Controller 400 (MC 400).
MC 400 comprises the necessary hardware and software infrastructure to realize the products
including communication facilities.
The following sections outline the required functionality that are provided by the VIP protocol.

A.3.2 Data Conversion

The MC 400 system can only handle 16 bit integers in the data messages. All scale
factors and other unit information should be handled as configuration parameters, which
are manually handled in each system.

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Appendix A Vendor Internet Protocol (VIP)

A.3.3 Strip Tensiometer and Roll Force Meter Communication

A.3.3.1 Input Package Sent to MST and MRF

Table A-4. Input Package Sent to MST and MRF

Data Type Description

gainParS1O1 int16 The wrap gain parameter for side 1 of object 1, in the defined unit (MST only)
gainParS2O1 int16 The wrap gain parameter for side 2 of object 1, in the defined unit (MST only)
gainParS1O2 int16 The wrap gain parameter for side 1 of object 2, in the defined unit (MST only)
gainParS2O2 int16 The wrap gain parameter for side 2 of object 2, in the defined unit (MST only)
Value5 int16 Not used
Value6 int16 Not used
Value7 int16 Not used
Value8 Int16 Not used
Command1 packed bool 16 A packed boolean where each bit is “0” or “1” as described below. 1)
Bit No.
0 Zero set (Zero set measuring signals from load cells in Measuring Object 1)
1 Zero set (Zero set measuring signals from load cells in Measuring Object 2)
2 Zero set (Zero set measuring signals from load cells in Measuring Object 3)
3 Zero set (Zero set measuring signals from load cells in Measuring Object 4)
4 Lock sys (Lock System)
5-15 Not used
Command2 packed bool 16 Not used.
1)
The Zero set signal is flank triggered and reacts when the bit
Menu example is changed from “0” to “1”.
The bit has to be “1” for at least 50 ms before it can be changed
Setup object 301 back to “0” again.
1 Measuring Object 1 Zero setting time is approximately 1 s per object.
2 Measuring Object 2
3 Not defined The Lock sys status depends on the bit value (“0” = unlocked, “1” = locked).
4 DCin4@Measuring Object 1
Multi view
Not defined Note. Do not send the Zero set command to help objects.
Setup Remove End No. 4 in the “Setup object” menu to the left, “DCin4@Measuring Object 1”, is a
help object (no load cells used).
It is automatically created (MST only) if an analog input Port is used for coiler
diameter or pass line deviation input.
The help object “DCin4@Measuring Object 1” belongs to “Measuring Object 1”
and is automatically created when setting up “Measuring Object 1”.
Port 4, DCin4 (the last free analog input Port) is used, and the help object is
placed as No. 4 (the last free object place).

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Section A.3.3 Strip Tensiometer and Roll Force Meter Communication

A.3.3.2 Output Package Produced by MST and MRF

Table A-5. Output Package Produced by MST and MRF

Data Type Description

valueA1 int16 The measured Tension or Roll Force, in scaled units, from load cell/cells connected
to analog input, Port 1. Filter time: MST = 500ms; MRF = 100 ms
valueB1 int16 The measured Tension or Roll Force, in scaled units, from load cell/cells connected
to analog input, Port 2. Filter time: MST = 500ms; MRF = 100 ms
valueA2 int16 The measured Tension or Roll Force, in scaled units, from load cell/cells connected
to analog input, Port 3. Filter time: MST = 500ms; MRF = 100 ms
valueB2 int16 The measured Tension or Roll Force, in scaled units, from load cell/cells connected
to analog input, Port 4. Filter time: MST = 500ms; MRF = 100 ms
Value5 int16 This field is not used.
Value6 int16 This field is not used
Value7 int16 This field is not used
Value8 int16 This field is not used
Status1 packed bool 16 A packed boolean where each bit is “1”, if the corresponding value is valid.
Bit No.
0-3 Not used
4 Sys. locked (System is locked by input “Lock system”)
5 Ready all1) (All objects in the control unit are working)
6 Not used
7 Sys. error (A system error has been detected)
8 Not used
9 SingleCell1 (Roll Object 1 is running in Single cell A or B mode)
10 Single cell A1 (Roll Object 1 is using load cell A)
11 Single cell B1 (Roll Object 1 is using load cell B)
12 SingleCell2 (Roll Object 2 is running in Single cell A or B mode)
13 Single cell A2 (Roll Object 2 is using load cell A)
14 Single cell B2 (Roll Object 2 is using load cell B)
15 Not used
Status2 packed bool 16 Not used.

1)
Ready all is recommended output for indication of working (measuring) system.

