Rollmax Digital Signal Processor DSP2 (Version B) User's Manual

Rollmax Digital Signal Processor
DSP2 (Version B) User's Manual
90509 Rev B
December 2020
© Copyright 2020
The contents of this manual and the associated software are the property
of KELK (Vishay Precision Group Canada ULC) and are copyrighted. All
Rights Reserved. No part of this publication may be reproduced, stored
in a retrieval system, or transmitted in any form or by any means, without
the prior written permission of KELK.
Company Information
Vishay Precision Group Canada ULC (KELK)
48 Lesmill Road
Toronto, Ontario
M3B 2T5, Canada
Phone: (416) 445-5850
Fax: (416) 445-5972
E-mail: kelk@vpgsensors.com
Web: http://www.kelk.com
Warranty
The KELK Rollmax Digital Signal Processor, Model DSP2 (Version B), is
warranted against defects in materials and workmanship for one year
from the date of installation or 18 months from the date of shipment,
whichever occurs first. This warranty is independent of the KELK
Rollmax Load Cell Five Year Conditional Warranty.
If the equipment proves to be defective during the warranty period, the
obligation of KELK is limited to repair or replacement at our factory or at
the premises of our designated local agent. If the customer wants KELK
to do the repair or replacement at their site:
 The customer must agree to pay KELK’s standard hourly service

rates for site and travel time, plus transportation costs and living
expenses at cost.
 If feasible, KELK will do the necessary work at a suitable

location in the customer’s premises free of any charges for
replaced materials or components.
Products submitted for a warranty claim shall be shipped prepaid by the
customer to and from our factory where they will be inspected and
repaired or replaced, at our option.
Under no circumstances shall KELK be liable for consequential damages.
Table of Contents
Table of Contents
Table of Contents................................................................ 3
1 About this Manual ......................................................... 7

1.1 Intended Use ............................................................................. 7
1.2 Symbols Used in This Manual ................................................... 7
1.3 Safety Information ..................................................................... 8
1.3.1 Anti-static Precautions ......................................................... 9
1.3.2 Electric Safety ...................................................................... 9
1.4 Related Publications .................................................................. 9
2 About the DSP2 ........................................................... 10

2.1 Conformity ............................................................................... 10
2.2 Hardware Configuration .......................................................... 11
2.2.1 Basic Configuration ........................................................... 12
2.2.2 Optional Circuit Boards ...................................................... 12
2.3 System Features ..................................................................... 13
2.3.1 Single Sensor Operation ................................................... 13
2.3.2 Calibration.......................................................................... 13
2.3.3 Zero ................................................................................... 14
2.3.4 Self-Test ............................................................................ 14
2.3.5 Wrap Angle Compensation ................................................ 14
2.3.6 Lockout .............................................................................. 14
2.4 Signal Processing, Load Outputs and Alarms......................... 15
2.4.1 Roll Force, Pressure and Fixed-wrap-angle Tension
Applications ....................................................................... 15
2.4.2 Variable-wrap-angle Tension Applications ........................ 18
2.5 System Specifications ............................................................. 20
2.5.1 Physical and Power Specifications .................................... 20
2.5.2 Performance ...................................................................... 20
3 Front Panel Interface ................................................... 23

3.1 Display and Keypad ................................................................ 23
3.2 Menu Structure ........................................................................ 25
3.2.1 Symbols Used in Menu Mode ............................................ 26
3.2.2 Setup Menu ....................................................................... 27
3.2.3 Diagnostics Menu .............................................................. 39
3.2.4 Operations Menu ............................................................... 40
4 User Access Program ................................................. 41

4.1 Key UAP Features ................................................................... 41
4.2 About the UAP Window ........................................................... 42
4.2.1 Menu Bar ........................................................................... 43
4.2.2 Toolbar............................................................................... 49
90509 Rev B, December 2020 Page 3

Table of Contents
4.2.3 Navigation Panel ............................................................... 50

4.3 Device Main Panel .................................................................. 51
4.4 Setup Panel ............................................................................. 55
4.4.1 Input Channels .................................................................. 56
4.4.2 Analog Outputs .................................................................. 59
4.4.3 Load Alarms....................................................................... 60
4.4.4 Communication .................................................................. 61
4.4.5 FPI Display ........................................................................ 63
4.4.6 IBA ..................................................................................... 65
4.4.7 I/O Settings ........................................................................ 69
4.5 Diagnostics Panel .................................................................... 70
4.5.1 System Status.................................................................... 70
4.5.2 Hardware Identification ...................................................... 72
4.5.3 Channel Configuration Data .............................................. 73
4.5.4 Factory Calibration............................................................. 73
4.5.5 Simulation/Test .................................................................. 74
4.5.6 IO Test ............................................................................... 76
4.6 UAP Configuration File ............................................................ 77
4.6.1 Load Device Configurations from a Configuration File ...... 77
4.6.2 Load Setup Data from a Configuration File to a Device .... 78
4.7 Event Logging.......................................................................... 80
4.8 Additional UAP Functionality ................................................... 82
4.8.1 SAG Mill Applications ........................................................ 82
4.8.2 Disabling Alarm Reporting in Negative Load (SGIB Mask
Faults) ................................................................................ 82
4.9 Software Upload ...................................................................... 83
5 Installation ................................................................... 85
5.1 Unpacking the DSP2 or DSP2 Cabinet ................................... 86
5.2 Installing the DSP2 Cabinet .................................................... 87
5.3 Connecting Cables or Wiring ................................................... 90
5.3.1 AC Power Cable ................................................................ 94
5.3.2 Sensor Wiring .................................................................... 94
5.3.3 Logic I/O Wiring ................................................................. 98
5.3.4 Analog Output Wiring ........................................................ 98
5.3.5 Auxiliary Analog Input Wiring ............................................. 98
5.3.6 Ethernet Cables ................................................................. 99
6 Setup and Configuration ........................................... 100

6.1 Sensor Calibration ................................................................. 101
6.1.1 Measure Interconnect Cable Resistance ......................... 103
6.1.2 Calculate CTL with Resistance Correction for four-
conductor wiring............................................................... 104
6.2 Signal Processing, Limits and Scaling .................................. 105
6.2.1 Channel Input Range ....................................................... 105
6.2.2 Load Measurement Set ................................................... 105
6.2.3 Analog Outputs and Output Scaling ................................ 107
6.2.4 Load Alarms and Threshold Limits .................................. 108

Table of Contents
6.3 Signal Filtering ....................................................................... 109

6.4 Tension Measurement Calibration ........................................ 112
6.4.1 Tensiometer Setup Data Sheet ....................................... 113
6.4.2 Tensiometer Application Data Sheet ............................... 115
6.4.3 Wrap Angle Compensation .............................................. 117
6.5 Pre Power-up Check ............................................................. 119
6.6 Setup and Configuration - User Access Program ................. 119
6.6.1 Set Up UAP-to-DSP2 Communications ........................... 119
6.6.2 Set Up Input Channels .................................................... 123
6.6.3 Specify Analog Outputs ................................................... 138
6.6.4 Configure Load Alarms .................................................... 139
6.6.5 Set Up Communication Ports .......................................... 140
6.6.6 Configure the FPI Display ................................................ 142
6.6.7 Set Up IBA ....................................................................... 143
6.6.8 Change Logic I/O Settings ............................................... 150
6.6.9 Apply Changes and Run Configuration ........................... 151
6.6.10 Verify Setup and Load Output ......................................... 153
6.6.11 Save Configuration .......................................................... 157
6.7 Setup and Configuration - Front Panel Interface................... 159
6.7.1 Configure Ethernet Ports ................................................. 160
6.7.2 Set Up Input Channels .................................................... 162
6.7.3 Specify Analog Outputs ................................................... 165
6.7.4 Configure the FPI Display ................................................ 166
6.7.5 Configure Load Alarms .................................................... 168
6.7.6 Change Logic I/O Factory Settings .................................. 169
6.7.7 Initiate Configuration ........................................................ 171
7 System Monitoring and Controls ............................. 172

7.1 Load Display .......................................................................... 172
7.2 Load Alarms .......................................................................... 173
7.3 System Status ....................................................................... 173
7.4 Single Sensor Operation ....................................................... 173
7.5 Zero ....................................................................................... 174
7.6 Calibration ............................................................................. 176
7.7 Wrap Angle Compensation ................................................... 177
7.8 Self-Test ................................................................................ 178
7.9 Reset ..................................................................................... 179
7.10 Lockout .................................................................................. 179
8 Maintenance ............................................................... 181

8.1 Replacing a Fuse .................................................................. 181
8.2 Replacing the DSP2 ............................................................. 183
8.3 Packing the DSP2 or Sensors for Returning to Factory ........ 186
9 Troubleshooting ........................................................ 187

9.1 Viewing Fault Condition and Status ...................................... 187
9.2 Troubleshooting .................................................................... 190
9.3 Troubleshooting Channel and SGIB Faults ........................... 191
9.4 Checking Analog Output Fault .............................................. 196
9.5 Interpreting User Initiated Error Conditions ........................... 197

Table of Contents
9.6 Correcting Unexpected Loads and Alarms ........................... 198

9.7 Doing the Cable and Sensor Tests ....................................... 199
9.7.1 System Test ..................................................................... 199
9.7.2 Load Cell Cable Test ....................................................... 201
9.7.3 Sensor Test ..................................................................... 201
9.8 Simulating Loads ................................................................... 203
9.9 Interpreting Event Status Log ................................................ 204
10 Parts Data................................................................... 208

10.1 Options and Spares ............................................................... 208
10.2 DSP2 Order ........................................................................... 209
10.3 DSP2 Wiring Harness ........................................................... 209
11 Fieldbus Interfaces and Setups................................ 211

11.1 Ethernet Modbus/TCP Communication and Setup ............... 211
11.1.1 Modbus-TCP Module and Indicators ............................... 212
11.1.2 Ethernet Settings ............................................................. 213
11.1.3 Processing ....................................................................... 215
11.1.4 Data Format for Communications .................................... 216
11.1.5 Modbus-TCP Memory Map.............................................. 218
11.2 Profibus Communications & Setup ....................................... 220
11.2.1 Profibus DP-V1 X-gateway .............................................. 220
11.2.2 Profibus DP-V1 X-gateway External View ....................... 222
11.2.3 Profibus DP-V1 Connector .............................................. 223
11.2.4 Profibus DP-V1 Status Indicators .................................... 223
11.3 Profinet Communications & Setup ........................................ 225
11.3.1 Profinet X-gateway External View ................................... 225
11.3.2 Status LEDs ..................................................................... 227
11.3.3 Profinet Connectors ......................................................... 228
11.3.4 Profinet GSD File ............................................................. 228
11.3.5 Data Format for Communications .................................... 228
11.3.6 Data Identification ............................................................ 230
12 Glossary of Terms and Acronyms ........................... 231

About this Manual
1 About this Manual

This User’s Manual contains important instructions for safe and efficient use of the Rollmax
Digital Signal Processor model DSP2 (Version B). The model DSP2 (Version B) is referred as
the DSP2 throughout this manual. In addition, this manual is also part of the Load Measuring
System Manual or Tension Measuring System Manual. It must be kept accessible in the nearby
area for any persons working with this equipment.
To set up and configure the DSP2, you must read carefully and follow the applicable procedures
in this User’s Manual before using the DSP2 system. In addition, you must take precautions as
to the Warnings and Cautions contained in this manual. Note also that:
 Information and illustrations in this User’s Manual are for basic understanding and can
vary from the model and software revision of this system.
 KELK (Vishay Precision Group Canada ULC) reserves the right to change the
specifications of the hardware and the software described in this manual at any time and
without prior notice.
 Translation of this manual into another language may result in loss of meaning and
content; in all cases, the content of the English version upon which the translation was
based prevails.
 If additional technical assistance is required, call or contact KELK or our designated

agent. Company information is on the back of the title page.
1.1 Intended Use

Use the DSP2 only with factory calibrated KELK strain gage sensors in
load, pressure or tension measuring systems. Do not use the DSP2 in
any other way not expressly described in this manual or approved by
authorized KELK personnel.
Failure to operate the system other than its intended use and making
modifications to the system and its components can lead to personal
injury or equipment damage for which KELK assumes no liability. In
addition, the outputs and the alarms will be unpredictable.
Only trained personnel who are knowledgeable of general electrical
safety measures for electrical devices should operate this system.
1.2 Symbols Used in This Manual

This user’s manual uses following symbols for safety instructions and
important notices:

About this Manual
Caution or Warning
Indicates a potentially hazardous situation which, if not
avoided, can result in personal injury.
Electrical Hazard
Indicates a potentially hazardous electrical condition which,
if not avoided, can result in personal injury or equipment
damage.
ESD precautions
Indicates Electrostatic Discharge (ESD) condition existed
and precautions must be used to protect electronic
components.
Note, Important or Tip

Provides special information, references or tips about
how to operating the system more efficiently.
1.3 Safety Information

The precautions outlined below must be followed strictly for protecting the
equipment. Failure to follow these precautions can result in personal
injury or cause permanent damage to the system.
 Electrical Hazard: Do not apply voltage levels

that exceed the specified voltage range. Doing
so could cause fire or an electrical shock.
 Before installing or moving the system, turn off

the power and disconnect the power cord from
the power source.
 Cautions:
 Do not use the system in a high-humidity environment. Do not

place the system near a high-humidity environment. Doing so
could cause fire or an electrical shock.
 Do not disassemble any system components. Do not attempt

to pull apart; repair or modify system components on your
own. Contact KELK for repair or modification.

About this Manual
1.3.1 Anti-static Precautions

Electrostatic discharge (ESD) can cause serious damage to electronic
components in the DSP2. Dry climates are especially susceptible to
ESD. Whenever you open the DSP2 and handle any of the electrical
components, use the following anti-static precautions and guidelines:
 Wear an anti-static wristband: Wearing an anti-static

wristband can help to prevent ESD from damaging any
electrical component.
 Ground yourself frequently: Before handling any

electrical component, touch any grounded conducting
material. When you handle electrical component,
frequently touch any conducting materials that are
connected to the ground.
 Use an anti-static pad: When configuring or working

with an electrical component, place it on an anti-static
pad. This reduces the possibility of ESD damage.
 Handle electrical component by its edges: When

handling the electrical component, hold the electrical
component by its edge only.
1.3.2 Electric Safety
 Caution: Carefully route the power cord so it is not a

work hazard. Do not place heavy objects over the
power cord. If the equipment is not used for an
extended period, disconnect it from the power source.
1.4 Related Publications
Manual Publication #
Tension Measurement System Manual or Job No. specific

Load Measurement System Manual
ibaPDA and ibaAnalyzer User’s Manual 90444
Floor Mounted Cabinet Description & Specifications DS.FMC.551
Wall Mounted Cabinet Description & Specifications DS.WMC.552
DSP2 Description & Specifications DS.DSP2.803
Interconnecting Cable DS.INC.555

About the DSP2
2 About the DSP2

The Rollmax Digital Signal Processor, Model DSP2 is a principal component of KELK load or
tension measuring systems. It is used with KELK strain gage sensors as a stand-alone system
or in combination with other systems in providing:
 Force, tension or pressure measurement in the rolling and forming of steel sheet and
sections
 Tension measurement in steel, aluminum, paper process lines or other mills
 Force & Pressure measurement in harsh industrial and mining environments.
2.1 Conformity
The DSP2 conforms to the requirements of the following organizations
and regulations:
CE marking and certification

CE marking is a declaration by the manufacturer that a product meets all the
appropriate provisions of the relevant legislation implementing certain European
Directives.
This equipment fulfills the requirements of current European and national
regulations relating to the following:
 CE EMC Directive 2014/30/EU, complying with the following Standards:

IEC 61326-1:2012 / EN 61326-1:2013, CISPR 11:2009 +A1:2010/EN
55011:2009 +A1:2010, and FCC Part 15, Subpart B, Class A
 Safety Standards: IEC 61010-1:2010, per LVD Directive 2014/35/EU
The conformity has been tested and the corresponding declarations and
documentation are available from KELK.
Restriction of Hazardous Substances Compliant

Restriction of Hazardous Substances (RoHS) has been adopted by the European
Union and prohibits the use of six hazardous substances in electrical and
electronic products put on the market after July 1, 2006.
This equipment fulfills the requirements of current European and national
regulations concerning RoHS conformity.

