Magnetic Power Systems, Inc.

1626 Manufacturers Drive. Fenton, MO 63026

Tel: 636.343.5550 Fax: 636.326.0608 [email protected]

INSTRUCTION MANUAL
DIGITRAC% 2
DIGITAL TENSION READOUT AND CONTROL

TABLE OF CONTENTS
Section Title Page Figure Title Page
1 Introduction ........................... 2 Specifications ....................... 20
2 Installation............................. 2 1 Wiring Isolated Inputs .......... 15
3 Electrical Connections .......... 3 2 System Types....................... 16
4 Setup and Calibration ........... 3 3 PA-2 Installation ................... 17
5 PA-2/PA-90 Installation......... 5 4 Wiring Diagrams................... 18
6 Optional Features ................. 6 5 Outline Dimensions .............. 19
7 Trouble Shooting ................ 12 6 Screen Flow Chart................ 21
8 Reset Procedures ............... 15

All of the information herein is the exclusive proprietary property of Magnetic Power Systems, Inc., and is
disclosed with the understanding that it will be retained in confidence and will neither be duplicated nor copied in
whole or in part nor be used for any purpose other than for which disclosed.

Copyright 2002, all rights reserved.

850A154-1
8/02 Rev. D
1. INTRODUCTION

The MAGPOWR% Model DIGITRAC% 2 is a microprocessor based control, designed for precise closed loop
tension control of a moving web. All data entry and calibration is done through the touch pad keyboard. The
DIGITRAC 2 is capable of controlling web tension in unwind, rewind, or point-to-point applications. Throughout
this manual, bold words or symbols represent keystrokes.

2. INSTALLATION

INSTALLATION

The DIGITRAC 2, Model D2E and its variants are intended for mounting on any flat vertical surface capable of
supporting it. See Figure 4 for dimensions. The D2E meets the environmental and mechanical requirements of
EN50178 with the exception that the degree of protection provided by the D2E enclosure is IP65 which is more
stringent than the standard. If the IP65 rating is required in the final installation, sealing type cable grips should
be used for cable entry. Four mounting holes are provided for attachment of the D2E to the mounting surface.
The means of attachment should comply with the essential requirements of the appropriate standard(s) and is
the responsibility of the installer.

The DIGITRAC 2, Model D2 and its variants are intended for installation through a DIN panel opening. The
panel itself should exhibit sufficient strength to support the weight of the D2 as well as insure the integrity of the
environmental seal. The D2 maintains a degree of protection of IP65 over its front panel. It also meets the
environmental and mechanical requirements of EN50178. The D2 mounting clips found on both sides of the
enclosure behind the front panel will accommodate panel thickness of 0.06 inches (1.5mm) to 0.5 inches
(12mm).

Wiring to and from the enclosure must be done with double or reinforced insulation or protective screening which
provides protective separation. All wiring outside either of the DIGITRAC 2 enclosures should comply with the
essential requirements of the appropriate standard(s) and is the responsibility of the installer.

If using a magnetic particle clutch or brake, see Section 5 to install the Model PA-2 or PA-90 Power Amplifier.

WARNING: DISCONNECT MAINS BEFORE OPENING ENCLOSURE

MAINTENANCE

The only maintenance that may be required on DIGITRAC 2 is fuse replacement. Replacement of any fuse
requires opening the enclosure, which circumvents the enclosure IP rating. To replace a fuse:

On Model D2 and its variants: On Model D2E and its variants:

1. Disconnect the supply mains. 1. Disconnect the supply mains.

2. Remove the two screws on the rear of the D2 2. Open the door of the D2E by loosening the
which retain the top cover. two retaining screws.
3. Remove the top cover. 3. Remove the PA-2 or PA-90 power amplifier
4. Remove the PA-2 or PA-90 power amplifier if present.
if present 4. Remove and replace the blown fuse.
5. Remove and replace the blown fuse. 5. Re-install the PA-2 or PA-90.
6. Re-install the PA-2 or PA-90 and the top cover. 6. Close the door and re-tighten the retaining screws.
7. Reconnect supply mains. 7. Reconnect supply mains.

2
3. ELECTRICAL CONNECTIONS

Figure 3 shows the connections that are required for the basic DIGITRAC 2 system. They are:

115 or 230 vac power

One or two MAGPOWR tension sensors
RUN/STOP using the DIGITRAC 2 internal logic supply
OUTPUT to clutch, brake, motor controller, etc
Power Amplifier input (if used) 115 vac for 90 vdc clutch or brake, or 24 vdc for a 24 vdc clutch or brake.