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Appendix A Vendor Internet Protocol (VIP)

A.3.4 Strip Scanner Communication

A.3.4.1 Input Package Sent to MSS

Table A-6. Input Package Sent to MSS

Data Type Description

Value1 int16 Not used
Value2 int16 Not used
Value3 int16 Not used
Value4 int16 Not used
Value5 int16 Not used
Value6 int16 Not used
NomWidth int16 The nominal width for the current strip (mm/10).
NomThick int16 The nominal thickness for the current strip (µm).
Command1 packed bool 16 A packed boolean where each bit is “0” or “1” as described below. 1)
Bit No.
0 Zero set
1 Loop Comp (Switch to desired loop compensation alternative)
2-3 Not used
4 Lock sys (Lock System)
5-15 Not used
Command2 packed bool 16 Not used

1) Signal Zero set is flank triggered.

They react when the bit is changed from “0” to “1”.
The bit has to be “1” for at least 50 ms before it can be
changed back to “0” again.
The Lock sys status depends on the bit value
(“0” = unlocked, “1” = locked).
The Loop Comp status depends on the bit value,
(“0” = Comp set 1, “1” = Comp set 2.

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Section A.3.4 Strip Scanner Communication

A.3.4.2 Output Package Produced by MSS

Table A-7. Output Package Produced by MSS

Data Type Description

OffCentre int16 The distance between the centres of the mill and the strip (mm/10).
Width int16 The actual measured strip width (mm/10).
Diff int16 The difference between Width and NomWidth (mm/10).
Edge A int16 The distance between the centre of the mill and Edge A (mm/10).
Edge B int16 The distance between the centre of the mill and Edge B (mm/10).
Value6 int16 This field is not used.
NomWidth int16 The nominal width for the current strip (mm/10).
NomThick int16 The nominal thickness for the current strip (µm).
Status1 packed bool 16 A packed boolean (16 bit) where each bit is “1”, if the corresponding value is valid.
Bit No.
0 Metal (StripEdge within measuring range and distance < 70 mm)
1 Primary (StripEdge within measuring range and distance < 50 mm.)
2 Comp Set (Indicates used Comp set for loop compensation;
Comp set 1 = “0”, Comp set 2 = “1”)
3 Not used
4 Sys. locked (System is locked by input “Lock system”)
5 Ready all (All objects in the control unit are working)
6 Not used
7 Sys. error (A system error has been detected)
8 Level det. 1 (Output for level detector 1)
9 Level det. 2 (Output for level detector 2)
10 Level det. 3 (Output for level detector 3)
11 Level det. 4 (Output for level detector 4)
12 Single Edge (The object is running in SingleEdge A or SingleEdge B mode)
13 Single Edge A (The object is running in SingleEdge A mode)
14 Single Edge B (The object is running in SingleEdge B mode)
15 Not used
Status2 packed bool 16 Not used.

Strip Scanner Processing

The Strip Scanner system produces information about the position of the strip, which is
sent to the consumer.
A valid measurement is indicated by Metal and Primary signals.
If the measurement fails the calculated width will be the nominal width and the
OffCentre value is set to zero.

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Appendix A Vendor Internet Protocol (VIP)

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 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section B.1 About This Appendix

Appendix B Profibus-DP Fieldbus Communication

B.1 About This Appendix

This appendix contains:
General Description See B.2
• General data about Profibus DP See B.2.1
• Master-slave communication See B.2.2
• Variants of communication blocks See B.2.3
• Block description See B.2.4
• Blocks See B.2.5
Input buffer See B.2.5.1
Output buffer See B.2.5.2
• GSD file for Profibus DP slave See B.2.6
Installation See B.3
Commissioning See B.4
Technical Specifications See B.5
Examples of Recommended Setup See B.6

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Appendix B Profibus-DP Fieldbus Communication

B.2 General Description

This appendix may cover products not included in this manual, however this is generic guide to
fieldbus communication and parts not applicable to the product concerned should be ignored.

B.2.1 General Data about Profibus DP

The purpose of the Profibus DP communication implemented in the Millmate Controller 400
(MC 400) system is to provide a high speed communication link between external computers
and the MC 400.
The implementation supports the main applications Millmate Roll Force (MRF), Millmate Strip
Tensiometer (MST) and Millmate Strip Scanner (MSS).
Profibus DP is a multidrop communication protocol intended to connect a number of PLCs and
PLCs to sensors (DP means “Distributed Peripherals”).
The physical interface is RS 485 (two wire cable) or optical.
The maximum transfer rate is 12 Mbit/s.
The protocol is based on a master-slave principle. The MC 400 is a slave.
A Profibus master polls the slaves all the time, that means the polling is going on with a fixed
time interval even when no new data is available from the MC 400.
The shortest Profibus polling interval is less than a millisecond.
There can be several masters polling their own slaves on the same bus.
Each slave has an address in the range 0 to 125.
Profibus requires that the message format, communication parameters and error codes
of slaves are made available in a so called type file, also known as GSD file. This file is then
stored in the Profibus Master.
At start-up the Profibus Master verifies that the Slave with the given type file is indeed available
on the bus.