About the DSP2
2.2 Hardware Configuration

The DSP2 is in an enclosed electronics unit suitable for 19-inch rack
mounting. The power switch and all connections are located on the rear
connector panel.
Figure 1 shows the hardware configuration of the DSP2. Note that the
basic hardware is shown in black color and optional circuit boards are
shown in blue color.
Figure 1: DSP2 Configuration

About the DSP2
2.2.1 Basic Configuration

The basic hardware configuration of the DSP2 shown in Figure 1
includes:
 A front panel assembly, which contains a LCD/OLED digital

display, input keys and LED system status signals
 A motherboard, which includes:

 Signal Processor Board containing circuitry to control system
functionality and measurement data processing and alarms
 A processor mezzanine board with:
 Connections for Ethernet communications
 Slots for other Proprietary Communications Boards
 Logic Inputs and Outputs (I/O):
 Accepts initiation of six functions: self-test, calibration,
zero, single sensor A operation, single sensor B operation,
and lockout. The inputs require either user supply DC
voltage or DSP2 internal power supply.
 Provides eight logic outputs for indication of system fault,
channel A fault, channel B fault, single sensor operation
and four load levels or load alarms
 Power supply that provides all applicable voltages to the

motherboard, circuit boards and other electronic components
within the DSP2
 Two Strain Gage Interface Boards (SGIBs). The SGIB provides

sensor excitation and analog signal processing, one for each
sensor
2.2.2 Optional Circuit Boards

The following optional boards shown in Figure 1 are installed as
necessary for applicable measuring application:
 Up to three Analog Output Boards, for a maximum of six analog

outputs
 An Auxiliary Analog Input Board for inputting analog wrap angle

data in tension measuring application with varying wrap angles
 A fieldbus interface card for the high-speed transmission of

digital data using Modbus/TCP protocol.

About the DSP2
2.3 System Features

The DSP2 has the following features and capabilities:
 Continuous monitoring of the measuring system, including the

DSP2 and two sensors
 Menu driven setup and configuration through the Front Panel
Interface or the User Access Program (UAP), no manual
hardware adjustments are required
 Individual, sum and difference load measurement, with analog
and digital outputs, programmable
 Sensor excitation and signal conditioning
 Load level and load alarms
 Data logging of measured values for Process Data Acquisition
System (ibaPDA)
 Self-Test
 Calibration
 Zero
 Single sensor operation
 Optional Wrap Angle Compensation (WAC) for tension
measuring application with variable wrap angles
 Load Simulation
 Lockout — to control user access
 Upgrade Electronic unit software
2.3.1 Single Sensor Operation

Single Sensor Operation, also known as load doubling, connects both
Channel A and B registers in the Load Measurement Set to the same
sensor channel. In case of a sensor or Strain Gage Interface Board
failure, use this operation to provide an output on both channels.
2.3.2 Calibration
The calibration operation fine-tunes the software offsets and software
gains to set the outputs of both channels to zero and recalibrate the

About the DSP2
system. Initiate this operation to verify and fine-tune the load measuring
system.
2.3.3 Zero
The zero operation (command) compensates for small changes in tare
weight, without affecting other measurement system settings. If the zero
operation is initiated, it adjusts the fine offsets to set both channel outputs
to zero and if enabled, indicates accumulated offset falls outside a range
of ± 20% of the defined channel input range.
2.3.4 Self-Test
The Self-Test is set to run automatically each time the system is powered
on. You can also initiate the self-test manually. Self-test temporarily
stops the digital and analog outputs and runs tests to verify parameters
used for normal system operation. Self-test gives results (status) of the
system only and does not take any corrective actions.
2.3.5 Wrap Angle Compensation

If one or both strip wrap angles vary in tension measuring applications, an
adjustment is required. Wrap Angle Compensation (WAC) provides this
adjustment by generating and applying a scaling factor using wrap angle
magnitude data.
2.3.6 Lockout
Lockout prevents making changes to the system setup and usage of the
Configuration, Reset and Simulation functions though the Front Panel
Interface (FPI). However, operations for Single Sensor, Zero, Calibration
and Self-Test are not locked out.

About the DSP2
2.4 Signal Processing, Load Outputs and Alarms

The DSP2 processes signals according to the setup configuration, then
calculates the load measurement sets and produces the applicable load
outputs and alarms. However, signal processing is different for roll force,
pressure and fixed-wrap-angle tension applications and variable-wrap-
angle tension applications.
2.4.1 Roll Force, Pressure and Fixed-wrap-angle Tension

Applications
Figure 2 shows an overview of the on-line signal processing for roll force,
pressure and fixed-wrap-angle tension measuring applications. For these
applications, the DSP2 processes the sensor signals as follows:
1. Apply zero offsets to the sensor signals.
2. Apply gain adjustments to yield Channel A and Channel B loads.
3. Calculate the sum (A+B) load and difference (A-B) load to complete
the Load Measurement Set.
Note: Figure 2 shows only one Load Measurement Set.

There are two measurement sets. One is
configurable signal filtering used for digital and
analog load outputs. The other, used for the
alarms, does not include the filter.
4. For mill control purposes, load measurement data are accessible

through:
 The Analog Outputs — each output can be configured for load

A, B, A+B or A-B, scaling factor adjusted and set to voltage or
current output
 Profibus DP or Profinet Interface
 Modbus/TCP
Note: Figure 2 shows only one analog output and one

load alarm. You can configure all analog outputs
(up to six) and four load alarms individually.

About the DSP2
5. The Load Alarms can be configured for load A, B, SUM (A+B) or DIF
(A-B), the threshold and response time are also configurable.
The zero offsets (Step 1) and gains (Step 2) are applied in two stages:
 During analog signal processing — set to coarse levels, during

Configuration to provide optimum resolution following
Analog/Digital (A/D) conversion. Configuration is done during
installation to obtain the optimum input scaling for the measuring
system, including tare weight compensation
 During subsequent digital signal processing — set to fine-tune

the offsets and gains for any adjustments introduced by
Calibration and Zero operations
The Load Measurement Set is also accessible, at a rate suitable for
monitoring and data logging, through the two Ethernet ports and the
optional Profibus/Profinet interface.
.

About the DSP2
Sensor A Shunt Resistor Sensor B
Sensor A Sensor B
Zero Offset A Calibration Calibration Zero Offset B
Target Load Target Load
Gain A Gain B
Channel A Channel B
Load Channel B Load Normal operation Load
Single Sensor
A Operation
Load Measurement Set
Channel A + Channel A -
Channel A Channel B Channel B Channel B
Ethernet
1&2 Output Scale Threshold
(Modbus/TCP)
Optional Analog Output Load Alarms

Profibus/Profinet A, B, SUM (A+B) for A, B, SUM (A+B)
Interface or DIF (A-B) or DIF (A-B)
Figure 2: Signal Processing: Roll Force, Pressure and Fixed-wrap-angle Tension Measuring
Applications

About the DSP2
2.4.2 Variable-wrap-angle Tension Applications

Signal processing for variable wrap angle tension measuring applications
is shown in Figure 3. Signal processing is the same as described in sub-
section 2.4.1 except that a scaling factor is applied following the gain
adjustment to compensate for the changes in the angles.
The scaling factor is calculated using lookup tables (entered during setup)
and mill sensors (connected to analog input) or manual inputs of wrap
angle magnitude.

About the DSP2
Sensor A Sensor B
Gain A Gain B
Wrap Angle Input 1 Wrap Angle Input 2
Lookup Table 1 Lookup Table 2
Wrap Angle Wrap Angle

Scaling Factor Wrap Angle Scaling Factor Scaling Factor
Channel A Channel B Load Channel B

Normal operation
Load Load
Single Sensor A
Operation
Ethernet
1&2 Output Scale Threshold
(Modbus/TCP)

Interface or DIF (A-B) or DIF (A-B)
Figure 3: Signal Processing: Variable-wrap-angle Tension Measurement

About the DSP2
2.5 System Specifications

The DSP2 system conforms to the following specifications:
2.5.1 Physical and Power Specifications
Operating Environment:
Location Fixed, indoors

Temperature 0°C to 50°C (32°F to 122°F)
Humidity 10 to 90%, non-condensing
Altitude 4000 m (13,120 ft.), maximum
Pollution degree 2. Ref IEC 61010-1
Storage Environment:
Temperature -20°C to 80°C (-4°F to 176°F)

Humidity 70% maximum at 40°C (104°F)
DSP2 Enclosure:
Style 19 inch rack mounting

Width 483 mm (19 in.)
Height 133.4 mm (5.25 in.)
Depth 225 mm (8.87 in.)
Weight 6 kg (13 lb.)
Cabinet Depth The depth of any cabinet in which the DSP2
is installed must be 345 mm (13.5 inch)
minimum to provide clearance for cabling
Input power:
120 VAC 90 – 135 V, 47 – 63 Hz, 50 VA
240 VAC 175 – 264 V, 47 – 63 Hz, 75 VA
Installation overvoltage II. Ref. IEC 61010-1
category
Fuse Quantity: 1, 1.25 A, Time Lag, 5 mm x 20 mm
2.5.2 Performance
The following components/devices have these performance
specifications:

About the DSP2
2.5.2.1 Sensor Inputs (SGIB)
Sensor Input Specification:
Input resolution 16 bit minimum
Sampling rate 64,000 per second minimum
Update rate 16 kHz minimum

0.010% for any selected 5-50 mV full
Ripple and noise scale input ranges for 10 V or 20 V
excitation
±0.01% for any selected 2.5 – 25 mV

Calibration accuracy
full scale input ranges
Gain drift ±0.005% of full scale
Zero drift ±0.005% of full scale
Computation accuracy < 0.001 % of full scale

Linearity 0.02% of full scale
Signal bandwidth 3.2 kHz
0.5 – 1.0 ms from 10 to 90% of full

Step response
scale output without overshoot
Maximum excitation power 1.33 W
Load measurement range At least +175% to -35%
2.5.2.2 Analog Outputs
Analog Outputs:
Update rate 16 kHz
Modes (full scale) 0-10 V, ±10 V, 4-20 mA, 0-20 mA
Gain drift at the analog outputs 0.01% of full scale per °C
Ripple and noise At isolated analog voltage output 5 mV

RMS for 3.2 kHz noise bandwidth
At isolated analog current output 10 µA
RMS for 3.2 kHz noise bandwidth
Resolution < 0.01% of full scale input
Linearity 0.03% of full scale input

About the DSP2
2.5.2.3 Logic Inputs and Outputs
Logic inputs
Sampling rate 100 Hz

Logic outputs
System status:
Update rate 10 Hz
Minimum on time 500 ms
Load and rate limits:
Update rate 1 kHz
Minimum on time 500 ms
2.5.2.4 WAC Computation
WAC Computation:
Computation update rate 10 Hz
Input resolution 1/1000
Compensation accuracy 0.1% of full scale
Computation accuracy 0.01% of full scale
2.5.2.5 Digital Outputs
On-board Modbus:
Update rate 1 kHz

Resolution 0.01% of full scale input
Optional Fieldbus (Profibus DP or Modbus/TCP Module)
Update rate 500 Hz

Front Panel Interface
3 Front Panel Interface

The Front Panel Interface (FPI) shown in Figure 4 contains:
 A Liquid Crystal Display (LCD) or Organic Light-Emitting Diode (OLED) panel that can
display up to four lines of 20 alphanumeric characters
 A keypad that provides access for system setup, configuration and control, using simple
menu driven procedures
 Six system status indicators:

 Electronics Healthy
 System Fault
 Channel A Fault
 Channel B Fault
 Single Sensor
 Auxiliary
Figure 4: DSP2 Front Panel Interface
3.1 Display and Keypad

The display panel can operate in two modes: load display and menu
display. The load display shows measurements of the load sensors. The
menu display lets you set up the load display, configure parameters or
view diagnostics information.
When you set the power switch of the DSP2 unit to ON, the display panel
shows a typical load display (Figure 5) after initialization is complete. The
Load display shows four lines of configured measurement values in real
time and is the most actively used mode. Note that there is a label on
each line with some values. The values on the four lines are updated
every 300 ms. For information on how to set up and configure the load
display, refer to sub-section 3.2.2.5 FPI Submenu.

When you press the MENU key on the keypad, the panel exits the load
display and shows the initial screen of menu mode as shown below.
A% ##.## A# ##.## lb SETUP

B% ##.## B# ##.## lb  SYSTEM
MENU
∑% ##.## EN0 IP ADDRESS
Δ% ##.## ▪ 192.009.001.075
Load display Initial menu display
Figure 5: Load Display and Menu Display
The keypad contains nine input keys and they have the following
functions:
Key Function
To exit live load display mode and enter menu mode,

MENU
or back to live load display mode from menu mode
To undo the menu selection/change and return to

ESC previous level of menu or navigate back to live load
display mode
To cycle through available items or parameters on

  the same level of menu forward or backward
In edit mode, use also with the ↑ and ↓ keys to enter
a numerical values
To navigate through various levels of menu items up

  or down in the display
In edit mode:
 cycle through available items or parameters
 use also with the  and  keys to enter a
numerical values
ENTER
To enter edit mode of a parameter or accept a
ee parameter change
enter
To initiate the calibration operation. This key is
CAL independent of menu operation
To initiate the zero operation. This key is

ZERO
independent of menu operation.