See Section 6 for other options and connections.

Route AC power away from sensor and control wiring. MAGPOWR sensor cables are color coded on the
nameplate. Run all wiring in shielded cable. Connect shields to the enclosure using the standoffs provided.
Maximum shield length and maximum length of wires outside of the shield is 3 inches (75 mm).

4. SETUP AND CALIBRATION

Apply power.
Screen contrast can be adjusted using SHIFT,B and é orê.

SETUP #

STATUS

A = AUTOMATIC
S = STOPPING
H = HOLD
M = MANUAL USE
E = E-STOP ANALOG DIGITAL CONFIGURE
OFF BAR GRAPH READOUT TO SELECT
OF TENSION OF TENSION UNITS &
LANGUAGE

The home screen (above) always appears at power up. HOME also returns you to this screen.

Keyboard Layout and Programming See Cover for keypad layout.

CLEAR clears numeric inputs and other keystrokes.

SHIFT selects the shifted (white) functions
NEXT and PRIOR change to next or prior screens. é or ê change the value of the parameter displayed on the
screen. See Figure 6 for a complete programming flow chart.

3
4.1 System Set up

Basic calibration cannot be performed if E-STOP is open,

or if RUN/STOP is in run mode.

A complete flow chart is shown in Figure 6.

To begin basic calibration, do the following:

Press SHIFT,
Press PROGram,
Use or to select )PROGRAM: CALIBRATE(,
Press NEXT to select )CALIBRATE BASIC(,
Press NEXT to display )SELECT SYSTEM(.

Use é or ê to select desired system type. See Figure 1 for a

description of system types. If using a regenerative drive, see
Section 6.9 to determine system type.

Then continue through the flow chart at right entering the

desired data in each screen.

4.2 Tension Sensor Calibration

NOTE: Continuing beyond this point will erase any

previous sensor calibration in this setup.

Sensor calibration will require loading the sensor roll

with a known force. The known force will be applied
using a weight and a temporary web as shown below.
The temporary web should be threaded as the web
would normally be threaded in the machine to ensure
the same wrap angles. In wide web applications, the
known force should be applied near the center of the
sensing roll using a narrow web such as a rope.

Follow the steps at the right to calibrate the tension

sensors.

4
4.3 Dynamic Tuning

Use NEXT or PRIOR to enter the DESIRED TENSION screen and enter the
desired value. Follow the flow chart, Figure 6, to enter CALIBRATE DYNAMICS.

When asked to OPTIMIZE in any of the following steps do the following:

1. Press and hold ê until the tension becomes

unstable.
2. Press and hold é until the tension is again stable. System stability can
be observed on the bar graph.

Run the machine at a moderate speed, with the control in AUTOMATIC

mode and perform dynamic calibration using the above procedure in the
indicated sequence.

STABility is normally optimized at full roll. COMPensation is normally

optimized at core. If the tension becomes unstable at some other roll
diameter see )Tension Oscillates( in Troubleshooting, Section 7.

5. INSTALLATION OF MODEL PA-90 or PA-2 Power Amplifier (if used)

5.1 PA-90

Install the PA-90 before applying power to the control

Remove the D2 cover, or open the D2E door.
Set JP6 on the D2 p.c. board to “0-10V” and “voltage”.
Set JP1 on the power amplifier for the desired output current range.
On Model D2, unplug TB6 and remove the knockout from the rear of the enclosure.
Mount Power Amplifier per Figure 2 using the standoffs provided with the PA-90.
Resecure cover or door.

When using the PA-90, the DIGITRAC 2’s 0 to 10 vdc control output is still active but no longer isolated, and is
referenced to the AC line.

5.2 PA-2

Install the PA-2 before applying power to the control.

Remove the D2 cover, or open the D2E door.
Set JP6 on the main PCB to )0-10V( and )VOLTAGE(.
Set JP1 and JP2 on the power amplifier per Figure 2 for the desired output voltage and current range.
On model D2 unplug TB7 and remove the knock-out from the rear of the enclosure.
Mount Power Amplifier per Figure 2 using the standoffs provided with the PA-2.

When using the PA-2, the DIGITRAC 2’s 0 to 10 vdc control output is still active but no longer isolated, and is
referenced to the AC line.