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Section B.2.2 Master-slave Communication

B.2.2 Master-slave Communication

The Master and the slave communicate via an output buffer and an input buffer.
The master reads the input buffer and writes to the output buffer once every scan cycle for
Profibus.
The slave polls the output buffer and updates values in the input buffer at a rate that for MC 400
depends on the type of data, see B.2.4.1.

Slave – MC400

Output buffer MC400

Master - PLC measuring
process
Input buffer

All exchanged information follows standard Profibus data type formats.

B.2.3 Variants of Communication Blocks

The MC 400 slave supports only one set of communication blocks.

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Appendix B Profibus-DP Fieldbus Communication

B.2.4 Block Description

B.2.4.1 Input Buffer, Communication Block from MC 400 to PLC

This block contains four measurement and eight Boolean values as process signals.
These values are updated continuously, see Table 2-1.
Value Four (4) integer measuring values from MC 400.
What these values represent is defined at setup of the MC 400 measurement
system, see B.4.3.
The values are presented as integers. What each unit (division) represents
is defined at setup of the MC 400 measurement system.
See B.2.5.3 and B.2.5.4 for division data.
Boolean in Eight (8) Boolean values from MC 400.
What these values represent is defined at setup of the MC 400 measurement
system, see B.4.3.

B.2.4.2 Output Buffer, Communication Block from PLC to MC 400

This block contains eight Boolean values for process control of MC 400 and two variables for
measurement control. These data are read continuously, see Table 1-1.
Variable Two (2) input variables to MC 400 as integer values.
What these variables represent is defined at setup of the
MC 400 measurement system.
The variables are given as integer values (without decimals).
See B.2.5.3 and B.2.5.4 for division data.
Boolean out Eight (8) Boolean values to MC 400.
What these values represent is defined at setup of the
MC 400 measurement system, see B.4.4.

Table 2-1. MC400 Internal Update Time for Profibus DP

Application Value Boolean Boolean

in out
MRF Millmate Roll Force (1638 Hz) 0.3 ms 0.3 ms 5 ms
PFVL 141, PFVL 101
MRF Millmate Roll Force (330 Hz) 1.5 ms 1.5 ms 12 ms
QGPR 102/104
MST Millmate Tensiometer (330 Hz) 1.5 ms 1.5 ms 12 ms
PFTL 101/201/301
PFCL 101/201/301
PFRL 101
PFBL 101/141
MSS Millmate Strip Scanner 1.5 ms 1.5 ms 12 ms

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Section B.2.5 Blocks

B.2.5 Blocks
Compact blocks for fast data exchange only. These blocks are optimized for fast control.

B.2.5.1 Input Buffer, Communication Block from MC 400 to PLC

Bit No.
Data Byte No.
7 6 5 4 3 2 1 0
01 MSB
Value 1
02 LSB
03 MSB
Value 2
04 LSB
05 MSB
Value 3
06 LSB
07 MSB
Value 4
08 LSB
Boolean in 09 No. 8 No. 7 No. 6 No. 5 No. 4 No. 3 No. 2 No. 1
10 Spare for future use

B.2.5.2 Output Buffer, Communication Block from PLC to MC 400

Bit No.
Data Byte No.
7 6 5 4 3 2 1 0
01 MSB
Variable 1
02 LSB
03 MSB
Variable 2
04 LSB
Boolean out 05 No. 8 No. 7 No. 6 No. 5 No. 4 No. 3 No. 2 No. 1
06 Not used

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Appendix B Profibus-DP Fieldbus Communication

B.2.5.3 Resolution for Roll Force and Tensiometer Objects

Measurement values
For Roll Force and Tensiometer objects, the resolution of measurement values is a function of
the measuring range, and is presented on the display as “Load division” according to the figure
below.

From “Setup” in menu 301

Object Information 305

Name Std1@ABB225
Application Standard measurement
Lc type PFVL 141
Lc size 20.00 MN
Lc at port 1, 2
Load division 0.05 MN
To menu 320
Modify End

Input variables
The resolution for input variables is the same as the unit used for the rest of the mechanical
settings. The variable should be given as an integer value (without decimals).

B.2.5.4 Resolution for Strip Scanner Objects

For Strip Scanner objects, the resolution is fixed.