3.2 Menu Structure

To access the menu mode, press the MENU key when the display panel
is in load display mode as shown in Figure 5. In menu mode, the Setup
menu of the main menu is displayed by default. Using the  or  key,
you can cycle through the other menus of the main menu as shown in
Figure 6:
Setup menu Diagnostics menu Operations menu
SETUP DIAGNOSTICS OPERATIONS

SYSTEM ELECTRONICS CONFIGURATION
EN0 IP ADDRESS  
No error
▪ 192.009.001.075  ▪

▪
Figure 6: FPI Main Menu
While in the main menu, navigate as follows:
 To access a submenu for a particular menu, use the down arrow

key (↓)
 To return to a high level of menu, use the up arrow key (↑)
 To return to the load display, press MENU or ESC.
Note: Make sure that the logic input circuit does not lock
out the display (lockout is disabled). If lockout is
enabled, you can only view the menus and their
parameter settings but cannot edit them. Refer to
sub-section 7.10 Lockout for more details on
lockout.
Refer to the following sub-sections for more information about the

structure of Setup menu, Diagnostic menu and Operations menu.

3.2.1 Symbols Used in Menu Mode

Special symbols are used throughout the menu displays. The following
figure and table show these symbols and explain their functions.
Indicates active
menu level
SETUP
 SYSTEM
Blinking (▪) indicates EN0 IP ADDRESS
system heart ▪ 192.009.001.075
beat is enable
SETUP
░ SGIB COMMON SETTI
APPLICATION
▪ Roll Force
Blinking (░) Indicates more

indicates characters on the line
editing mode
Figure 7: Symbols and Indicators on Menu Display
Key Function
 Indicates the active menu level or line. You can use the ↑
and ↓ keys to move from this level to the sub-level below or a
upper level above.
▪ Blinking ▪ is the heartbeat of the system. It indicates that the

system is active and responsive.
The ellipsis () indicates more characters or word on a line.

 To view more character/ word, enable line editing mode by
pressing the ENTER key and then use the  key. See also
the ░ symbol below.
░ Blinking ░ symbol indicates editing mode. Use the  and 

keys to select digit or displaying the line to the end or to the
beginning. To exit line editing mode, press the ENTER key.

3.2.2 Setup Menu

The setup menu contains ten submenus. To cycle through the
submenus, use the down arrow key (↓) to access the System submenu
first, then use the  or  key to navigate to other submenus.
SETUP
 ANALOG OUTPUTS Analog
A01 SOURCE Outputs
▪ OFF
SETUP
 SYSTEM
System
EN0 IP ADDRESS submenu
▪ 192.009.001.075
SETUP
 FPI
 FPI
 submenu
1ST ROW PAIR
▪ CHANNEL A&B (%) 
SETUP
 SGIB A SETTINGS SGIB A
SHUNT Settings
▪ 50 kOhm
SETUP
Alarms
 ALARMS
submenu
ALARM 1 SOURCE
▪ OFF

SETUP
SGIB B
 SGIB B SETTINGS Settings
SHUNT
▪ 50 kOhm
SETUP Logic I/O
 LOGIC IO FACTORY  Factory
ALARM 1 POLARITY Settings
▪ CLOSED ON ALARM
SETUP
 SGIB COMMON SETTI SGIB
APPLICATION Common
▪ Roll Force Settings
SETUP
System
 SYS INFO Information
NAME
▪ sn18
Figure 8: Setup Submenus

3.2.2.1 System Submenu

The System submenu lets you specify the network settings for the two
Ethernet connections for communication with other system devices. To
access the parameter settings of the system submenu, use the down
arrow key (↓) to access the first parameter EN0 IP address first, then use
the  or  key to navigate to other parameters as shown in Figure 9.
Note: The EN0 parameters correspond to the J10-EN0

connector on the back of the DSP2 unit, and the
EN1 parameters correspond to the J11-EN1
connector.
SETUP SETUP
SYSTEM SYSTEM
 EN0 IP ADDRESS  EN1 IP ADDRESS
▪ 192.009.001.075 ▪ 011.011.000.136
 
 
SETUP SETUP
SYSTEM SYSTEM
 EN0 NETMASK  EN1 NETMASK
▪ 255.255.255.000 ▪ 255.255.255.000
SETUP SETUP
SYSTEM SYSTEM
 EN0 GATEWAY  EN1 GATEWAY
▪ 000.000.000.000 ▪ 000.000.000.000
SETUP SETUP
SYSTEM SYSTEM
 EN0 MAC ADDRESS  EN1 MAC ADDRESS
▪ XX:XX:XX:XX:FF:FF ▪ XX:XX:XX:XX:FF:FF
SETUP SETUP
SYSTEM SYSTEM
 EN0 DHCP  EN1 DHCP
▪ Disable ▪ Disable

 

Figure 9: System Submenu

To edit a parameter setting:

1. Press the down arrow key (↓) so that the active indicator is on the
parameter line. See example shown in Figure 10.
2. Press ENTER so that the parameter line is in editing mode with a
blinking ░ symbol.
SETUP
SYSTEM
EN0 IP ADDRESS
 ░92.009.001.075
Figure 10: Editing Parameter
3. Enter the required value using  and  keys to select digit, and ↑
and ↓ keys to increment or decrement digit.
4. To change EN0 DHCP (Dynamic Host Configuration Protocol) or EN1
DHCP settings, use the ↓ ↑ key to select Disable or Enable.
5. To exit edit mode, press ENTER.
6. Restart the DSP2 unit.
3.2.2.2 SGIB A Settings and SGIB B Settings

The SGIB A Settings submenu is for Strain Gage Interface Board (SGIB)
settings for sensor A, whereas the SGIB B Settings submenu is for SGIB
settings for sensor B. You can specify individually the following
parameters for sensor A and sensor B:
 Calibration shunt resistor (SHUNT)

Setting can be 50, 100, 150, 200, 250, 300, 350, 400, 450, 500,
550, 600, 650, 700, 750 or 800 kΩ
 Calibration Target Load (CTL)

Valid range is from 20 to 150% (02000 to 15000).
Note: If you enter any value outside this range, the

ENTER key will not allow you to exit the edit mode.
To access the SGIB A or B settings submenu, use the down arrow

key (↓) to access the first parameter SHUNT (Shunt resistor value)
first, then use the  or  key to navigate to other parameters.
To select the value of the shunt resistor or edit the value of CTL,
refer to Figure 11.

SETUP  SETUP
SGIB A SETTINGS  SGIB A SETTINGS
 SHUNT  CTL
▪ 50 kOhm ▪ 09499 %
↓↑ ↓↑
SETUP SETUP
SGIB A SETTINGS SGIB A SETTINGS
SHUNT CTL
 50 kOhm  09499 %
ENTER ENTER
SETUP SETUP
SHUNT CTL
 ░0 kOhm  ░9499 %
↓↑
50 kOhm, 100 kOhm, Enter the required value
150 kOhm, 200 kOhm, using  and  keys to
250 kOhm, 300 kOhm, select digit, and ↑ and ↓
350 kOhm, 400 kOhm, keys to increment or
450 kOhm, 500 kOhm, decrement digit.
550 kOhm, 600 kOhm, Valid range is 02000 to
650 kOhm, 700 kOhm 15000 (20 – 150)%
750 kOhm, 800 kOhm
ENTER ENTER
Figure 11: SGIB A Settings
3.2.2.3 SGIB Common Settings

The SGIB Common Settings submenu contains two settings that are
applicable to both SGIB boards for sensor A and B:
 Application
 Single Sensor
To access the SGIB Common Settings submenu, use the down arrow key
(↓) to access the first parameter Application, then use the  or  key to
navigate to other parameters.

To edit a parameter or select a particular parameter, refer to Figure 12.
↓ and
SETUP SETUP
ENTER
SGIB COMMON SETTI SGIB COMMON SETTI
 APPLICATION APPLICATION
▪ Roll Force  ░oll Force
↓↑
 Roll Force
 ENTER
 Tension
 and ↑
 Pressure
SETUP ↓ and SETUP

SGIB COMMON SETTI ENTER SGIB COMMON SETTI
 SINGLE SENSOR SINGLE SENSOR
▪ A & B  ░ & B
↓↑
 A & B
ENTER
 2 * A
and ↑
 2 * B
Figure 12: SGIB Common Settings
3.2.2.4 Analog Outputs

The Analog Output Submenu is for setting the configuration of six Analog
Outputs AO1–AO6). Each output has the following parameters:
 Source
 Mode
 FSL (Full Scale Load)
To access the Analog Outputs submenu, use the down arrow key (↓) to
access the first parameter AO1 SOURCE, then use the  or  key to
navigate to other parameters.
Note: The valid range of FSL is 0010 – 9999 % (The

actual value is divided by 10, which is 1–999.9%).

If you enter any value outside this range, the

ENTER key will not allow you to exit the edit mode.
SETUP ↓ and SETUP ↓↑  OFF

ANALOG OUTPUTS ENTER ANALOG OUTPUTS
 AO1 SOURCE AO1 SOURCE  A
▪ OFF  ░FF  B
 SUM
  DIF

SETUP ↓ and SETUP

ANALOG OUTPUTS ENTER ANALOG OUTPUTS ENTER
 AO1 MODE AO1 MODE
and ↑
▪ VOLTAGE  ░ OLTAGE
↓↑
  Voltage
  0–20 mA Current ENTER and ↑
 4–20 mA Current
↓ and
SETUP ENTER SETUP
ANALOG OUTPUTS ANALOG OUTPUTS
 AO1 FSL AO1 FSL
▪ 0010 %  ░010 %


Enter the value using 
SETUP and  keys to select
ANALOG OUTPUTS digit, and ↑ and ↓ keys to
 AO2 SOURCE increment or decrement
▪ OFF digit.
Valid range is 0010 to
9999 (1–999.9 %).


Analog Outputs for
AO2 to AO6 are the ENTER and ↑
same as AO1
Figure 13: Analog Outputs

3.2.2.5 FPI Submenu

The Front Panel Interface (FPI) submenu is for configuring the load
display of the front panel. There are six parameters for the load display:
 1St ROW PAIR — lets you select one of eight values (Figure 14)
to be displayed on the first two lines of the front panel.
 2nd ROW PAIR — lets you select one of eight values to be

displayed on the third and fourth lines of the front panel (Figure
33). Note that:
 % represents % full scale and # represents designated load

unit which you select in the Load Unit parameter.
 BAR represents bar graph.
 SUM (∑) represents the sum of Channel A + Channel B and

DIF (Δ) represents the different of Channel A - Channel B.
 Examples of the eight display settings are shown in Figure 34.
 Aux Indicator (view only) — shows which one of the alarms or

any alarm that the Auxiliary Indicator on the front panel will be
monitored.
 FSL Format (view only) — shows the Full Scale Load (FSL) and
display format (how many decimal digits) from a range of 1.000
– 9999999.
Note: FSL equals the scale factor. For example; for a

Scale Factor of 600, A# 0600 and B# 0600
correspond to A%100.00 and B%100.00
respectively.
 Load Unit — lets you select the measurement unit to be

displayed for A# and B#.
 Heart Beat — lets you enable or disable the heartbeat on the

display. The default setting is set to ON (enabled). If the
heartbeat is disabled, the blinking dot in the lower left corner will
disappear.
To access the FPI submenu, use the down arrow key (↓) to access the
first parameter 1St ROW PAIR, then use the  or  key to navigate to
other parameters.

SETUP ↓ and SETUP  CHANNEL A&B (%) & (#)

FPI ENTER FPI ↓↑
 CHANNEL A&B (%)
 1ST ROW PAIR 1ST ROW PAIR
▪ CHANNEL A&B (%) …  ░ CHANNEL A&B (%)…  CHANNEL A&B (#)
 CHANNEL A&B BAR
  SUM & DIF (%) & (#)

 SUM & DIF (%)
SETUP ↓ and SETUP ↓↑  SUM & DIF (#)
FPI ENTER FPI  SUM & DIF BAR
 2ND ROW PAIR 2ND ROW PAIR
▪ SUM & DIF (%)  ░ UM & DIF (%)


Shows setting only.
SETUP
FPI Setting can be OFF, ENTER and ↑
 AUX INDICATOR
ALARM1, ALARM2,
▪ ALARM1
ALARM3, ALARM4 or
ANY ALARM


SETUP Shows setting only.

FPI Setting can be
 FSL FORMAT changed using the
▪ 10000 UAP.


SETUP
↓ and SETUP
FPI ENTER FPI
↓↑ lb, kg, N, kN, MN
 LOAD UNIT LOAD UNIT t (SI), ton (US)
▪ lb  ░b psi, bar, MPa
 ENTER and ↑

SETUP ↓ and SETUP ↓↑

FPI ENTER FPI  Enable
 HEART BEAT HEART BEAT  Disable
▪ Enable  ░nable
Figure 14: FPI Submenu

3.2.2.6 Alarms Submenu

The Alarms submenu is for setting up four load alarms (relays). You can
configure following parameters for each alarm:
 Alarm Source — lets you specify the source to be either OFF, A,

B, A+B (SUM) or A-B (DIF)
 Alarm Threshold — lets you set the threshold. Valid range is

0001 – 1500 (actual value is divided by 10 = 0.1 – 150.0%)
 Alarm Time — lets you specify the time. Valid range is

001 – 999 ms.
↓ and SETUP
SETUP ENTER
ALARMS ALARMS
ALARM 1 SOURCE
 ALARM 1 SOURCE
▪ OFF  ░FF
↓↑
 ENTER OFF, A, B,

and ↑ SUM, or DIF
↓ and
SETUP ENTER SETUP
ALARMS ALARMS
 ALARM 1 THRESHOLD  ALARM 1 THRESHOLD
▪ 1500 % ▪ ░500 %
ENTER Enter the value using  and  keys


and ↑ to select digit, and ↑ and ↓ keys to
 increment or decrement digit.
Valid range is 0001 to 1500.
↓ and
SETUP ENTER SETUP
ALARMS
ALARMS
 ALARM 1 TIME
 ALARM 1 TIME
▪ 001 ms
▪ ░01 ms

 ENTER
and ↑ Enter the value using  and
 keys to select digit, and ↑
Parameters for and ↓ keys to increment or
Alarm 2 to Alarm decrement digit.
4 are the same as Valid range is 001 to 999 ms.
Alarm 1
Figure 15: Alarms Submenu

3.2.2.7 Logic I/O Factory Settings

The Logic I/O Factory Settings submenu contains factory settings for your
system. You can change any default settings as required for your
system.
To access the Logic I/O Factory Settings submenu, use the down arrow
key (↓) to access the first parameter ALARM 1 POLARITY, then use the
 or  key to navigate to other settings as shown in Figure 16.
You can change factory settings for the following logic inputs and outputs:
 Alarm Polarity (1-4) — sets the relay state of Alarm (1-4) to

closed on alarm or open on alarm when the alarm is active
 In Zero Polarity — sets the zero input trigger to be on the rising

edge or the falling edge
 In Calibration Polarity — sets the calibration input trigger to be

on the rising edge or the falling edge
 In 2xA Polarity — sets the input trigger for single sensor (A) to
be on the rising edge or the falling edge
 In 2xB Polarity — sets the input trigger for single sensor (B) to
be on the rising edge or the falling edge
 In Self-Test Polarity — sets the input trigger for self-test to be on

the rising edge or the falling edge
 In Lockout Polarity — sets the input level for enable lockout to

lock on open input or lock by 24V applied
 Out Channel A Fault Polarity — sets the output polarity of relay

to be closed on fault or open on fault when Channel A Fault is
active
 Out Channel B Fault Polarity — sets the output polarity of relay

to be closed on fault or open on fault when Channel B Fault is
active
 Out System Fault Polarity — sets the output polarity of relay to

be closed on fault or open on fault when System Fault is active
 Out Single Sensor Polarity — sets the output polarity of relay to

closed on fault or open on fault when Single Sensor is active

↓ and ↓ and SETUP

SETUP ENTER ENTER LOGIC IO FACTORY …
LOGIC IO FACTORY …  IN SELF TEST POL …
 ALARM 1 POLARITY ▪ ON RISING EDGE
▪ CLOSED ON ALARM
Use ↑ or ↓ to 
 select Closed on