5
6. OPTIONAL CONNECTIONS, FUNCTIONS AND OTHER TECHNICAL INFORMATION

TABLE OF CONTENTS
HARDWARE

ALTERNATE TENSION INPUTS ............................................................... 6.1

DIAMETER INPUT ..................................................................................... 6.2
WEB SPEED INPUT................................................................................... 6.3
RUN/STOP ................................................................................................. 6.4
E-STOP ...................................................................................................... 6.5
REMOTE TENSION ON/OFF..................................................................... 6.6
ISOLATED LOGIC INPUTS (RUN/STOP, ETC.) ....................................... 6.7
SELECTING OUTPUT VOLTAGE/CURRENT........................................... 6.8
+5 vdc SUPPLY .......................................................................................... 6.9

PROGRAM OPTIONS

OPERATOR SCREENS ............................................................................. 6.10

UNITS OF MEASURE ................................................................................ 6.11
LANGUAGE ................................................................................................ 6.12
MANUAL MODE ......................................................................................... 6.13
TAPER TENSION....................................................................................... 6.14
INERTIA COMPENSATION ....................................................................... 6.15
HOLD LEVEL CONTROL ........................................................................... 6.16
OPTIMIZE METHOD .................................................................................. 6.17
SETUPS AND COPY SETUPS .................................................................. 6.18
SECURITY.................................................................................................. 6.19
ITEM NUMBERS AND SCREEN DESCRIPTIONS.................................... 6.20

6.1 ALTERNATE TENSION INPUTS

100 mv/v TENSION SENSORS

On the main PCB cut jumpers JP11 and JP12.

Connect wires to TB2 and TB3 as shown using shielded
wiring. Only one full bridge can be used.

10 vdc TENSION SIGNAL

On main PCB cut jumpers JP10, JP11, JP12 and JP13.

Connect signal between terminals TB2.1(+) and TB2.2(-)
using shielded wiring. TB2.2(-) should also be connected to
TB3.1 (GND).

6.2 DIAMETER INPUT

The DIGITRAC 2 uses the diameter of the roll on unwinds and rewinds for inertia compensated stopping and on
rewinds for providing taper tension. When no diameter input is provided the DIGITRAC 2 estimates diameter.
Using a diameter input gives more accurate results.

Select the DIAMETER INPUT TYPE under PROGRAM-CONFIGURE. Connect a diameter sensor between
TB3.7(+) and TB3.6(-) using shielded wiring.

VOLTAGE (0 to 10 vdc) Voltage must be proportional to diameter (i.e. the output at core cannot be 0 vdc).
Select )VOLTAGE( on JP15 on the main PCB.

6
PULSE (0 to 5 vdc, 0 to10,000 pps) Diameter is calculated by dividing web speed by this signal, which is
proportional to unwind/rewind RPM. Select )PULSE( on JP15 on main PCB. TB3.5 can be used to supply 5vdc
to the pulse generator. See current limitation in Paragraph 6.9. A web speed signal must be provided if the
diameter signal is )PULSE(.

6.3 WEB SPEED INPUT

The DIGITRAC 2 needs a web speed input if a PULSE type input is used to calculate diameter of the roll on
unwinds and rewinds.

Select the SPEED INPUT TYPE under PROGRAM-CONFIGURE. Connect a web speed sensor between
TB3.8(+) and TB3.6(-) using shielded wiring.

VOLTAGE (0 to 10 vdc) Select )VOLTAGE( ON JP9 on main PCB.

PULSE (0 to 5vdc, 0 to 10,000 pps) Select )PULSE( on JP9 on main PCB. TB3.5 can be used to supply 5 vdc to
the pulse generator. See current limitation in Paragraph 6.9.

6.4 LOGIC INPUTS

The logic inputs may be isolated with an external (5 to 24 vdc) power supply to interface with other equipment or
for increased noise immunity. Set JP7-8 (OPTO SUPPLY) to EXT (external) for an external isolated 5 to 24 vdc
power supply as shown in Figure 5. The current flowing in the logic inputs switches is 2 madc.

6.4.1 RUN/STOP
Connect TB4.4 to TB4.3 to initiate the stopping function. During STOP TIME the DIGITRAC 2 continues to
control tension as a closed loop system but INERTIA COMP and STOP MULTIPLIER are also activated.