Measurement values Resolution

• Off Center 0.1 mm
• Width 0.1 mm
• Edge A, Edge B 0.1 mm
Input variables
• Nominal Thickness 0.001 mm
• Nominal width 0.1 mm

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Section B.2.6 GSD File

B.2.6 GSD File

;==========================================
; GSD file for Profibus DP slave
; Millmate Controller 400
; Author : C.Gustafsson
; Stand : 03-03-03
; =========================================
#Profibus_DP
GSD_Revision =1
Vendor_Name = "ABB Automation"
Model_Name = "Millmate Controller 400"
Revision = "2.0-1"
Ident_Number = 0x0585
Protocol_Ident =0
Station_Type =0
FMS_supp =0
Hardware_Release = "Rev J"
Software_Release = "2.1-0"
;
9.6_supp =1
19.2_supp =1
93.75_supp =1
187.5_supp =1
500_supp =1
1.5M_supp =1
3M_supp =1
6M_supp =1
12M_supp =1
;
MaxTsdr_9.6 = 60
MaxTsdr_19.2 = 60
MaxTsdr_93.75 = 60
MaxTsdr_187.5 = 60
MaxTsdr_500 = 100
MaxTsdr_1.5M = 150
MaxTsdr_3M = 250
MaxTsdr_6M = 450
MaxTsdr_12M = 800
;
Redundancy =0
Repeater_Ctrl_Sig =0
24V_Pins =0
;
Freeze_Mode_supp =0
Sync_Mode_supp =0
Auto_Baud_supp =1
;
Set_Slave_Add_supp = 0
Min_Slave_Intervall =1
Max_Diag_Data_Len =6
Slave_Family =0
Modular_Station =0
;
User_Prm_Data_Len =1
User_Prm_Data = 0x00
;
; <Module-Definition-List>
Module = "MC400" 0x53,0x61,0x30,0x30
EndModule

The GSD-file can also be output from the MC 400 control unit. For further information,

3BSE023139R0401 Rev A B-7

Millmate Roll Force Systems with Millmate Controller 400, User Manual
Appendix B Profibus-DP Fieldbus Communication

B.3 Installation
This section describes the cabling and setup of the Profibus in the MC 400.

B.3.1 Profibus Physical Media

The bus line is specified in EN 50170 as line type A. Line type B should be avoided.
The physical properties of the media are shown in Table 2-2 and Table 2-3.

Table 2-2. Line Parameters

Line type B
Parameter Line type A
(Avoid if possible)
Impedance in  135 to 165 100 to 130
Capacitance per unit length (pF/m) <30 <60
Loop resistance ( /km) 110 ---
Core diameter (mm) 0.64 > 0.53
Core cross section (mm2) > 0.34 > 0.22

The specified line parameters result in the following lengths of a bus segment.

Table 2-3. Maximum Cable Lengths per Segment

Maximum bus Transmission rate in kbit/s

segment length (m) 9.6 19.2 93.75 187.5 500 1500 12000
Wire A 1200 1200 1200 1000 400 200 100
Wire B 1200 1200 1200 600 200 - -

Stub lines up to 1500 kbit/s < 6.6 m.

If you are using 12 Mbits/s you should avoid stub lines.
If you are using line A as specified by EN 50 170, the bus terminating resistance combination
is as shown in figure 2-1, so that a defined idle state potential is ensured on the line.

B-8 3BSE023139R0401 Rev A

 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section B.3.1 Profibus Physical Media

Signals on the Connector Terminating Resistance of the Bus

Pin No. in Brackets
VP(6)
390 
Data line - B(3)
220 
Data line - A(8)
390 
GND (5)

Figure 2-1. Line Termination of Wire A in Accordance with EN 50170

Table 2-4. Pin Allocation of the Bus Plug Connector

X 31 X 30
Pin Pin Signal Designation
No. No.
1 Shield Shield/protective ground
2 N.C NOT USED
3 1 RxD/TxD-p*) Receive data/transmission data plus
4 CNTR-P Control signal for repeaters (direction control)
5 DGND Data Transmission potential (Ground to 5 V)
6 VP Supply voltage of the terminating resistance-P, (P5V)
7 N.C. NOT USED
8 2 RxD/TxD-N*) Receive data/transmission data negative
9 CNTR-N Control signal for repeaters (direction control)

*) The mandatory signals must be supported by the user.

The line shield should be led to the protective ground (usually the electrically conductive
housing) of the connected device to prevent EMC interference from penetrating the device.
Data transmission of the serial bus system using twisted wire pair lines with connected shield
is defined in the specifications of the RS 485 interface which is not susceptible to interference.
In accordance with EN 50 170, the plug connector allocation on the Profibus cable is specified
for a 9-pin, sub D plug connector. (This gives a slave a socket connection.)
MC 400 provides 5 volts and GND to pins 5 and 6 so that the bus can be terminated with
terminating resistors.
If the protection rating prevents use of the recommended 9-pin, sub D plug connector,
connection can be made to X30, use only the mandatory signals RxD/TxD-P and RxD/TxD-N.