 Alarm or Open ↓ and
on Alarm. ENTER SETUP
Displays of Alarm 2 to To return to the LOGIC IO FACTORY …
Alarm 4 Polarity, same previous screen,  IN LOCKOUT POLAR …
as Alarm 1 Polarity press ENTER ▪ LOCK ON OPEN INP…
and ↑. Use ↑ or ↓ to
select Lock on
Open Input or
↓ and Lock by 24V
ENTER Applied.
SETUP
LOGIC IO FACTORY … To return to the
 IN ZERO POLARITY previous SETUP
▪ ON RISING EDGE screen, press LOGIC IO FACTORY …
ENTER and ↑.  OUT CHANNEL A FA …
▪ CLOSE ON FAULT
Use ↑ or ↓ to
SETUP select On
LOGIC IO FACTORY … Rising Edge
↓ and SETUP
 IN CALIBRATION P … or On Falling
ENTER LOGIC IO FACTORY …
▪ ON RISING EDGE Edge.
 OUT CHANNEL B FA …
To return to ▪ CLOSE ON FAULT
the previous
screen, press
ENTER and ↑.
SETUP
LOGIC IO FACTORY … SETUP
 IN 2XA POLARITY LOGIC IO FACTORY …
▪ ON RISING EDGE  OUT SYSTEM FAULT …
Use ↑ or ↓ to
▪ CLOSE ON FAULT
select Close
On Fault or
Open On Fault.
SETUP To return to the

previous SETUP
LOGIC IO FACTORY …
screen, press LOGIC IO FACTORY …
 IN 2XB POLARITY ENTER and ↑.
▪ ON RISING EDGE  OUT SINGLE SENSO …
▪ CLOSE ON FAULT

 

Figure 16: Logic I/O Factory Settings Submenu

3.2.2.8 System Information

The System Information submenu is a view only display. To access the
system Information submenu, use the down arrow key (↓) to access the
first parameter NAME, then use the  or  key to navigate to other
settings as shown below.
SETUP
 SYS INFO
NAME
▪ sn18
SETUP
SYS INFO
↓↑  SW VERSION
▪ DSP2-R03-XX
SETUP

SYS INFO
 NAME

▪ sn18
SETUP
SYS INFO

 MEZ FW VERSION

▪ X.XX


Figure 17: System Information

3.2.3 Diagnostics Menu

The Diagnostics menu displays the current temperature within the
electronics unit and the current states of the following components that
the system has monitored:
 Electronics
 Channel A and Channel B
 SGIB A and SGIB B
The Diagnostics menu contains six submenus as shown in Figure 18 and
all submenus are view only. If the system detects a fault condition, one or
more System Status LEDs on the front panel will be on and a descriptive
fault status is displayed in the applicable diagnostics submenu. Refer to
sub-sections 9.2 and 9.3 for more troubleshooting information.
To cycle through the submenus, use the down arrow key (↓) to access the
Electronics submenu first, then use the  or  key to navigate to other
submenus.
DIAGNOSTICS DIAGNOSTICS
 ELECTRONICS  SGIB A
No error No error
▪ ▪
 
 
 CHANNEL A  SGIB B
No error Input Saturation
▪
▪
 
 Error
 status
 CHANNEL B  TEMPERATURE
SGIB alarm 43.5˚ C
▪ detected ▪


Error 
status 
Figure 18: Diagnostics Submenu

3.2.4 Operations Menu

The Operations menu lets you initiate Configuration or start a Self-Test.
The configuration process lets the DSP2 accept selected parameters and
use them to define Full Scale Input, to calibrate and define the zero
reference point for both channels and to zero both channels. For more
details about the self-test, refer to sub-section 7.8 Self-Test.
To cycle through the Operations submenus, use the down arrow key (↓)
to access the CONFIGURATION submenu first, then use the  or  key
to navigate to the SELF TEST submenus as shown in Figure 19.
If you select YES for Configuration or Self-Test and press ENTER:
 The DSP2 starts the applicable process and display a message

that shows Configuration / Self-Test In Progress, Please Wait!
 When the process is done, the display exits the menu mode and
shows the load display.
 If the system detects a fault condition, one or more System

Status LEDs on the front panel turn ON. You can view the fault
messages in the applicable diagnostics submenu.

OPERATIONS OPERATIONS

 CONFIGURATION  SELF TEST
▪ ▪
ENTER ENTER
CONFIGURATION SELF TEST
 ░NO  ░ NO
▪ ▪
↓↑ ↓↑
CONFIGURATION SELF TEST
 ░ YES  ░YES
▪ ▪
ENTER
or
ESC
Figure 19: Operations Submenu

User Access Program
4 User Access Program

The User Access Program (UAP) is a comprehensive Windows application for setting up,
monitoring, and controlling the DSP2. It lets you define and set various parameters and optional
features so that the DSP2 can operate with different types of strain gage sensors in different
applications. The UAP also provides access to additional features on the DSP2 not provided by
the FPI.
The UAP application must be installed in a Windows based computer or laptop, with language
set as English, and set up correctly to establish a TCP/IP connection with the DSP2 electronics
unit using port 502 and 5009, if there is a firewall between the UAP and the EU, access must be
provided through it to these ports. For procedures on how to install the UAP on a PC and set up
the UAP-to-DSP2 Communications, refer to sub-section 6.6.1 Set Up UAP-to-DSP2
Communications.
4.1 Key UAP Features

When the laptop or PC with UAP installed has established the connection
with the DSP2, UAP automatically assesses the hardware configuration
of the DSP2. The UAP provides the following features:
 A device main screen (Figure 20) to monitor the load outputs

from each channel and to determine the System Status and
Load Alarms of the Logic Outputs
 A Setup screen where you can set up and configure the

following:
 Input channels
 Analog outputs
 Load alarms
 Communications
 Front panel display
 IBA (ibaPDA)
 I/O settings.
 A Diagnostics screen where you can:
 Check the channel status, electronics status, analog outputs

status and operating temperature
 View hardware identification, configuration data and factory

calibration
 Run simulation tests, test digital output signals or view discrete

input signals.

User Access Program
 The program uses standard conventions and menu structure for

its operation. Each screen is self-explanatory. Areas or
selections on any screen not available are shown in gray.
4.2 About the UAP Window

When you start the UAP and it connects with the DSP2, a typical window
shown below is displayed.
Figure 20: UAP Main Screen
The UAP has a Menu Bar and a Toolbar at the top of the window, a
Navigation Panel at the left and a Main display on the right (Figure 21).
Depending on the navigation panel selection, the main display can be a
main device screen as shown in Figure 20, a setup screen, or a
diagnostic screen.

User Access Program
Menu bar
Toolbar
Navigation
Panel
Figure 21: UAP Window
4.2.1 Menu Bar

The menu bar uses standard Windows menu selections. It contains four
menus: File, Device, Operations and Help. Choices or selections under
these menus that are unavailable for a particular setup or configuration
are grayed out.
4.2.1.1 File Menu

The File menu has the following choices shown below. If there is no
device on the navigation panel, the Save and Save All choices are
disabled (unavailable).

User Access Program
Selection Function
Load Loads an existing local or remote configuration file to UAP. It
either creates new device(s) or overwrites the existing one(s).
See UAP Configuration File for more details about loading

configuration options.
Save Saves the current configuration of a selected device on the
Navigation Pane to a configuration file.
Save All Saves the current configuration of all devices on the Navigation
Panel to a configuration file.
Print Captures (prints) the screen-shot and sends it to a specified

Screen printer.
Event Enables fault status logging for the selected device. For more
Logger details about setting up the event logger, refer to sub-section 4.7
Event Logging.
Exit Updates the Configuration file and its backup version when UAP
detects some change in any device configuration. Then, closes
the UAP application.

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4.2.1.2 Devices Menu

The Devices menu has the following choices shown below. If there is no
device shown on the navigation panel, only the Add choice is enabled; all
other choices are disabled (grayed out). If the device is not connected,
some choices are also disabled.
Selection Function
Add Opens the Device Properties window shown below for

adding a new device to UAP.
To add the device (DSP2) to the UAP, refer to procedure

in 6.6.1.3 Add DSP2’s to the UAP.
Remove
Removes the selected device on the navigation panel
from the UAP.
Properties Opens the Device Properties window for editing of device

properties.

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Selection Function
Read Reads the configuration for a selected device and

updates the corresponding values of UAP display.
Apply Changes Writes changes to the device, and runs the device
configuration (if needed). Run configuration is necessary
if any CTL, shunt resistor, or excitation settings of
Note: sensors have changed. Refer to procedure in 6.6.9
Do not initiate Run Apply Changes and Run Configuration. for detailed
Configuration when steps.
load simulation is
Run Configures a selected device. To run Configuration for a
active. If you do this, a
Configuration device (DSP2), refer to procedure in 6.6.9 Apply
warning message will
Changes and Run Configuration.
appear and block the
operation. Reset Resets the selected device.
Upload Software
Loads new software to the selected device. For detailed
steps to load new software to a selected device, refer to
procedure in Software Upload.
4.2.1.3 Operations menu

The Operations menu contains the following choices:

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Selection Function
Single Sensor Opens a Single Sensor Operation window where you can
set the DSP2 system to single sensor operation using
either 2*A (sensor A) or 2*B (sensor B).
To reset the DSP2 system that runs single sensor

operation to two-sensor operation (A and B), select
Single Sensor again and specify A&B on the Single
Sensor Operation window.
Calibration Calibrates the selected device. When the calibration

process is done, the UAP returns to the Device Main
screen.
Note:
Do not initiate Zero Performs a device zeroing operation. When the zeroing
Calibration, Zero or Self- process is done, the UAP returns to the Device Main
Test when load screen.
simulation is active. If
you do this, a warning Self-Test Performs a self-test operation. When the self-test is
message will appear and done, the UAP returns to the Device Main screen.
block the operation.
WAC Input Opens a Wrap Angle Compensation window and lets you
set the current wrap angle compensation inputs.
A typical window is shown below, where you can enter
the Counts (default) for Input 1 or 2.
Note that this choice is enabled only when the Wrap

Input source setting on the Application Wizard is set to
Manual (Figure 76). Depending on the setting of the
application configuration, the other input option displayed
on the above window can be Collier Diameter, Strip
Thickness, Pass Line or Angle.

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Operations such as Run Configuration, Upload Software, Zero,

Calibration and Self-Test will take longer to complete. A progress window
will display the current progress for these operations.
When the operation is done, the progress window will close. For more
details about the above functions, refer to section 7 System Monitoring
and Controls.
4.2.1.4 Help Menu

The Help menu contains two choices: Manual and About.
The Open Manual selection opens the DSP2 User’s Manual of Adobe
Document Format (PDF) in an Adobe Reader. Your PC must have the
Adobe Reader application installed to view the contents of the User’s
manual.
When you select About, it opens a window showing the UAP version, a
Log File button, a Kelk Logo and a VPG logo as shown below:

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To view the log file in Notepad of Windows, click the Log File button. If
necessary, you can save the log file for further analysis.
When you click on either logos, KELK or VPG web site is automatically
open in the default web browser.
4.2.2 Toolbar
The toolbar provides a quick way of accessing the functions available in
the Menu Bar. Icon functions that are unavailable for a particular setup or
configuration are grayed out.
The toolbar contains six icons. You can display the icon name by rolling
the mouse curser on top of the icon. The icons, if enabled, provide quick
access to the following functions:
Icon Name Function
Single sensor Opens a Single Sensor Operation window.

This is same as selecting Operations >
Single Sensor from the Menu Bar.
Calibration Calibrates the selected device. This is the

same as selecting Operations > Calibration
from the Menu Bar.
Zero Performs a device zeroing operation. This is

the same as selecting Operations > Zero
from the Menu Bar.

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Self-Test Starts a self-test operation. This is the same

as selecting Operations > Self-Test from
the Menu Bar.
Wrap Input Opens a Wrap Angle Compensation window.

This is the same as selecting Operations >
Wrap Input from the Menu Bar.
Apply Changes Writes changes to the device, and runs the

device configuration (if needed). This is the
same as selecting Device > Apply Changes
from the Menu Bar.
4.2.3 Navigation Panel

Navigation Panel lists all devices that are added to the UAP (Figure 22).
Each device contains two sections: Setup and Diagnostics.
 The Setup section, when selected, displays the Setup Panel on

the main screen on the right.
 The Diagnostic section, when selected, displays the Diagnostic

Panel on the main screen.
Connected
Device
Disconnected
Device
Navigation
Panel
Pop-up
menu
Figure 22: Navigation Panel
To indicate the current connection status of device, the icons and

are used next to the device name. The icon indicates the device is
connected whereas the icon indicates the device is disconnected as
shown in the above screen. The connection status is refreshed every
second for all devices in the Navigation Panel.

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Right clicking the mouse button on any space of the Navigation Panel will
open a pop-up menu shown on the above screen capture. If there is no
device on the navigation panel, the Remove and Properties selections of
the pop-up menu are disabled. The selections, if enabled, provide quick
access to the following functions:
Selection Function
Add Adds a new device to UAP. This is the same as selecting

Device > Add from the Menu Bar
Remove Removes the selected device on the navigation panel from the
UAP. This is the same as selecting Device > Remove from
the Menu Bar
Load Loads an existing local or remote configuration file to UAP. It

either creates new device(s) or overwrites the existing one(s).
This is the same as selecting File > Load from the Menu Bar
Properties Opens the Device Properties Window for editing of device

properties. This is the same as selecting Device > Properties
from the Menu Bar
4.3 Device Main Panel

When you select a device name in the Navigation Panel, the main screen
displays the Device Main Panel. A typical DSP2 that sets up for tension
measurement is shown in Figure 23.
The device main panel has the following areas:
1. Title of measurement system
The title reflects the application configured in the set up panel of the
UAP or the SGIB Common Setting of the FPI. The application type
can be Tension, Roll force or Pressure.
2. Channel name and description
The channel description shows the setting specified in the channel

description fields of Device Properties window.

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1 2
Measurement
type Channel
description
3 4
5
6
Figure 23: Device Main Panel for Tension Measurement
3. Measurement graph for channel A and B
The graphic shows the actual measurement load over a short period
of time for both Channel A and Channel B. Red color is used for
channel A and blue color is used for channel B. You can choose to
view it in % of Full Scale or in Load Units. The load unit of
measurement is retrieved from setup of FPI display in UAP.
The graphic is plotted while the device main panel is active. If you
leave the main panel or changes to another device, the graphic is
cleaned. You can also zoom in and out of the X and Y coordinates of
the measurement graph using the mouse. To zoom in a graph, press
and hold the mouse button and drag the mouse pointer to define a
new area as shown in below figure an release the button. To zoom
out the measurement graph, click the zoom out button ( ).