See Section 6.7 to use isolated logic inputs (5 to 24vdc).

6.4.2 E-STOP (E-STOP IS AN AUXILIARY FUNCTION NOT INTENDED TO PROVIDE

CATEGORY 1 SAFETY PROTECTION)
Open the connection between TB4.2 and TB4.1 to initiate E-STOP. On unwinds the output goes full on. On all
other systems the output goes to zero.

See Section 6.7 to use isolated logic inputs (5 to 24vdc).

6.4.3 REMOTE TENSION ON/OFF

TENSION OFF sets the output to zero for all types of systems. For Type 2 and 3 systems OUTPUT LEVEL will
display 100% since these systems are reverse acting (i.e. tension decreases with increasing output).

Either of two optional modes of operation are selected using PROGRAM-CONFIGURE.

TOGGLE duplicates TENSION ON/OFF on the keypad. A momentary connection should be made between
TB4.5 and TB4.3 will toggle between TENSION ON and OFF. The TENSION ON/OFF key remains functional.

LEVEL turns TENSION OFF when TB4.5 is connected to TB4.3. The TENSION ON/OFF key is disabled.

See Section 6.7 to use isolated logic inputs (5 to 24vdc).

6.5 ISOLATED LOGIC INPUTS

If it is desired to isolate the logic inputs on TB4 to interface with other equipment or for increased noise immunity,
an external power supply can be used as shown in Figure 15. On the main PCB set JP8-7 (OPTO SUPPLY) to
EXT (external).

7
6.6 SELECTING OUTPUT VOLTAGE/CURRENT
The output voltage/current at TB5.1(+) and TB5.2(-) is set by positioning jumpers on JP6 as shown below. JP6
must be set for 0 to 10 vdc when the PA-2 or PA-90 Power Amplifier is used.

The –10 vdc to +10 vdc output is normally used with regenerative drives in torque mode. If the drive is wired so
that +10vdc creates torque in the first quadrant, use SYSTEM TYPE 2 or 4. Otherwise use SYSTEM TYPE
1 or 3. In either case tension can now increase or decrease from T1 to T2. See Figure 1.

If the PA-2 or PA-90 Power Amplifier is used, select current and voltage per Figure 2.

6.7 +5vdc SUPPLY (TB3.5(+) to TB3.6(-))

Total current capacity is 150 madc. Subtract sensor current of:

30 madc per MAGPOWR sensor

45 madc per 120 ohm sensor connected per Section 6.1

6.8 OPERATOR SCREENS

The operator screens are those normally used during machine operation and are accessed using NEXT ITEM or
PRIOR ITEM from the HOME screen. These are the only screens affected by the language selected per Section
6.10 and the only screens which are accessible when security is set per Section 6.17. The operator screens are
)TENSION(, )DESIRED TENSION(, )MANUAL LEVEL(, )OUTPUT LEVEL(, )TAPER PERCENT( (if TAPER
TENSION is selected), and )WEB SPOOL WIDTH( (if INERTIA COMPENSATION is selected).

6.9 UNITS OF MEASURE

PROGRAM-CONFIGURE can be used to select units of measure from:

ENGLISH (lb, in)

METRIC (kg, mm)
METRIC (n, mm)
6.10 LANGUAGE

PROGRAM-CONFIGURE can be used to select different languages. The selected language is used for the
operator screens which are )TENSION(, )DESIRED TENSION(, )MANUAL LEVEL(, )OUTPUT LEVEL(, )TAPER
PERCENT( and )WEB SPOOL WIDTH(. The available languages are:

ENGLISH (factory default)

FRANCAIS
DEUTSCH
ESPANOL
ITALIANO

8
6.11 MANUAL MODE

Switch to MANUAL mode at any time using SHIFT,. The output is now fixed at the level set in the MANUAL
LEVEL screen. Switch back to AUTOMATIC mode using SHIFT,

6.12 TAPER TENSION

Taper tension is used on rewinds to make better rolls by reducing full roll tension compared to core tension. Use
PROGRAM-CONFIGURE to select TAPER TENSION. Input the CORE DIAMETER and FULL ROLL
DIAMETER. TAPER PERCENT can now be entered on an operator screen. Percent taper is defined as the
percent decrease in tension from core to full roll.