3BSE023139R0401 Rev A B-9

Millmate Roll Force Systems with Millmate Controller 400, User Manual
Appendix B Profibus-DP Fieldbus Communication

Since the data lines are connected through in the Profibus connection plug, the failure
of one station does not affect other stations.
The failure of a slave is detected by the Profibus master during the next data cycle,
and indicated.
Line type A
Typical connection capacity of a bus station (e.g., plug connectors, line length to
the RS 485 driver, RS 485 driver, components, etc.): 15 to 25pF.
Stub lines should not be used at high transfer rates.
The tolerance of the capacitive load of the station should be in the range of 15 to 25 pF.
Otherwise, a repeater must be used for the bus connection to prevent errors.

To bridge longer distances and bypass EMC interference, transmission with optical fiber
conductors (glass or plastic) is also specified.
Standard bus plug connectors are available for transmission with optical fiber conductors.
These connectors convert RS 485 signals to optical fiber conductor signals and vice versa.
(OLP = optical link plug).
In addition, repeaters are available to handle this signal conversion.
This gives you the option of switching between the two transmission techniques within
one system if necessary.
You can connect up to 126 stations to one Profibus system.
To be able to handle this number of participants on the bus, the bus system must be divided
into individual segments, containing maximum 32 stations each.
These segments are linked by repeaters.

B-10 3BSE023139R0401 Rev A

 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section B.3.2 MC 400 Profibus Interface

B.3.2 MC 400 Profibus Interface

Run Fault
Profibus indication
Syserr
LAN
Profibus
C
lamp
RS-485 RS-232 RS-232:2 RS-232:1
X27 X26
DO1 DO5
DO2 DO6
DO3 DO7
DO4 DO8

Profibus DP
(X31)
(X30)
Profibus X35
X34
X31 X24 X25
T2A T2A Digital in Digital out
F1 F2
85-264V~ X30 X23
47-63Hz 140W Profibus RS-485

1 2 3 4 5 1 2 3 4 5

X13 X15 X16 X18

S1 X2 X3 X5 X6 X8
X1

Figure 2-2. The Profibus Connectors on MC 400

Termination switch R
R
in ON position

Termination switch
R
in OFF position
R

Figure 2-3. Profibus Cable Connector

3BSE023139R0401 Rev A B-11

Millmate Roll Force Systems with Millmate Controller 400, User Manual
Appendix B Profibus-DP Fieldbus Communication

B.4 Commissioning
This section contains:
Safety information
Setting up the Fieldbus
Selecting measurement values (signal values) Section B.4.2
Configuring digital inputs Section B.4.3
Configuring digital outputs Section B.4.4
Error handling Section B.4.5

B.4.1 Safety Information

The safety instructions in this chapter should always be followed to minimize the risk of
personal injury, and also the risk of damaging the equipment, when operating the
MC 400 System. However, local regulations, if stricter, always take precedence.

B.4.1.1 Personal Safety

DANGER
Be careful when working with the measurement system with mains voltage
applied to it. The voltage in the equipment can injure, or even kill.

The following must be observed:

• Everyone working with or around the measurement system must know where the main
circuit breaker for the system is located and how it is operated.
• Safety devices and such like must be checked by a responsible person when parts of the
measurement system have been tested and run. All personnel concerned must be informed
of future test runs.
• A process technician must be present when testing and running the system.
• Never start the system without knowing the effect of start up.
• Remember that the measurement system can be influenced by remote objects via digital
and analog inputs, superior control systems or terminals.

B.4.1.2 Equipment Safety

Observe the following cautions:
• Avoid static discharges by grounding both tools and your-self before handling circuit
boards and other parts of the measurement system.
• Before electrical welding is carried out in the surroundings of the system, switch off the
equipment and disconnect the wires in the terminal blocks.

B-12 3BSE023139R0401 Rev A

 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section B.4.2 Setting up Fieldbus

B.4.2 Setting up Fieldbus

Check that all the cables are connected, including the Profibus cable.
Power on the system.
The picture shows an example of a menu tree.

Service FieldBus 270

None Profibus Address 123 Enter unit Address.
Output Object Signal
1 Entry Load cell A
2 Entry Load cell B B
Service 3 Not defined -
4 Not defined -
Input
1 Not defined -
2 Not defined -
Next
Input Output Signal End
Boolean Boolean values
Next

Comm.
setup

Fieldbus
Select value
Profibus

Signal values 271

Set up Booleans from Set up Booleans to Object Measurement value
Tot. Diff. A B C D
PLC to MC 400. Use PLC from MC 400. Entry

the menus for digital Use the menus for

inputs. digital outputs.
See B.4.3 See B.4.4
A A End

3BSE023139R0401 Rev A B-13

Millmate Roll Force Systems with Millmate Controller 400, User Manual
Appendix B Profibus-DP Fieldbus Communication

B.4.3 Configuring Boolean Inputs

The eight digital inputs can be configured for a number of signals in the control unit.
See Table 2-5.