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Drag mouse pointer to define

scale area for new display
Zoom out button New display

(example only)
Figure 24: Zooming in and out of the Measurement Graph
You may need to zoom in again a few times to display the graph in
applicable scale that you want.
4. Status indicators
The status indicators show the current system and load alarm states.
The icon color indicates the following:
The state not detected

The device is healthy (Electronic healthy)
A fault detected (System fault, Channel A fault, Channel B fault or
Single Sensor activated)
A load alarm triggered

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5. Load measurement table
The measurement table shows both the load percentage and the
actual load. The percentage values are read from the DSP2 and
displayed with two decimal places. The load units for SUM and DIF
are calculated by adding and subtracting load values of A and B. The
unit of measurement is specified by setup of load units for FPI display
in UAP.
6. Analog output table
Analog Output table displays voltage or current readings as

configured by the settings for analog output via the UAP or FPI.
The DSP2 can house three analog output boards. If only one analog
output board is installed and detected by the DSP2, then only the first
two lines (analog outputs 1 and 2) are enabled as shown in Figure 23.
The third to sixth lines are grayed out indicating that the output is not
used if the second and third analog boards are not installed.
7. Status list table
The Status list shows the last 20 events that were detected on the
selected device. The list content is cleared after successful
Configuration. If any problem develops in the DSP2, you can use
status events to troubleshot and take the corrective actions to resolve
the problem. Refer to Section 9 Troubleshooting for more details.

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4.4 Setup Panel

When you select under any device name in the Navigation Panel,
the main screen displays the Setup Panel. A typical setup panel for the
Input Channels tab is shown in Figure 25.
The Setup panel has seven configuration tabs at the top of the screen.
Each tab lets you configure a group of settings or parameters for
particular devices or functions.
Configuration tabs
Displaying
tool tip Highlighted
change
Highlighted
change
Figure 25: Setup Panel for Input Channels

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All the setup screens have the following features:
 You can display a tool tip on a particular parameter or field by

positioning the mouse cursor over it as shown in Figure 25.
 When you enter an invalid entry in a field (for example the entry
is outside a specified range), it is highlighted in red.
 When you change a setting or a piece of information in any field,

it is highlighted in yellow as well as the tab it is within. This
shows there is a pending change. When you apply all the
changes to the device using the Apply Changes icon on the
toolbar or select Device > Apply Changes from the menu bar,
highlights are removed.
You can also set up the device configuration off site. Note that if the UAP
is not connected to the device, the apply Changes operation is disable.
However, you can configure the settings for these tabs and save the
configuration to a file by selecting File > Save on the menu bar. Make
sure the file name is not config.kcm. While you are on-site, load the
saved configuration file to UAP according to procedure in 4.6.2.
4.4.1 Input Channels

When you select the Input Channels tab, the setup panel displays the
parameter settings for the Strain Gage Interface Board (Figure 25). This
screen lets you configure the two channels of the sensors for the
measurement application.
You can enter load cell data in either Normal or Expert mode. In expert
mode, all you need to enter are the basic sensor data, the values for
application shunt resistor and calibration target load as shown in Figure
26. To set up input channels using expert mode, refer to the procedure in
sub-section 6.6.2.4.
Usually, you set up the input channels using normal mode. In normal
mode, you need to fill in the sensor data and all applicable parameters,
including load cell cable compensation as necessary, for channel A and
channel B as shown in Figure 27. To set up input channels for roll force,
or pressure application in normal mode, refer to the procedure in sub-
section 6.6.2.1.

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Figure 26: Setup Input Channels in Expert Mode
Figure 27: Setup Input Channels in Normal Mode

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To accurately set up the input channels for tension applications, the wrap
angles and rated tension must be known and be factored into the
calibration. You must use the Application Wizard to enter your inputs and
selections. Then let the Application Wizard calculates the Utilization
Factor (UF) and the wrap angle compensation (WAC) tables.
After the UF is applied to the setup parameter, you can click the
Recalculate CTL button to recalibrate a new Calibration Target Load
(CTL) to complete the setup process (Figure 28).
Because setting up the input channels for tension application and using
the Application Wizard program are very complex, please refer to the
following sub-sections for details and setup procedures:
 6.4 Tension Measurement Calibration
 6.6.2.2 Tension Application – Fixed Wrap Angles
 6.6.2.3 Tension Application – Variable Wrap Angles
Figure 28: Setup Input Channels for Tension Application

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4.4.2 Analog Outputs

When you select the Analog Outputs tab, the setup panel displays the
parameter settings of the Analog Outputs (Figure 29). This screen lets
you configure the analog outputs of the system.
The DSP2 can have a maximum of six analog outputs from three analog
output boards. If only one analog output board is installed, only two
outputs are enabled as shown in Figure 29. The other outputs are grayed
out indicating two optional boards are not installed.
For each analog output:
 The source can be configured as: OFF, A (sensor A), B (sensor

B), A+B (sum of A and B) and A-B (Difference of A and B)
 The mode can be configured as: 0-10 V, 0-20 mA or 4-20 mA for

A, B or A+B; and ±10 V, 0-20 mA or 4-20 mA for A-B
 The scaling factor can be configured in the range of 1.0–999.9%
For more information about analog outputs, refer to following sub-sections:
 6.2.3 Analog Outputs and Output Scaling
 6.6.3 Specify Analog Outputs
Figure 29: Setup Panel for Analog Outputs

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4.4.3 Load Alarms

When you select the Load Alarms tab, the setup panel displays the four
relay settings for the load alarms (Figure 30). This screen lets you
configure up to four logic outputs for the load alarms. A load alarm is
triggered when a load level exceeds a set threshold.
For each relay:
 The source can be configured as: OFF, A (sensor A), B (sensor

B), SUM (A+B) and DIF (A-B)
 The threshold can be configured in the range of 0.1–150.0%
 The time delay can be configured in the range of 1–999 ms
For more information about setting up the load alarms, refer to following
sub-sections:
 6.2.4 Load Alarms and Threshold Limits
 6.6.4 Configure Load Alarms.
Figure 30: Setup Panel for Load Alarms

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4.4.4 Communication
When you select the Communication tab, the setup panel displays the
communication settings for Ethernet J10, Ethernet J11 and Fieldbus J9
(Figure 31). This screen lets you configure the network settings of the
Ethernet cards and Fieldbus card. The Modbus fields or Profibus Node
field may be enabled or disabled depending on the installed option in the
Fieldbus J9 slot.
Note that:
 If the UAP is connected to the DSP2 and no communication

card is installed in the J9 slot of the DSP2, the two field groups
(Modbus and Profibus) are unavailable (disabled) as shown in
Figure 31.
 If the UAP is not connected to the DSP2, all fields of Fieldbus J9

are enabled so they can be configured off-line.
 If you change any communication parameter, apply the changes

and reset the DSP2.
If the UAP is connected to the DSP2 using a physical IP address via

Ethernet J10, you can change the connection using an automatic
generated IP address if the DSP2 is connected to a network server with
DHCP (Dynamic Host Configuration Protocol).
Figure 31: Setup Panel for Communication Ports

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To connect the UAP with a DHCP generated IP address, do the steps

that follow:
1. In the Ethernet J10 or J11 group, set DHCP to Enabled.
2. Apply the changes by selecting Device > Apply changes from the
menu bar.
3. On the Confirmation window shown below appears, click Yes,
continue.
4. When an Operation is successful message appears, click OK.

5. Monitor the progress on the front panel Interface, verify that:
 The message EN0 and/or EN1 DHCP Waiting… appear on the

FPI during the initialization process.
Note: While the system is processing DHCP, the front

panel is still functional and lets you configure the
DSP2.
 If DHCP operation is successful on the EN0 or EN1 adapter, the

front panel switches to live load display. Go to step 6.
 If after one minute, you see another message DHCP Aborted…

blinking for 5 seconds before returning to live load display, this
indicates that the adapters cannot complete the DHCP
operation. Check the network setting or contact the network
administrator. Disable DHCP as necessary.
6. On the FPI, press MENU and note the new IP address of ENO.
7. On the UAP, open the Device Properties window by selecting Device
> Properties from the menu bar.
8. Update the IP address field with the new IP address from the DSP2
and click OK.
9. Verify that the UAP establishes the connection with the DSP2.
For more information about setting up the communication ports, refer to
sub-section 6.6.5 Set Up Communication Ports. For more information
about Profibus and Modbus communications and setups, refer to section
11 Fieldbus Interfaces and Setups.

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4.4.5 FPI Display

When you select the FPI Display tab, the setup panel displays the six
settings as shown in Figure 32. This screen lets you configure the 4-line
LED display as well as the auxiliary status indicator on the front panel.
Figure 32: Setup Panel for FPI Display
The six settings have the following functions:
 First pair — lets you select one of eight values Figure 14 to be

displayed on the first two lines of the front panel (Figure 33).
 Second pair — lets you select one of eight values Figure 14 to

be displayed on the third and fourth lines of the front panel.
Note that:
 % represents percentage of full scale and # represents

designated load unit which you select in the load unit setting.
 BAR represents bar graph.
 SUM (∑) represents the sum of Channel A + Channel B and

DIF (Δ) represents the different of Channel A - Channel B.
First pair A% - ##.## A# -##.## lb

B% - ##.## B# -##.## lb
∑% - ##.##
Second pair
Δ% - ##.##
Character or dot blinking if

heart beat is set to enable
Figure 33: Load Display

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 Example of the eight settings are shown in the following figure:
CHANNEL A&B (%) & (#)

A% ##.## A# ##.## lb
B% ##.## B# ##.## lb
CHANNEL A&B (%)
A% ##.##
B% ##.##
CHANNEL A&B (#)

A# ##.## lb
B# ##.## lb
A:
CHANNEL A&B BAR
B:
∑% ##.## ∑# ##.## lb
SUM & DIF (%) & (#)
Δ% ##.## Δ# ##.## lb
∑% ##.##
SUM & DIF (%)
Δ% ##.##
SUM & DIF (#)

∑# ##.## lb
Δ# ##.## lb
SUM & DIF BAR
∑:
Δ:
Figure 34: Load Display Examples
 Full scale — lets you specify the Full Scale Load (FSL) and
display format (how many decimal digits) from a range of 1.000
– 9999999.
 Load Unit — lets you select the measurement unit to be

displayed for A# and B#. Applicable load can be in lb, kg, N, kN,
MN, t (SI), ton (US), psi, bar or MPa.
Note: Changing load units does not affect full scale number.
 Auxiliary Indicator — selects which one of the alarms or any

alarm that the Auxiliary Indicator on the front panel will be
monitoring.
 Heart Beat — lets you enable or disable the heartbeat on the

display. The default setting is set to enable. If the heartbeat is
disabled, the blinking dot in the lower left corner will disappear.

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4.4.6 IBA
When you select the IBA tab, the setup panel displays the IBA client
settings (Figure 35). This screen lets you configure the IBA Data
Acquisition (PDA) client so that a remote PDA server can connect to the
DSP2 and collect data for logging and analysis.
Figure 35: Setup Panel for IBA
In the IBA tab, you can configure two modules: Generic and Custom.
 The Generic index is assigned an index number of 200 if

enabled (Figure 36).
 The custom index is assigned an index number of 201 if

enabled.
 Both index numbers can be changed to other integer numbers.

This allows the PDA server to show different indexes from
different DSP2’s.
Each index contains 32 module mappings as shown in the mapping table.
The mappings provide the PDA server what the Modbus registers are
used for these signals and the signal descriptions.
The mappings for generic modules are view only, whereas the mappings
for custom modules are editable. UAP reads and writes the mapping
according to the pattern below:
Map = SL,R,RT,MI,O, where:

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 SL is the Source Length [always 1 (integer)]

 R is the Register number (Modbus input register)
 RT is the Register Type [always 2 (input register)]
 MI is the Module Index (always X)
 O is the Offset (0 to 31)
Vie Edit
w able
Figure 36: Configuring Module Indexes
Details of Modbus registers and description of the signals for generic and
custom index are in Table 1 and Table 2. When editing the custom index,
you only need to change the register number.
For more information about setting up IBA and updating configuration
about the PDA server, refer to the following sub-sections:
 6.6.7 Set Up IBA

 6.6.7.1 Update TCP/IP Module Index in ibaPDA
 6.6.7.2 Modify Custom Module
 6.6.7.3 Update Custom Module in ibaPda I/O Manager

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Module Generic Modbus IR Description

00 map=1,0,2,X,0 0 Load A %
01 map=1,1,2,X,1 1 Load B %
02 map=1,2,2,X,2 2 Status of Logical Outputs
03 map=1,3,2,X,3 3 Sum A+B %
04 map=1,4,2,X,4 4 Difference A-B %
05 map=1,12,2,X,5 12 Electronics Status
06 map=1,13,2,X,6 13 Channel A Status
07 map=1,14,2,X,7 14 Channel B Status
08 map=1,15,2,X,8 15 Electronics Temperature
09 map=1,20,2,X,9 20 Load A # High Word
10 map=1,21,2,X,10 21 Load A # Low Word
11 map=1,22,2,X,11 22 Load B # High Word
12 map=1,23,2,X,12 23 Load B # Low Word
13 map=1,24,2,X,13 24 Sum A+B # High Word
14 map=1,25,2,X,14 25 Sum A+B # Low Word
15 map=1,26,2,X,15 26 Difference A-B # High Word
16 map=1,27,2,X,16 27 Difference A-B # Low Word
17 map=1,41,2,X,17 41 FPI Keypad Code
18 map=1,48,2,X,18 48 SGIB A Status
19 map=1,56,2,X,19 56 SGIB B Status
20 map=1,49,2,X,20 49 SGIB A Arm 1 Voltage
21 map=1,50,2,X,21 50 SGIB A Arm 2 Voltage
22 map=1,51,2,X,22 51 SGIB A Excitation Voltage
23 map=1,52,2,X,23 52 SGIB A Excitation Current
24 map=1,57,2,X,24 57 SGIB B Arm 1 Voltage
25 map=1,58,2,X,25 58 SGIB B Arm 2 Voltage
26 map=1,59,2,X,26 59 SGIB B Excitation Voltage
27 map=1,60,2,X,27 60 SGIB B Excitation Current
28 map=1,140,2,X,28 140 Zero Accumulator A High Word
29 map=1,141,2,X,29 141 Zero Accumulator A Low Word
30 map=1,142,2,X,30 142 Zero Accumulator B High Word
31 map=1,143,2,X,31 143 Zero Accumulator B Low Word
Table 1: Mappings for Generic Modules

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Module Custom Modbus IR Description