If a diameter input is not used the DIGITRAC 2 estimates diameter. More accurate results are obtained if a
diameter input is provided. See Section 6.2. Either way, diameter must be calibrated using PROGRAM-
CALIBRATE-DIAMETER. When calibrating diameter, set TAPER PERCENT to 0.

6.13 INERTIA COMPENSATION

Extra torque is often needed to help stop large unwind rolls. STOP MULTIPLIER is available to increase the
output as a multiple of the present running torque. If better stopping results are required, they can be attained by
selecting INERTIA COMP using PROGRAM-CONFIGURE.

The DIGITRAC 2 asks for information needed to calculate the inertia of the unwind roll. The DIGITRAC 2 needs
this information to calculate the inertia and required stopping torque as the roll diameter changes.

If a diameter input is not used, the DIGITRAC 2 estimates diameter. More accurate results are obtained if a
diameter input is provided. See Section 6.2. Either way, diameter must be calibrated using PROGRAM-
CALIBRATE-DIAMETER. You must select INERTIA COMP before calibrating diameter.

Diameter must be calibrated while the machine is running, so required stopping torque can be
calculated.

The DIGITRAC 2 must also know roll width to calculate roll inertia. A new screen now appears in the operator
loop to input this information when INERTIA COMP is selected.

6.14 HOLD LEVEL CONTROL

During normal automatic operation the output changes to correct for changes in DESIRED TENSION, roll
diameter, etc. During the STOP TIME the DIGITRAC 2 is still in automatic mode, but the output is momentarily
changed by STOP MULTIPLIER or INERTIA COMP to help stop the unwind roll. At the end of STOP TIME the
DIGITRAC 2 switches to HOLD mode. In HOLD mode the output is fixed at the HOLD LEVEL. PROGRAM-
CONFIGURE can be used to set HOLD LEVEL CHANGES WITH TENSION and / or HOLD LEVEL CHANGES
WITH DIAMETER.

6.15 OPTIMIZE METHOD

You should normally select PI (Proportional-Integral) for tension control applications. OPTIMIZE changes P and
I to give optimum response. For special applications PID (Proportional-Integral-Derivative) can be selected
using PROGRAM-CONFIGURE.

9
6.16 SETUPS AND COPY SETUPS

There are six independent setups. Each contains its own complete set of parameters. Switch between setups
only while stopped using SHIFT, 1, etc. Each setup can be calibrated individually as described in Section 4, or
the sensor calibration and parameters in any one setup can be copied to any other setup. Complete setups can
be copied using PROGRAM-COPY SETUPS. COPY SETUPS always copies from a selected setup to the
present setup. You can also copy the factory DEFAULTS to the present setup.

6.17 PROGRAM-SECURITY

PROGRAM-SECURITY can be used to prevent changes to all the programming parameters. When secured,
only values in the operator screens can be changed.

6.18 ITEM NUMBERS AND SCREEN DESCRIPTIONS

The numbers following each screen parameter can be used to change the value using SHIFT, ITEM.

OPERATOR SCREENS

TENSION Displays current measured tension, setup number and operating mode.

DESIRED TENSION (18) The tension set point for AUTOMATIC mode and STOPPING mode.
(Does not appear when taper tension is used).

CORE TENSION (18) This is the DESIRED TENSION at CORE DIAMETER when taper
tension is used.

MANUAL LEVEL (48) The output set point percent when in MANUAL mode.

OUTPUT LEVEL Current output as a percent of maximum.

TAPER PERCENT (20) Appears only when taper tension is used. The core tension is reduced
by this percentage as the rewind roll increases to FULL ROLL
DIAMETER.
WEB SPOOL WIDTH (10) Appears only when inertia comp is used. Enter the width of the present
web to enable calculation of roll inertia.

PROGRAM-PARAMETER SCREENS

BAR GRAPH TIME (29) Update time for the tension / output bar graph.
Default is .050 sec.

DERIVATIVE TIME (34) Part of PID control. Gives an output adjustment proportional to the rate
of change of tension error. Error is the difference between the desired
tension and the measured tension.

ERROR LIMIT (19) This value limits the percent of error that is acted upon.

HOLD LEVEL (26) The output will stay at this percent level while in HOLD mode.

INTEGRATOR TIME (32) This time adjusts the response to errors. Larger values slow down the
response to rapidly changing error.

NUMERIC DISPLAY TIME (28) Update time for the tension / output digital readout.