A
Enter the function to be executed when
the selected input port is activated.
– The selected digital input No is
Booleans to MC400 from PLC 273 disconnected if “Signal” is set to “-”.
No Invert Signal Object
1 Zero set Inlet – The input function can be inverted
2 - -
3 - - by marking the “Invert” column.
4 - - Return to the main menu and save
5 - -
6 - - the modifications with “End”.
7 - -
8 - -
Signal Select End
list object

Select the object that the signal belongs

to. For signal types that control the entire
control unit, the object name doesn’t
Select Object 275 matter.
Select object
Std1@ABB225
Std2@ABB225

End
Select desired input signal to be
connected to the digital input bit.
“Not active” disconnects the input bit,
selected in menu 273.
Input Signal List 274
Not active Not active
EXON Lc exc on
EXOFF Lc exc off
LOCK Lock sys
SYTEST Sys. test
ZS Zero set
SCCA Single cell A
SCCB Single cell B
DCC Double cell
SDON Step det on
End

B-14 3BSE023139R0401 Rev A

 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section B.4.3 Configuring Boolean Inputs

Table 2-5. Functions That Can Be Activated by Digital Input Signals

Signal name Description MRF MST MSS

Not active Used to disconnect an input bit x x x
EXON Switch on load cell excitation x x
EXOFF Switch off load cell excitation x x
LOCK Lock System x x x
SYTEST Start System test x x x
ZS Zero set x x x
SCCA Change to Single Cell Operation x x
with load cell A
SCCB Change to Single Cell Operation x x
with load cell B
DCC Change to Double Cell Operation x x
SDON Set step detector x
SDOFF Reset step detector x
Single Edge A Change to Single Edge Operation x
with Sensor A
Single Edge B Change to Single Edge Operation x
with Sensor B
Dual Edge Change to Dual Edge Operation x
Comp Set Select used set of compensation x
values for closed metal loop

All these signals, except “Lock System”, are flank triggered. They react when the bit is changed
from “0” to “1”. The bit has to be “1” for at least 50 ms before it can be changed back to “0”
again.

3BSE023139R0401 Rev A B-15

Millmate Roll Force Systems with Millmate Controller 400, User Manual
Appendix B Profibus-DP Fieldbus Communication

B.4.4 Configuring Boolean Outputs

The eight digital outputs can be configured for a number of signals in the control unit.
See Table 2-6.

Enter the function to be executed when

B the selected output port is activated.
– Output 7 is preset to the signal
“Ready all”.
A – Output 8 is preset to the signal
“Sys. error” (System error).
– Outputs 7 and 8 can be changed to
Booleans from MC400 to PLC 276 other functions.
No Invert Signal Object – The selected digital output No is
1 - -
2 - - disconnected if “Signal” is set to “-”.
3 - -
4 - -
– The output function can be inverted
5 - - by marking the “Invert” column.
6 - -
7 Ready all - – Non-inverted outputs are closed
8 Sys. error -
when activated.
Signal Select End
list object Return to the main menu and save
the modifications with “End”.

Select the object that the signal

Select Object 278 belongs to. For signals that belong to
Select object
Std1@ABB225 the entire control unit, the object name
Std2@ABB225 doesn’t matter.

Next

Select desired output signal to be

connected to the digital output bit.
Output Signal List 277 “Not active” disconnects the output bit,
Not active Not active
Healthy Healthy selected in menu 276.
ReadyA Ready all
LCEXON Lc excitation
SYSERR Sys. error
Locked Sys. locked
TEST Test mode
SIMU Simulation mode
READY Ready
LD1 Level det. 1

End

B-16 3BSE023139R0401 Rev A

 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section B.4.4 Configuring Boolean Outputs

Table 2-6. Functions on Digital Outputs

Signal name Description MRF MST MSS

Not active Disconnects the output port, selected in x x x
menu 276.
Healthy No unconfirmed system errors in system. x x x
ReadyA All objects in the control unit are working. x* x* x*
LCEXON Load cell excitation is working. x x x
SYSERR A system error has been detected. x x x
Locket System is locked by input “Lock system”. x x x
TEST System test is now running. x x x
SIMU System is running in Simulation Mode. x x x
READY One per object. Object is working. x x
LD. 1-4 Four per object. Outputs for level x x x
detectors 1-4.
Metal StripEdge within measuring range and x
distance < 70 mm
Primary StripEdge within measuring range and x
distance < 50 mm
Comp Set Indicates used Comp Set x
SD Output for step detector x
SC One per object. The object is running in x x
Single cell A or B mode.
SCA One per object. Object is running in x x
Single cell A mode.
SCB One per object. Object is running in x x
Single cell B mode.
Single Edge The object is running in Single Edge A x
mode or Single Edge B mode
Single Edge A The object is running in Single Edge A x
mode
Single Edge B The object is running in Single Edge B x
mode
* ReadyA is recommended output for indication of working system