00 map=1,0,2,X,0 0 Load A %
01 map=1,1,2,X,1 1 Load B %
02 map=1,2,2,X,2 2 Status of Logical Outputs
03 map=1,3,2,X,3 3 Sum A+B %
04 map=1,4,2,X,4 4 Difference A-B %
05 map=1,10,2,X,5 10 Timer Counter High Word
06 map=1,11,2,X,6 11 Timer Counter Low Word
07 map=1,20,2,X,7 20 Load A # High Word
08 map=1,21,2,X,8 21 Load A # Low Word
09 map=1,22,2,X,9 22 Load B # High Word
10 map=1,23,2,X,10 23 Load B # Low Word
11 map=1,24,2,X,11 24 Sum A+B # High Word
12 map=1,25,2,X,12 25 Sum A+B # Low Word
13 map=1,26,2,X,13 26 Difference A-B # High Word
14 map=1,27,2,X,14 27 Difference A-B # Low Word
15 map=1,32,2,X,15 32 WAC 1 Input
16 map=1,33,2,X,16 33 WAC 2 Input
17 map=1,53,2,X,17 53 SGIB A Temperature
18 map=1,54,2,X,18 54 Not Used
19 map=1,61,2,X,19 61 SGIB B Temperature
20 map=1,62,2,X,20 62 Not Used
21 map=1,100,2,X,21 100 A_1K High Word
22 map=1,101,2,X,22 101 A_1K Low Word
23 map=1,102,2,X,23 102 B_1K High Word
24 map=1,103,2,X,24 103 B_1K Low Word
25 map=1,132,2,X,25 132 Calculated bridge resistance A High Word
26 map=1,133,2,X,26 133 Calculated bridge resistance A Low Word
27 map=1,134,2,X,27 134 Calculated bridge resistance B High Word
28 map=1,135,2,X,28 135 Calculated bridge resistance B Low Word
29 map=1,205,2,X,29 205 AO1 Status
30 map=1,211,2,X,30 211 AO2 Status
31 map=1,240,2,X,31 240 CPU Load
Table 2: Mappings for Custom Modules

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4.4.7 I/O Settings

When you select the I/O Settings tab, the setup panel displays the
factory polarity settings for various inputs and outputs (Figure 37). This
screen lets you change the following polarity settings if necessary.
 Alarm (1-4) — sets the relay state for Alarm (1-4) to Closed On
Alarm or Open On Alarm when the alarm is active
 Zero — sets the zero input trigger to be On Rising Edge or On
Falling Edge
 2xA input trigger — sets the input trigger for single sensor (A) to
be On Rising Edge or On Falling Edge
 2xB input trigger — sets the input trigger for single sensor (B) to
be On Rising Edge or On Falling Edge
 Self-test input trigger — sets the input trigger for self-test to be
On Rising Edge or On Falling Edge
 Lockout input trigger — sets the input level for enable lockout to
Lock On Open Input or Lock By 24V Applied
 Calibration input trigger — sets the calibration input trigger to be
On Rising Edge or On Falling Edge
 Single Sensor — sets the relay state to Closed On Fault or
Open On Fault when Single Sensor is active
 System Fault — sets the output polarity of relay to be Closed On
Fault or Open On Fault when System Fault is active
 Channel A Fault — sets the output polarity of relay to be Closed
On Fault or Open On Fault when Channel A Fault is active
 Channel B Fault — sets the output polarity of relay to be Closed
On Fault or Open On Fault when Channel B Fault is active
Figure 37: I/O Settings

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4.5 Diagnostics Panel

When you select under any device name in the Navigation
Panel, the main screen changes according to the tab being selected at
the top of the screen. The displays for the first four tabs are read only.
These tabs let you view system status, detailed information about the
boards, configuration data, and factory calibration data (Figure 38). The
last tab, Simulation/Test, lets you simulate loads for the channels and test
the output and load alarms.
Selection tabs
Figure 38: Diagnostics Panel: Status Tab
4.5.1 System Status

When you select the Status tab, the diagnostic panel displays the current
system status of the DSP2 as shown in Figure 39. The status screen is
refreshed every 250 ms and displays the following:
 Channel status for both channels

 Electronics status
 Internal temperature of the device
 Analog output status
The color of status indicators on the Status screen indicates the following:
The state not detected (OFF)

The state detected (ON)
For example, If the internal temperature of the DSP2 is over 70ºC (158
ºF), the status icon for excessive internal temperature changes to
(ON). Also, if the system is running single sensor operation, the channel
status icon for Signal off (other channel doubled) changes to (ON).
If the WAC board not recognized text is grayed out, it indicates that there
is no auxiliary analog Input board in the system. If A03, A04, A05 and

User Access Program
A06 are unavailable as shown in Figure 39, they indicate that there is only
one analog output board (A1 and A2) and no additional boards in the
system.
Note: When the DSP2 is operating normally, all status

icons on this screen are OFF. If you see that any
status icon is ON, the system has detected an
abnormal or fault condition. Refer to Section
9 Troubleshooting for descriptions of all fault
conditions and applicable corrective actions.
Single sensor
No auxiliary
operation
analog input
board
No additional analog
output boards
Figure 39: System Status

User Access Program
4.5.2 Hardware Identification

When you select the Identification tab, the diagnostic panel displays the
serial number and software version of the system (DSP2). Also, the
screen shows versions of hardware, software or firmware for all hardware
component in the system (Figure 40). This screen also identifies boards
or adaptors that are not connected or installed.
Figure 40: Hardware Identification

User Access Program
4.5.3 Channel Configuration Data

When you select the Configuration Data tab, the diagnostic panel
displays a table of Strain Gage Input parameters, which lists the internal
settings for both input channels in the DSP2 (Figure 41).
Figure 41: Channel Configuration Data
4.5.4 Factory Calibration

When you select the Factory Calibration tab, the diagnostic panel
displays the factory set calibration parameters for the analog output and
auxiliary analog input boards (Figure 42).
Number of counts
Figure 42: Factory Calibration

User Access Program
4.5.5 Simulation/Test
When you select the Simulation/Test tab, the diagnostic panel displays
the simulation and test screen as shown in Figure 43. In this screen, you
can select the following options:
 Simulation A — simulates load data to channel A to check

channel A load measurement
 Simulation B — simulates load data to channel B to check
channel B load measurement
 Simulation A&B — simulates load data to channels A and B to
check load measurements of both channels
 Shunt A — applies shunt resistor to channel A
 Shunt B — applies shunt resistor to channel B
 Shunt A&B — applies shunt resistors to channel A and channel
B
Figure 43: Simulation/Test
If you select any of the above options and the following error message
appears on the screen, this means the DSP2 was locked out for
simulation and the UAP cannot continue.
User Access Program
This indicates that another user is connected to the same DSP2 and
running simulation, self-test or configuration operation at the same time.
You must wait until the process from other user is done before using
these features.
When the selected Simulation Option is Simulation A, Simulation B, or
Simulation A&B, you can enter the load directly or move the slider on the
left side of the vertical bar up or down to a specific value.
When the selected Simulation Option is Shunt A, Shunt B, or Shunt A&B,
the value of the simulated load is displayed on the two measurement
charts on the right side of the screen.
For detailed procedures on how to run simulation and apply shunt resistor
to measure the CTLs. Refer to 6.6.10 Verify Setup and Load Output.
Note: The simulation/test is set to OFF by default. Also, if

you navigate away from the Simulation/Test tab or
close the UAP, simulation/test will be turned off.

User Access Program
4.5.6 IO Test
When you select the IO Test tab, the diagnostic panel displays the test
screen as shown in Figure 44. In this screen, the system displays the
current state of the digital input and output hardware, regardless of which
mode the system is operating in. If the user enters Test Mode by clicking
on the test mode button, the digital output signal is expected to be set and
cleared by the user for test purposes.
This screen must be active while in test mode, if the screen is not active,
the UAP will send a command to the EU to exit safe mode, returning to
the EU normal operation.
Figure 44: IO Test Tab
Note: The test mode will affect all I/O with the Mill
communications. Be sure that taking the system
offline will not affect the operation of the mill in an
unexpected manner before doing so.

User Access Program
4.6 UAP Configuration File

The configuration file contains the configuration settings of all devices.
The file is updated when any of the following events occur:
 Closing or exiting the UAP

 A device is added, removed, or edited
 Changes are applied to a device.
Before updating the configuration file, the UAP creates a backup
configuration file with the previous configuration. The configuration file
and the backup file are saved in the user's space and named config.kcm
and config_bkp.kcm respectively.
The following information is kept in the Configuration File for all devices in
the UAP:
 Device Properties
 Measurement type
 Setup data: Input Channels, Analog Outputs, Load Alarms,
Communication, FPI Display, IBA and I/O Settings
 Diagnostics data: Boards Identification, Channel Configuration
Data and Factory Calibration
You can also save the configuration file using Save or Save All under the
File menu. To save the configuration file after setup of the DSP2, refer to
the procedure in sub-section 6.6.11 Save Configuration. If necessary,
you can recover the previous device configuration by loading the UAP
backup configuration file or the saved configuration file.
4.6.1 Load Device Configurations from a Configuration File

To load device(s) and their configuration data from a saved configuration
file to the UAP:
1. Open the UAP and make sure that there is no device on the
Navigation Panel.
2. If there are devices on the Navigation Panel, select each device and
do the following sub-steps until the navigation panel is empty:
 Select Device > Remove from the menu bar.
 Click Yes to confirm device removal.
3. Select File > Load from the menu bar.

4. On the Load KCM window that appears, use the navigation icons to
navigate to the folder where you stored the configuration file.

User Access Program
5. Select the configuration file and click Open.

6. Verify that all devices in the configuration file are loaded and
displayed in the Navigation Panel.
4.6.2 Load Setup Data from a Configuration File to a

Device
To load setup data from a configuration file to a device in the UAP:
1. Open the UAP.
2. Select the device on the Navigation Panel that you wish to overwrite
its setup data with setup data from a configuration file.
3. Select File > Load from the menu bar.
4. On the Load KCM window that appears, use the navigation icons to
navigate to the folder where you stored the configuration file.
5. Select the applicable configuration file and click Open.
6. On the Devices in File

window that appears,
select the applicable
device and click Load
Selected Device.
7. Verify that the device name remains the same on the Navigation
Panel. When you select under the device name, the
changed settings and tabs that contains changes are highlighted in
yellow as shown in Figure 45.
8. Apply the changes as necessary.

User Access Program
Figure 45: Setup Panel with Changes Highlighted

User Access Program
4.7 Event Logging

You can log the fault status of a DSP2 to a file by enabling Status
Logging in the Event Logger. To display the Event Logger shown below,
select File on the menu bar and choose Event Logger.
Figure 46: Event Logger Window
The Event Logger uses the following default settings:
 Data Directory Path (log file folder) – user’s location
 Status check and load update rate – 0.5 second
 log file name is created as [device_sn_index.log], where:
 device: device name specified in the Device Properties

window
 sn: serial number read from the device (DSP2)
 index: auto increment number starting from 0. Whenever the
current log file reaches a maximum size of 1 MB, a new log file
is created with the index incremented by 1
 Maximum number of log file in folder – 50
When event logging is enabled, it has the following features:
 Events are logged only for a selected device on the

navigation panel. It automatically stops if the device is de-
selected and starts logging for the newly selected device.

User Access Program
 Maximum number of log files is computed per device.
 Logging is started automatically when the UAP is launched If

event logging was enabled previously.
 When a specified maximum number of log files is reached in the

folder, logging is disabled automatically. Also, the following
message will pop up on the screen.
You must either manually delete some log files or move the log
files to other location so that event logging can be enabled again.
To enable status logging:

1. On the menu bar, select File > Event Logger.
2. At the Event Logger window that appears, check mark Status Logging
as shown in Figure 46.
3. To take the default settings, click OK. If you want to change any
default settings, make the following applicable selections before
clicking OK:
 Change Data Directory Path by:
 Typing the path directly into the text field or
 Using the Browse button to bring up a Select Path window

where you can navigate to the applicable folder and Save the
specified location.
 Change Status check and load update rate using the up or

down arrow. Range is from 0.25 to 2 seconds in increments of
0.25 seconds.
 Change Maximum Number of Log Files in Folder by clicking

the down arrow and selecting either 50,100, 200 or 500.
Note: For more details about the contents of the event log
and how to interpret the fault status codes, refer to
sub section 9.9 Interpreting Event Status Log.

User Access Program
4.8 Additional UAP Functionality
4.8.1 SAG Mill Applications

For certain applications where the Tare Weight occupies a significant
portion of the measurement range and cannot readily be zeroed out using
the regular zero function, the “SAG” application in “Input Channels” tab
under “Setup” can be activated through SoftKey licensing, see Figure 47:
Additional UAP Functionality.
Refer to KELK Application Note AN 220 for details.
Once activated, the zero offset can be set for each individual channel
(between 0 to 100%) and the mill control can establish this as the zero
reference.
Note: If Calibration and/or Configuration functions are

initiated, this zero offset must be set again.
The zero offset can be directly inputted or calculated by the UAP based
on the load cell full scale and tonnes. See Figure 48: Zero Offset Setting.
When directly input it, simply type them in Offset A/B fields and click OK.
Otherwise, when calculated by the UAP, enter the required information
under Channel A/B sections and click Apply button to move the calculated
value to Offset A/B fields. After that click OK and the UAP will set the new
zero offset.
Please consult KELK for more details regarding when and how to use this
function.
4.8.2 Disabling Alarm Reporting in Negative Load (SGIB

Mask Faults)
In a very limited application which the load cell will experience both
positive and negative loading, the system fault and channel faults may
cause inconvenience to the mill control. In such case, all error reporting
can be ignored (masked) if enabled; refer to Figure 47: Additional UAP
Functionality.
Please consult KELK for more details regarding when and how to use this
function.

User Access Program
Figure 47: Additional UAP Functionality
Figure 48: Zero Offset Setting
4.9 Software Upload

Occasionally, you will be asked by KELK to update the software in the
Electronics unit (EU). To update the software, you will need both the
software file (with the .srec extension) and the password from KELK.
To upload the new software file to the EU:
Caution: The software update process will reset the

electronics unit. Make sure that the DSP2
system is offline and not used for mill control.
1. Select File > Save to save the current configuration of selected

device on the Navigation Pane to a configuration file.
2. At the Navigation Panel of the UAP, select the device that you want to
update the software.
3. On the menu bar, select Device > Upload Software.

User Access Program
4. At the Upload Software window that appears, enter the password

D$p2Update and click OK.
5. At the Select file window that appears (Figure 49), navigate to the
location where the software file is stored.
6. Select the applicable software file and click Open.
Figure 49: Select File Window
7. Wait for the upload process to complete.

8. When a Reset Device window appears with a message “The device
must be reset to run the new software”, Click Reset now.
9. Load saved configuration file and apply changes. Run Configuration
if prompted.