OUTPUT LIMIT (21) The output will not go above this percent of maximum.
PROPORTIONAL GAIN (33) Generates an output adjustment proportional to the error.

START TIME (22) Provides a soft-start when starting with a slack web. The output is
limited to the HOLD LEVEL at start, but the limit level is increased with
time. This is the time taken to increase the limit to full output. A longer
start time will provide a softer start.

STOP MULTIPLIER (24) Upon receipt of a stop signal, the output is increased by this multiplier
(1 creates no increase). Since the output is proportional to roll
diameter, this is a simple adjustment for roll inertia.

STOP TIME (23) This is the time that DIGITRAC 2 stays in STOPPING (automatic)
mode after the stop signal is received. At the end of this time the
control goes to HOLD mode. Stop time should be slightly longer than
actual machine stopping time.

PROGRAM-CONFIGURE SCREENS

DIAMETER INPUT TYPE (11) NONE, VOLTAGE, or PULSE.

IS INERTIA COMP USED YES, NO
IS TAPER TENSION USED YES, NO
HOLD LEVEL CHANGES YES, NO
WITH DIAMETER
HOLD LEVEL CHANGES YES, NO
WITH TENSION
OUTPUT RANGE Normal, -10 vdc to +10 vdc
OPTIMIZE METHOD (44) PI or PID.
SELECT LANGUAGE ENGLISH, FRANCAIS, DEUTSCH, ESPANOL, or ITALIANO
SELECT UNITS (42) (lb, in), (kgm, mm), (n, mm)
SPEED INPUT TYPE (47) NONE, VOLTAGE, or PULSE.
TENSION ON/OFF TOGGLE, LEVEL.

The following appear only if taper tension is used:

CORE DIAMETER (14) CORE TENSION is commanded at this diameter.

FULL ROLL DIA. (12) At this diameter the tension will be reduced by the taper percent.

11
 The following appear only if inertia comp is used:

DIAMETER AT THIS WEIGHT The roll diameter at the entered weight. Diameter must be
calibrated while the web is running. It is not necessary to calibrate
at the maximum velocity.
ROLL WEIGHT The roll weight at any diameter in lbs or kgm.
RUNNING VELOCITY The maximum running web velocity. Typical velocity can be used.
TIME TO ZERO SPEED The time it takes the machine to stop when running at the above
velocity.
WIDTH AT THIS WEIGHT This width is used to calculate density for the above roll weight.

7. TROUBLE SHOOTING

PROBLEM POSSIBLE CAUSE SOLUTION OR DIAGNOSTIC

Screen blank or hard to read Contrast misadjusted Press SHIFT, B and é or ê to adjust.

Power select switch Set 115/230 vac power select switch to the
improperly set. appropriate voltage.

Output always low TENSION ON/OFF set to If REMOTE TENSION ON/OFF is set to
OFF )TOGGLE( press TENSION ON/OFF on the
keypad once.

If REMOTE TENSION ON/OFF is set to

)LEVEL( one or more of the remote tension
off switches are closed.

E-STOP is active (except If the internal logic is being used (the factory
unwind). default) TB4.2 must be connected to TB4.1
to disable E-STOP. Also verify JP8-7 set to
E-STOP is wired incorrectly. )INT(.

JP8-7 not set for the proper If an external logic supply is used see
logic supply. Section 6.5.

Output always high E-STOP is active (unwinds See above.

only).

E-STOP is wired incorrectly.

JP8-7 not set for the proper

logic supply.

Cannot enter PROGRAM, Not in HOLD mode: If the internal logic supply is being used (the
CALIBRATE, BASIC factory default) TB4.4 must be connected to
RUN/STOP not wired TB4.3 to be in HOLD mode. Also verify
correctly. JP8-7 set to )INT(.

JP8-7 not set for the proper If an external logic supply is used see
logic supply. Section 6.5.

)EXCESSIVE ROLL Sensor(s) misapplied The total weight of the sensor idler roll and
WEIGHT( shaft must be less than of sensor rating.
When two sensors are used this is the
combined rating of both (i.e. 100 lbs for two
50 lb sensors).
)MAXIMUM TENSION TOO Selected maximum tension is Calibration can be completed by using a
HIGH( out of sensor range. smaller maximum tension. See )Maximum
tension is out of range( below.

)SENSOR SIGNAL TOO Maximum tension is out of 1. This problem is often caused by loading
LOW ( sensor range. the sensor in the wrong direction. It can be
corrected by reversing +SIG and -SIG
(TB2-1 and TB2-2).