3BSE023139R0401 Rev A B-17

Millmate Roll Force Systems with Millmate Controller 400, User Manual
Appendix B Profibus-DP Fieldbus Communication

B.4.5 Error Handling

When you start commissioning, first make sure that the bus stations have stored
the correct address.
Check that the bus is terminated correctly.
At the very beginning when installing the bus, be careful not to get the A and B lines
of the bus mixed up.
Interchanging the A and B lines in the plug connector to the slave can mean that you can reach
all other slaves but not this one.
If the mix-up occurs while looping through in the plug connector, you will also not be able to
access any of the stations behind.
If you have wired a short circuit (i.e., short circuited the A and B lines), this can mean that you
cannot access the slaves starting at a certain point.
Additional sources of errors which you can locate by evaluating the diagnostic information
are listed below.
Profibus indication lamp:
OFF = No communication
ON = Communication to MC 400 OK (address is correct and data is exchanged)
Flashing = Communication active but, with errors

B.5 Technical Specifications

• Communication type: Profibus-DP. The MC 400 is a slave.
• Interface: fully insulated RS 485.
• Transfer rate: 12 Mbits/s. Automatic slow down to 9600 bits/s.
• Input message: 10 bytes.
• Output message: 6 bytes.
• Implementation: ASIC SPC3.
• Connection according to Profibus standard EN 50 170 (connector X31).

B.6 Examples of Recommended Setup

This section gives recommendations on how to arrange and designate measurement values,
variables and Booleans when setting up the Fieldbus communication.

B-18 3BSE023139R0401 Rev A

 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section B.6.1 One Standard Load Cell Object for MRF or MST

B.6.1 One Standard Load Cell Object for MRF or MST

One standard object

Two load cells with separate signals

MC 400

Object 1

Signal input
A

Signals from MC 400 to PLC

Value 1 Load cell A Object 1
Value 2 Load cell B Object 1
Value 3 Total value Object 1
Value 4 Difference Object 1
Boolean in 7 Ready all Object 1
Boolean in 8 Syserr Object 1

Signals to MC 400 from PLC

Variable 1 Coiler diam.* or Pass line* Object 1
Boolean out 1 Zero Set Object 1

*) if this function is used

3BSE023139R0401 Rev A B-19

Millmate Roll Force Systems with Millmate Controller 400, User Manual
Appendix B Profibus-DP Fieldbus Communication

B.6.2 Two Standard Load Cell Objects for MRF or MST

Two standard objects

Two + two load cells with separate signals

MC 400
Object 1

Signal input
A

Object 2

Signal input
A

Signals from MC 400 to PLC

Value 1 Load cell A Object 1

Value 2 Load cell B Object 1

Value 3 Load cell A Object 2

Value 4 Load cell B Object 2

Boolean in No 5 Ready Object 1

Boolean in No 6 Ready Object 2

Boolean in No 7 Ready all Object 1**

Boolean in No 8 Syserr Object 1**

**) object No. identity does not matter

Signals to MC 400 from PLC

Variable 1 Coiler diam.* or Pass line* Object 1

Variable 2 Coiler diam.* or Pass line* Object 2

Boolean out No 1 Zero Set Object 1

Boolean out No 2 Zero Set Object 2

*) if this function is used

B-20 3BSE023139R0401 Rev A

 Millmate Roll Force Systems with Millmate Controller 400, User Manual
Section B.6.3 Millmate Strip Scanner Object

B.6.3 Millmate Strip Scanner Object

MC 400

RS-485

Signals from MC 400 to PLC

Value 1 Edge A Object 1

Value 2 Edge B Object 1

Value 3 Width Object 1

Value 4 Off Center Object 1

Boolean in No 2 Single Edge* Object 1

Boolean in No 3 Single Edge A* Object 1

Boolean in No 4 Single Edge B* Object 1

Boolean in No 5 Metal Object 1

Boolean in No 6 Primary Object 1

Boolean in No 7 Ready all

Boolean in No 8 Syserr

*) used in Single Edge Mode

Signals to MC 400 from PLC

Variable 1 Nominal Width*

Variable 2 Nominal Thickness

Boolean out No 1 Zero Set

Boolean out No 2 Single Edge A*

Boolean out No 3 Single Edge B*

Boolean out No 4 Dual Edge*

*) used in Single Edge Mode

3BSE023139R0401 Rev A B-21

Millmate Roll Force Systems with Millmate Controller 400, User Manual
Appendix B Profibus-DP Fieldbus Communication