Installation
5 Installation
KELK load measuring systems are designed and manufactured to provide excellent
performance in the demanding environments of the metals industry. To get their full potential
for high accuracy and long service life, they must be correctly and properly installed.
As parts of a load measuring system or a tension measuring system, the DSP2 unit(s) can be
installed in either a KELK floor-mounted cabinet, a KELK wall-mounted cabinet, or a customer
cabinet. The floor-mounted cabinet can house up to seven active DSP2’s and a spare, while the
wall-mounted cabinet accommodates up to two active DSP2’s. All DSP2 units are mounted on
a swing-out 19-inch rack.
The KELK cabinets that contain the DSP2’s have an enclosure protection rating of UL/cUL Type
12, IP55 which is suitable for rolling mills, grinding mills and other heavy industrial applications.
When you are installing the DSP2, make sure that:
 The site for installing the DSP2’s or the cabinet is prepared to provide a suitable
operating environment as indicated in the system specifications (sub-section 2.5.1
Physical and Power Specifications).
 Nothing is placed on top of any DSP2 cabinet.
 If mounted in a customized cabinet or other enclosed space, ensure that the

temperature adjacent to the DSP2 cabinet complies with the product Description and
Specification and provide adequate clearance for air flow.
 The user has easy access to the power cord and switch.
 All installation and connecting wiring comply with all applicable codes, regulations and
standards.
Caution: Following installation, you must setup and configure the

system according to Section 6 Setup and Configuration
before placing the system in on-line service.
If the system is not correctly setup and configured, the

Digital and Analog Outputs and the Load Alarms may be
inaccurate and their use for mill controls may cause off-
specification product or mill damage.
When power is first applied during installation, the Digital

and Analog Outputs and the Load Alarms are
unpredictable. Ensure that they are not connected to any
active mill control system as this may cause off-

Installation
5.1 Unpacking the DSP2 or DSP2 Cabinet

Pay attention to the cautions and labels when you are unpacking the
crate.
Warning: The floor-mounted cabinet weighs more than

175 kg (385 lb.) when fully loaded with the
DSP2 units. While moving or positioning the
cabinet, handle it with appropriate tools and
care to avoid any personal injury.
 Transport the cabinet enclosure

safely using the appropriate tools
such as crane or fork-lift truck.
 Use the lifting lugs (eyebolts)

provided on the top of the cabinet
for ease of handling.
 Check off each item in the

packing slip.
 Refer to the Installation package,

shipped with the equipment or
shipped separately. The CD
contains the User’s manual,
specific installation drawings for
your system and software
applications such as the User
Access Program.

Installation
5.2 Installing the DSP2 Cabinet

Make sure that you select a suitable location preferable in an air-
conditioned room away from high temperature and moisture for installing
the floor-mounted cabinet. Check the packing slip and verify which one of
the following models you received.
Model Description and Cabinet Rating
FMC2100-120*-S-S Sealed, solid door, NEMA 12 (comparable to IP55)
FMC2100-120-F-S Forced air cooled, NEMA 12 (comparable to IP55)
FMC2100-120-A-S Sealed and air conditioned, NEMA 12 (comparable

to IP55)
Note * : 120 refers to 120V power entry model.

Cabinet model number end with –G comes with glass door.
240V power option is also available.
For more details and features about these models, refer to the document
listed in sub-section 1.4 Related Publications.
The installation procedure for the DSP2 floor-mounted cabinet is
essentially the same for every model. Refer to the next two illustrations
that show the model FMC2100-S-S cabinet for following instructions.
When installing the floor-mounted cabinet:
 Use the lifting lugs (eyebolts) provided on the top of the cabinet
for ease of handling.
Warning: The floor-mounted cabinet weighs more than

175 kg (385 lb.) with the DSP2 units. While
moving or positioning the cabinet, handle it with
appropriate tools and care to avoid any
personal injury.
 If the cabinet is installed next to other similar sized cabinet,

provide about 95 mm (3.75 in.) of clearance at the hinged side of
cabinet to allow door to open fully (Figure 50).
 Provide sUFficient clearance for the door to open. A standard

KELK cabinet requires at least 145° floor allowance for the
swing-out rack to be opened fully for service (Figure 51).

Installation
Figure 50: KELK Floor-mounted Cabinet
Warning: Before securing the cabinet to the floor, make

sure that the cabinet is secured using the lifting
lugs. If you fail to secure the cabinet, it can tip
or fall when you open the front door with the
hinged rack, causing personal injury and
equipment damage.
 Secure floor-mounting cabinet to the floor to prevent tipping.

This is particularly important for cabinet with the swing-out rack.
The KELK floor-mounted cabinet has four holes in the base for
M12 or ½ in. bolts (Figure 51).

Installation
 If you do not want to secure the cabinet to the floor for any
reason, make that you secure lifting lugs to a permanent fixture
or wall with chains.
Figure 51: Cross Sectional View of Cabinet
Note: For model FMC2100-120-A-S cabinets, they are

equipped with air conditioning, these require a
separate power line from the electronics.

Installation
5.3 Connecting Cables or Wiring

For DSP2’s, all connections applicable to the system are installed on the
rear panel as shown in Figure 52. If the DSP2’s are installed in a KELK
cabinet, all connections for individual DSP2 are wired to a group of
terminal blocks mounted on a rail. Refer to Figure 53 and Figure 54 for
the general layout of the DSP2 units and the rails within a typical KELK
cabinet.
Note: As a customer, you are responsible for providing the

applicable power to the cabinet. Check nameplate
on the side of the cabinet for specific power
requirements.
Figure 52: DSP2 Rear Panel Connections
Rollmax DSP2 Power Distribution and Connections (drawing 48480) (or a

customer specific equivalent) is included as parts of the Load Measuring
System Manual or Tension Measuring System Manual to illustrate DSP2
cabinet installation and connection wiring.

Installation
Figure 53: Typical DSP2 Cabinet Wiring

Installation
Figure 54: Standard DSP2 Harness Assemblies and Terminal Rails

Installation
Figure 55: Power Distribution and Connections in a Typical DSP2 Cabinet
Refer to the following sub-sections for details on how to connect external

cables or wiring on the terminal blocks. If your system has the Fieldbus
option that use the Profibus, Profinet or Modbus/TCP protocol, refer to
sub-section 11.1.1, 11.2.1 or sub 11.2.2 for the applicable connection.

Installation
5.3.1 AC Power Cable

For DSP2’s within a KELK cabinet, the power cords or cables (Figure 56)
were connected from the DSP2’s to the power distribution terminals
already as indicated in Figure 53 and Figure 55.
For DSP2’s that are housed in a customer cabinet, connect the power
cord from the DSP2 to a suitable 120 or 240 VAC outlet. The DSP2
adjusts automatically to the voltage range. Make sure that:
 The power source is properly grounded.
 The three wires of the IEC power cord (Figure 56) are connected
correctly.
 The ferrite filter, KELK part number *09189 is added (mounted)

on the AC power cord next to the DSP2 socket (Figure 56).
 KELK also suggests that a Type 3 surge protection device in

compliance with IEC 61643-1 2005, EN 61643-11/A11 2007 and
UL 1449 be used
Figure 56: Power Cord
5.3.2 Sensor Wiring

For a new measuring system, make sure the mechanical installation of
the load sensors are:
 Done according to the instructions in the Load Cell manuals and

installation drawings
 Configured as specified by the commissioning group from your

company or KELK in accordance with the requirement of the
mill.
For existing systems, we recommend that you check the sensor wiring
and make sure it complies with recommendations in the following sub-
sections to ensure optimum system performance:

Installation
When you are checking the sensor wiring, refer to KELK drawing 48480
“ROLLMAX DSP2 Digital Signal Processor Power Distribution and
Connection” for the various ways to connect the sensors using various
cables.
5.3.2.1 About the Sensor Wiring
 KELK suggests that for best noise immunity and to make full use
of all the features provided by the DSP2, that you use KELK
interconnecting cable part number *09204. If using this cable
please ensure that the cable is not bent sharper than a 2”
(50mm) radius.
 Check that the sensor wiring is rated at least 300 V.
 Make sure that terminations are clean to eliminate contact

resistance or current leakage.
 Use good wiring practices. Route cables away from power

cables and other potential sources of electromagnetic
interference.
 Use of ferrules is recommended.
 Make sure that cable wiring is in a dry environment.
 Make sure that sensor cable/hose assemblies are free of

damage and kinks.
 Apply the ferrite filters *09194 on Load cell cable, next the
connector plugged in the DSP2 ports J1 and J2.
5.3.2.2 Checking the Junction Box

The sensor cables must be terminated in a vapor proof junction box.
Verify that the junction box:
 is mounted on a vertical surface, with the sensor cable/hose

entries at the bottom
 is in a location that precludes the accumulation of mill fluids

(above the pass line and clear of any coolant sprays) and
provides good accessibility, e.g. on top of the mill stand.
Inspect the junction box and take the necessary corrective steps as
follows:
 Open the junction box and inspect all connections. Replace all
dirty and corroded terminal blocks and lugs.

Installation
 Ensure that there are no frayed wires to cause momentary

shorts to ground.
 Ensure that the box and all internal components are dry. If you
see or suspect moisture on components, dry them with alcohol.
 Ensure that the cable shields are electrically isolated from the
box ground. Verify that ring and pin lugs are used in the junction
box.
 Check the cable entry points; reseal, if necessary.
 When replacing the junction box cover, position the gasket

properly to seal the enclosure. Tighten the bolts sequentially, in
two steps (snug, then tight) to prevent distortion or damage of
the cover and gasket.
5.3.2.3 Checking Wiring from Junction Box to DSP2
 For the 4-conductor interconnecting cable, the minimum wire

gage must be:
 18 AWG (1.0 mm2) for up to 90 m (300 ft.) runs
 16 AWG (1.5 mm2) for up to 150 m (500 ft.) runs
 14 AWG (2.5 mm2) for up to 240 m (800 ft.) runs.
 The preferred routing is through a metal conduit. However, after

leaving the junction box in a conduit, the cable may be run in low
signal cable trays.
 When running parallel to heavy power cables, a minimum
separation of 1 m (3.3 ft.) is required for runs of up to 30 m
(100 ft.)
 For longer runs, a minimum separation of 2 m (6.6 ft.) is
required.
5.3.2.4 Checking Sensor and Wiring before Connecting to DSP2

Before you connect the sensor wiring to the terminal block of the DSP2,
check the sensor and interconnecting cable wiring for the following:
Continuity
 Make sure that all connections are made in the junction
box as per KELK drawing 48480.
 Using an Ohmmeter with a resolution of 0.1Ω, measure:
 Input resistance between the green and black
conductors

Installation
 Output resistance between the red and white

conductors
 Verify that the measured values are within 1Ω of those
given on the Calibration Card supplied with the sensor,
plus the resistance of the interconnecting cable.
 Measure the resistance of the interconnecting cable (refer
to procedure in 6.1.1).
Leakage resistance
 Measure leakage resistance:

 between any conductor and the cable shield
 between any conductor and ground
 between the cable shield and ground.
 Verify that the measured values are greater than 100 MΩ.
Caution: Do not use an insulation tester with test

voltages in excess of 50V. Higher
voltages can damage the sensor.
If you encounter any problems, test the interconnecting and

sensor cables in accordance with the procedures in Section 9
Troubleshooting.

Installation
5.3.3 Logic I/O Wiring

Logic I/O wiring & Connector pinouts are listed in KELK drawing 48480.
Connecting cables must be rated at least 300 V. The following table
shows the typical voltage and current for the logic inputs and outputs.
Logic Inputs Logic Outputs
Voltage 5-30 VDC range 60 VDC maximum

24 VDC typical 60 VAC peak maximum
(42 VAC RMS maximum)
Current 5 mA maximum per input 250 mA maximum per output
5.3.3.1 Logic Inputs

For the logic inputs:
 Use a supplied voltage or contact closure as shown in KELK

drawing 48480 (Page 7).
 Before connecting to the Lockout logic input, remove the factory

installed jumper.
5.3.3.2 Logic Outputs

For the logic outputs:
 A user supplied voltage is required for a typical logic output

circuit as shown in KELK drawing 48480 (Page 7).
 The Channel A Fault relay is de-energized for a fault condition.
5.3.4 Analog Output Wiring

A maximum of three analog output boards can be installed in a DSP2.
KELK Drawing 48480 (Page 8) shows the analog output wiring for three
boards. There are two analog outputs in each connector for a board.
Each output can be connected for voltage or current as shown in KELK
drawing 48480 (Page 8).
An output must not be connected for both current and voltage at the
same time. Connecting cables must be rated at least 300V. Do not
route analog output cables near high voltage cables.
5.3.5 Auxiliary Analog Input Wiring

Analog wrap angle sensor signals are input through the Auxiliary Analog
Inputs. Wiring is shown in KELK drawing 48480 (Page 9). Connecting

Installation
cables must be rated at least 300V. The following cables, or their

equivalents, are recommended:
 One cable for 2 channels - Belden 8723 (or similar), 22 AWG. 2

twisted pairs, individually shielded, or
 Separate cables per channel - Belden 9451 (or similar), 22

AWG, 1 twisted pair, shielded.
Note: 22 AWG is equivalent to 0.33–0.38 mm2.
5.3.6 Ethernet Cables

The Ethernet ports on the DSP2 have standard RJ45 Ethernet
connectors. The table below shows the pin function of the RJ45 Ethernet
connector.
Connector pin Signal Description

1 TD+ Positive Transmit Data
2 TD- Negative Transmit Data
3 RD+ Positive Receive Data
4 NC
No Connection
5 NC RJ45
connector
6 RD- Negative Receive Data
7 NC
No Connection
8 NC
Casing PE Protective Earth
Table 3: RJ45 Pin Functions
For DSP2’s within a KELK cabinet, one Ethernet cable is connected from
each DSP2 unit to one Ethernet switch. It is expected that the mill
connection is made with one cable through the Ethernet switch. One
other port is available on the switch, for UAP communications using a
compatible computer.

Setup and Configuration
6 Setup and Configuration

A new measuring system must be correctly set up and configured before it can go into service.
Setup and configuration are also necessary whenever:
 A new DSP2 is used

 Any sensors (load cells) are changed
 The Calibration Target Load is changed.
Setup includes entering of sensor calibration data and the setting of all selectable options and
parameters. The DSP2 loads calibration data into memory and use them to set system
parameters during configuration. Then, the DSP2 can operate using this new configuration
immediately and automatically.
Important: Configuration is user initiated and applies data entered

during setup to calibrate the measurement system. It
must be done under static load conditions, for example:
with a fixed tare load and no active load applied.
Caution: If the system is not correctly set up and configured, the
Digital and Analog Outputs and the Load Alarms may
be inaccurate and their use for mill controls may cause
off-specification product or mill damage.
Configuration sets the load outputs to zero and calibrates the system. It first sets the analog
offsets and gains, and then adjusts the digital offsets and gains for optimum system accuracy.
If you are setting up and configuring the DSP2 for the first time, use the following guidelines:
 Review sub-sections 6.1 to 6.4 to get yourself familiar with the background of:
 Sensor calibration
 Signal processing, limits and scaling
 Signal filtering
 Tension measurement calibration.
 Complete the Pre Power-up Checks as described in sub-section 6.5.
 Complete the setup and configuration procedures in sub-sections 6.6 or 6.7. Note that
you can set up and configure the DSP2 using the User Access Program (UAP) or the
Front Panel Interface (FPI).
Tip: We recommend that you use the UAP instead of the FPI
because the UAP is much easier to use and the prime
function of FPI is for system monitoring, service and
setup adjustments. Refer to Sections 3 and 4 for more
information about the UAP and FPI interfaces.