2. If signal direction is correct, calibration

can often be completed by using a
larger maximum tension. See
)Maximum tension is out of range(
below.

Maximum tension is out of When maximum tension is applied the load

sensor range. on the sensors must be less than the total
sensor rating and greater than 1/8 of total
sensor rating. When two sensors are used
this is the combined rating of both (i.e.
100 lbs for two 50 lbs sensors). Calculate
this load from:
LOAD = 2*MAX*SIN(WRAP/2)
where:
MAX = maximum tension entered during
sensor calibration.
WRAP=wrap angle.

Tension oscillates DIAGNOSTIC:

1. From the home screen use NEXT or
PRIOR to go to OUTPUT LEVEL.
2. While the machine is running record the
approximate output level.
3. Enter this value in the MANUAL LEVEL.
4. Switch to MANUAL mode.
5. If the tension continues to oscillate there
is an out of round roll or other machine
generated tension variation.
6. If oscillation stops the control may be
mistuned. See “ERROR LIM needs
adjustment.”

ERROR LIM needs 1. Go to OPTIMIZE ERROR LIM.

adjustment 2. Press and hold é until the oscillation
stops.
If ERROR LIM is max go to )COMP needs
adjustment(.

COMP needs adjustment 1. Go to OPTIMIZE COMP (ignore reference

to core).
2. Press and hold é until the oscillation
stops.
3. If oscillations cease, optimize ERROR
LIMIT.
3. If COMP is max go to )STAB needs
adjustment(.
Tension oscillates (continued) STAB needs adjustment 1. Go to OPTIMIZE STAB (ignore reference
to full roll).
2. Press and hold é until the oscillation
stops.
3. If oscillations cease, optimize COMP and
then optimize ERROR LIM.
4. If STAB is max go to )STAB is max(.

Tension oscillates (continued) STAB is max This is extremely rare. You have a system
that needs more than a 150 sec integrator to
be stable. Verify this result by performing
the diagnostic under )Tension oscillates(. If
verified this system may need to use PID for
the OPTIMIZE METHOD. Consult the
factory.

Front panel TENSION DIGITRAC 2 configured for When LEVEL is selected for TENSION
ON/OFF does not work LEVEL for external TENSION ON/OFF only external tension on/off can be
ON/OFF used.

E-STOP is active If the internal logic is being used (the factory

default) TB4.2 must be connected to TB4.1
E-STOP is wired incorrectly to disable E-STOP. Also verify JP8-7 set to
)INT(.
JP8-7 not set for the proper
logic supply. If an external logic supply is used see
Section 6.7.

Cannot change to a different Not in HOLD mode If the internal logic supply is being used (the
setup factory default) TB4.4 must be connected to
RUN/STOP not wired TB4.3 to be in HOLD mode. Also verify
correctly JP8-7 set to )INT(.

JP8-7 not set for the proper If an external logic supply is used see
logic supply Section 6.7.

14
8. RESET PROCEDURES

If it is desired to reset parameters to factory default values perform one of the following reset procedures:

A. 1. Simultaneously pressé and ê and hold for 2 seconds. )RESETTING PARAMETERS( will
appear on the screen for 1 second.
2. Program reset is complete. The basic (tension sensor) calibration is still in memory, but
dynamic calibration must be reprogrammed.
or

B. 1. Connect TB4.6 to TB4.3 for 2 seconds.

2. When )REMOVE FORMAT SIGNAL TO START( appears, remove connection.
3. Program reset is complete. The basic (tension sensor) calibration is still in memory, but
dynamic calibration must be reprogrammed.

or

C. 1. Turn the power to the DIGITRAC 2 )OFF( for 5 seconds.

2. Press SHIFT and 3 simultaneously.
3. While holding the keys down, turn the power )ON(.
4. Release both keys when the screen appears. The screen will display )TEST OR NORMAL?
TEST(
5. Press ENTER to display )DISABLE WATCHDOG
NO(
6. Press PRIOR ITEM to display )TEST OR NORMAL?
TEST(
7. Pressé to display )TEST OR NORMAL?
NORMAL(
8. Press ENTER.

9. Program reset is complete. The basic (tension sensor) calibration has been erased, and all
other programming has been reset to factory default values. Begin at Section 4 to reprogram.

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

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