B-22 3BSE023139R0401 Rev A

 Millmate Roll Force Systems with Millmate Controller 400,
Appendix C Drawings Appendix C- Drawings
C.1 Millmate Controller 400 in Wall Cabinet, Dimension Drawing, 3BSE017454, Rev. B

3BSE023139R0401 Rev A C-1

Millmate Roll Force Systems with Millmate Controller 400,
Appendix C- Drawings C.2 Wall Cabinet Cylmate/Millmate Controller, Dimension Drawing, 3BSE022232D0064, Rev. C

C-2 3BSE023139R0401 Rev A

 Millmate Roll Force Systems with Millmate Controller 400,
C.3 MNS Select Cabinet, Dimension Drawing, 3BSE017052D64, Rev. B Appendix C- Drawings

3BSE023139R0401 Rev A C-3

Millmate Roll Force Systems with Millmate Controller 400,
Appendix C- Drawings C.4 Millmate Controller 400, Dimension Drawing, MC 400 on 19” Mounting Plate, 3BSE017453D0064, Rev. A

C-4 3BSE023139R0401 Rev A

 Millmate Roll Force Systems with Millmate Controller 400,
C.5 Millmate Controller 400, Dimension Drawing, 3BSE017585, Rev. A Appendix C- Drawings

3BSE023139R0401 Rev A C-5

Millmate Roll Force Systems with Millmate Controller 400,
Appendix C- Drawings C.6 PFVI 401 Excitation Unit, Dimension Drawing, 3BSE028251, Rev. -

C-6 3BSE023139R0401 Rev A

 Millmate Roll Force Systems with Millmate Controller 400,
C.7 Vibration Isolators for Millmate Controller 400, Erection Drawing, 3BSE017462D0090, Rev. - Appendix C- Drawings

3BSE023139R0401 Rev A C-7

Millmate Roll Force Systems with Millmate Controller 400,
Appendix C- Drawings C.8 Millmate Operator Unit 410 (PXAH 411), Dimension Drawing, 3BSE086846, Rev. -

C-8 3BSE023139R0401 Rev A

 A

c ABB Industrial Systems AB

3BSE023139R0401 Rev A
B
C.9 Relay Board, PFVK 128, Circuit Diagram, 3BSE010547D0002, Rev. B

Prep. PAMP/FMGE J Palmquist 2015-04-21 CIRCUIT DIAGRAM Cont.sh.

We reserve all rights in this document and the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly forbidden.
Appr. PAMP/FMGS F Norlund PFVK 128
Resp.dept. Relay Board -
PAMP/FMGS
Document number Lang. Rev. Sheet

Tuesday, April 21, 2015, 08:27:14 ABB Automation and Drives 3BSE010547D0002 en B 1

1 2 3 4 5 6

C-9
Millmate Roll Force Systems with Millmate Controller 400,
Appendix C- Drawings
Millmate Roll Force Systems with Millmate Controller 400,
Appendix C- Drawings C.10 Relay Board, PFVK 128, Arrangement Drawing, 3BSE010547D0004, Rev. E

C-10 3BSE023139R0401 Rev A

 c ABB Automation Products AB

3BSE023139R0401 Rev A
C.11 Matching Board, PFBK 401, Circuit Diagram, 3BSE027078D0002, Rev. -

Prep. ATCF/FM/GF J Palmquist 011204 CIRCUIT DIAGRAM Cont.sh.

We reserve all rights in this document and the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly forbidden.
Appr. ATCF/FM/GF E Wadman PFBK 401
Resp.dept. Matching Board -
ATCF/FM/GF
Document number Lang. Rev. Sheet
Tuesday, December 4, 2001, 18:23:10 ABB Automation Products AB 3BSE 027 078 D0002 en - 1

C-11
Millmate Roll Force Systems with Millmate Controller 400,
Appendix C- Drawings
Millmate Roll Force Systems with Millmate Controller 400,
Appendix C- Drawings C.12 Matching Device, PFVO 142, Circuit Diagram, 3BSE023732D2, Rev. A

C-12 3BSE023139R0401 Rev A

 Millmate Roll Force Systems with Millmate Controller 400,
C.13 Matching Device, PFVO 143, Circuit Diagram, 3BSE023150D2, Rev. A Appendix C- Drawings

3BSE023139R0401 Rev A C-13

Millmate Roll Force Systems with Millmate Controller 400,
Appendix C- Drawings

C-14 3BSE023139R0401 Rev A

—
ABB AB
Industrial Automation
Measurement & Analytics
Force Measurement
SE-721 59 Västerås Sweden
Tel: +46 21 32 50 00
Internet: www.abb.com/rollforce

3BSE023139R0401 en Rev A