6.1 Sensor Calibration

Each sensor (load cell) is factory calibrated to find its full load sensitivity
(output at its rated capacity). Then, with no load applied, a precision
shunt resistor of known value (calibration shunt resistor) is placed across
one arm of the sensor’s strain gage bridge to force a fixed and repeatable
output. The forced output, expressed as a percentage of Sensor
Capacity, is the sensor’s Calibration Target Load (CTL). The CTL is in
the range 20.00 to 150.00%.
KELK supplies each load cell with a calibration card. An example of a
calibration card is shown in Figure 57. The calibration card gives the
following details for the load cell:
 Model number
 Serial number
 Sensor rated capacity
 Sensitivity – sensor output, in millivolts per volt of applied
excitation, at rated capacity
 The value of the shunt resistor in Ω
 Output with shunt resistor, in millivolts per volt
 Calibration Target Load (in % of rated capacity)
 Input resistance
 Output resistance
Figure 57: Example of Load Cell Calibration Card

In roll force, pressure and load measuring systems, the load is applied
directly to the sensor, as it is during factory calibration. Typically, such
systems are calibrated such that Full Scale Input (FSI) for each channel
represents 100% of sensor capacity. The sensor CTL is used directly to
calibrate the load measuring system. For more information about FSI,
refer to sub-section 6.2 for more details.
In tension measuring systems, the magnitude of load applied to the
sensor is dependent on strip tension and wrap angles at which the strip
approaches and leaves the tensiometer roll. The wrap angles must be
accurately known to factor into the calibration of the system. Typically,
such systems are calibrated such that Full Scale Input (FSI) for each
channel represents 100% of rated tension (not sensor capacity).
For tension measuring systems, KELK computes CTLs for the
tensiometer, based on the mill and strip geometry defined by the user.
Relevant data are shown in a Tensiometer Setup Data Sheet and
Tensiometer Application Data Sheet supplied with each tensiometer.
Individual sensor calibration cards are supplied also. For more
information about tension calibration, Tensiometer Setup Data Sheet and
Tensiometer Setup Data Sheet, refer to 6.4 Tension Measurement
Calibration.
Caution: If a tensiometer is operated in geometry different

from that specified on the Tensiometer
Application Data Sheet (Form 858 or 859), the
Digital and Analog Outputs, and the Load
Alarms may be inaccurate. Their use for mill
controls may cause off-specification product or
mill damage.
The shunt resistor value and CTLs (from calibration cards for roll force,
pressure and load measuring applications and from the Setup Data
Sheets for tension measuring applications) are entered into the DSP2
during setup of input channels (SGIB). Then, during Configuration, the
DSP2 computes and sets the coarse gain, fine gain and offset to be
applied to the sensor signals to provide a calibrated output.
The CTLs given on calibration cards and Tensiometer Setup Data Sheet
are determined with only the sensor cables connected directly to the
calibrating electronics. Installation in the mill usually involves using much
longer interconnecting cables. Each CTL must be compensated for the
effect of this additional resistance.
If the sensor uses the new 6-conductor wiring, the correction is automatic
during the configuration process using the UAP or FPI. If the sensor uses
the old 4-conductor wiring, you must measure the resistance of the cable
and calculate the new CTL with correction as described in the following
procedures and use them for the setup.

6.1.1 Measure Interconnect Cable Resistance

If you use the UAP to set up channel inputs (Strain Gage) for sensors that
use 4-conductor wiring, enter the following values for each sensor:
 Sensor output resistance (RBR) from the sensor calibration card

 One conductor resistance of the cable (RL) measured on-site
To measure the resistance of one conductor at the site:
1. Open the junction box of the sensor.
2. Disconnect any two wires (for example, the green and black wires as
shown in Figure 58 that go to the DSP2 cabinet.
3. Install a jumper between the green and black wires.
Figure 58: Install Jumper and Take Resistance Measurement
4. Carefully open the DSP2 cabinet and identify the green and black
conductors from the junction box on the terminal block (TB11).
5. Disconnect and measure the resistance between the green and black
conductors using a multi-meter. Note that this value (RT) is for two
conductors.

6. Calculate the RL value using the formula RL = RT /2.

7. Remove the jumper and connect wires back on the terminal block of
the junction box.
8. Connect wires to TB11 3 and 4.
9. Carefully close the junction box, making sure the seal is tight to
prevent moisture from entering the box.
6.1.2 Calculate CTL with Resistance Correction for four-

conductor wiring
If you use the FPI to set up the channel inputs (SGIB A and B Settings)
for the sensors that uses four-conductor wiring, you need to enter the
following values for each sensor:
 Shunt resistor value from the sensor calibration card
 New CTL with cable resistance correction.
To calculate the new CTL with cable resistance correction:

1. Determine the resistance of one conductor of the interconnecting
cable by measurement as described in sub-section 6.1.1.
2. Determine Cf, the correction factor:
4RL
Cf = 1 +
RBR
Where:
 RL is the measured resistance of one conductor of the

interconnecting cable.
 RBR is the output resistance from the sensor calibration card.
3. Calculate new CTL with correction (CTLnew):
CTLnew = Cf x CTL
Where:
 CTL is the ratio of full-scale sensitivity and output obtained

from the calibration shunt resistor being applied during factory
calibration, expressed as a percentage of the full-scale output
for force and pressure (found on the Calibration Card). For
Tension applications, it is the percentage of the full-scale
tension from the Form 858 or 859.
 CTLnew is the Calibration Target Load corrected for the

interconnecting cable

An example of New CTL Calculation is shown below:
For a sensor with an output resistance (RBR) of 240 Ω connected to the

signal processor with 90 meters of 16 AWG (1.5 mm2) interconnecting
cable:
RL = 90 x 0.0133 Ω = 1.2 Ω
4𝑥1.2
Cf = 1 + =1.01
240
If the Calibration Card gives a Calibration Target Load of 79.73%, the

new Calibration Target Load is:
CTLnew = 1.02 x 79.73% = 81.32%
6.2 Signal Processing, Limits and Scaling

Figure 59 shows the signal processing of roll force, pressure and fixed-
wrap-angle tension measuring applications. The following sub-sections
provide more details about signal processing, load measurement set,
limits and scaling.
6.2.1 Channel Input Range

Typically, for Roll force and Pressure applications the Full Scale Input
(FSI) is equivalent to the input corresponding to the operation at rated
capacity. For tension applications, the FSI is normally the input
corresponding to the application of rated tension.
Typical channel input range is auto configured to +175% to -35% of full
scale. It may vary according to specific input parameters on Calibration
Card and installation geometry in tension applications.
6.2.2 Load Measurement Set

In operation, Sensor A and B outputs are amplified, digitized and adjusted
to yield Channel A and Channel B loads as percentages of the individual
Full Scale Inputs. This includes the application of zero offsets and gains
that were determined previously by:
 DSP2 during system setup and configuration
 Any subsequent Zero or Calibration operation, with the desired

tare load applied.

 Any subsequent Calibration, based on shunt resistor value and

Calibration Target Loads determined during factory calibration.
Sensor A Sensor B
Gain A Gain B
Channel A Channel B
Load Channel B Load Normal operation Load
Single Sensor
A Operation
Ethernet
Output Scale Threshold
1&2
(Modbus/TCP)

or DIF (A-B) or DIF (A-B)
Interface
Figure 59: Signal Processing – Roll force, Pressure and Fixed-wrap-angle

Tension Measuring Applications

 If the application is for Tension, there is also the application of

angle scaling factor. Refer to sub-section 6.4 Tension
Measurement Calibration for more details.
Using the Channel A and Channel B loads, two additional loads, Sum and
Difference are also computed. The Sum load (Channel A load + Channel
B load) is expressed as a percentage of total Full Scale Input. The
Difference load (Channel A Load - Channel B Load) is expressed as a
percentage of individual FSI.
The Sum calculations are different for Roll Force, Tension and Pressure
depending on how the output is expressed. They can be expressed as a
percentage of full scale or in units such as Tonnes or lbs/square inch, etc.
For all applications where the sum is expressed as a percentage of full
scale, the formula is (A+B)/2. If output is expressed in relative units, then
for tension and pressure the sum remains (A+B)/2, however for roll force
it is A+B.
These four loads (A, B, A+B and A-B) form two separate Load
Measurement Sets. One set includes user configurable signal filtering
and is the source for the digital and analog load outputs. The other set is
used for the alarms and has a separate filter.
The Load Measurement Set is accessible, at a rate of 100 Hz for
monitoring and data logging, through the two Ethernet ports and the
optional high-speed Profibus interface (500 Hz). Data is also derived
from the filtered Load Measurement Set for the Front Panel Display.
6.2.3 Analog Outputs and Output Scaling

The filtered Load Measurement Set is used for setting up the Analog
Outputs. You can program the Analog Outputs to represent A, B, A+B or
A-B with a scale factor to represent any percentage of the FSI from 1.0 to
999.9%. Then, a digital to analog (D/A) conversion is executed and the
Analog Output is available as a voltage or current signal.
You can use the scale factor [Full Scale Load (FSL)] to set the analog
outputs to give the best resolution to suit the needs of applications. For
example, set high resolution for differential load signals and lower
resolution. When a scale factor is set, it indicates the percentage of Full
Scale Input (FSI) to be represented by the full range (10V or 20 mA) of
the Analog Outputs.
Examples:
 For normal operation: Scale factor 100 yields 10V or 20 mA

equivalent to 100% FSI
 For lower resolution: Scale factor 200 yields 5V or 10 mA

equivalent to 100% FSI (10V or 20 mA equivalent to 200% FSI)

 For higher resolution (differential signal): Scale factor 20 yields

10V equivalent to 20% FSI
The following examples help you to determine the scale factors:

Application requirement
 Roll force
 Sensor Capacity: 500 T
 Required Analog Output Full Loads (10 V or 20 mA):

 A: 400 T
 B: 400 T
 A+B: 800 T
 A-B: 100 T
Scale factor calculation

Typically, you use the following formula to calculate the scale factor:
𝑆𝑐𝑎𝑙𝑒 𝑓𝑎𝑐𝑡𝑜𝑟 = 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 𝑜𝑢𝑡𝑝𝑢𝑡 ÷ 𝑠𝑒𝑛𝑠𝑜𝑟 𝑐𝑎𝑝𝑎𝑐𝑖𝑡𝑦 × 100%
 For Analog Output A or B, the scale factor is 400 T/500 T x100% = 80%.
 For Analog Output A+B, the scale factor is 800 T/1000 T x100% = 80%.
 For Analog Output A-B, the scale factor is 100 T/500 T x100% = 20%.
Overload protection
There is also a built in 10% overload detection, which allows the analog
output to go beyond 10V or 20mA. This allows the receiving side to
detect that the analog output signal is saturated.
6.2.4 Load Alarms and Threshold Limits

You can program four Logic Outputs as alarms to indicate that a specific
load threshold has been exceeded. The load threshold is usually set in
the range 1-150% of FSI. The threshold is expressed as a percentage of
individual FSI for A, B and DIF (A-B) and total FSI for SUM (A+B).
Alarms are processed as follows:
 The load (A, B, A+B or A-B) is read from the internally filtered
Load Measurement Set.

 The load is compared with a threshold value, entered during

setup.
 The alarm response time (time parameter) is specified during

setup. The time parameter is the time for which the load must
exceed the threshold before the alarm is set to ON. It is also a
time after the load has fallen below the threshold, before the
alarm is set to OFF.
 If the threshold is exceeded for a specified time (alarm response

time), the alarm is triggered.
 When the load falls below the threshold for a specified time, the
alarm is set to off.
The following examples help you to determine the thresholds:
Application requirement
 Roll force
 Sensor Capacity: 500 T
 Required Alarms:
 A equals or exceeds 350 T
 B equals or exceeds 350 T
 SUM (A+B) equals or exceeds 700 T
 DIF (A-B), negative or positive, equals or exceeds 40 T.
Threshold calculation
Typically, you use the formula below to calculate the alarm threshold:
𝐴𝑙𝑎𝑟𝑚 𝑡ℎ𝑟𝑒𝑠ℎ𝑜𝑙𝑑 = 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 𝑜𝑢𝑡𝑝𝑢𝑡 ÷ 𝑠𝑒𝑛𝑠𝑜𝑟 𝑐𝑎𝑝𝑎𝑐𝑖𝑡𝑦 × 100%
 For Analog Output A or B, the threshold is 350 T/500 T x100% = 70%.

 For Analog Output A+B, the threshold is 700 T/1000 T x100% = 70%.
 For Analog Output A-B, the threshold is 40 T/500 T x100% = 8%.
6.3 Signal Filtering

To provide applicable signal quality and speed for different applications,
you can set the filter length (count) in the Electronic Unit (EU) to 2, 4, 8,
16, 50, 100, 200, 400, 800 or 1600. The UAP remaps the filter length
read from the EU to its correspondent cutoff frequency in Hz and the
other way around when writing to EU according to Table 4.

Cut-off frequency (Hz) Filter length (count) Response (ms)

3500 2 0.19
1770 4 0.25
885 8 0.42
440 16 0.81
140 50 2.5
70 100 5.02
36 200 10.2
18 400 20
8 800 40
4 1600 81
Table 4: Filter Length Mapping in UAP and Response Time
To select the applicable digital filter bandwidth (cutoff frequency) in UAP,

use the Input Channels tab of the Setup Panel (Figure 27). The default
setting for digital filter bandwidth (cutoff frequency) is 3500 Hz. This gives
the fastest response time. If the signal quality is more important than fast
response for your application, you can set the cutoff frequency to a lower
value.
The factory test results for different filter lengths in an electronic unit are
shown in Table 5. Note that the rise time is the time required for the
analog output to rise from 10% to 90% of its final value. The delay is the
time measurement of the external event to the 50% of the rise time as
indicated in Figure 60 and Figure 61.

Output A Output B
Maximum
Filter Rise time, Rise time, Maximum rise time,
length Delay, µs µs Delay, µs µs delay, ms ms
2 820 188 848 184 0.85 0.19
4 874 250 910 248 0.91 0.25
8 1,000 412 1,050 418 1.05 0.42
16 1,236 806 1,290 802 1.29 0.81
50 2,300 2,500 2,330 2,500 2.33 2.5
100 3,880 5,000 3,920 5,020 3.92 5.02
200 6,420 10,200 7,060 10,060 7.06 10.2
400 13,100 19,800 13,500 20,000 13.5 20
800 25,800 40,000 26,200 39,800 26.2 40
1600 50,200 81,000 50,800 80,400 50.8 81
Table 5: Test Results of Specified Filter Lengths
Figure 60 shows the scope measurement of cutoff frequency of 3500 Hz

(filter length = 2). This filter length produces the fastest response. If the
cutoff frequency is set to a lower frequency(larger filter length), rise time
will increase, but the ability to reject noise increase also.
Delay
Rise
time
Figure 60: Scope Measurement for Filter Length = 2

Figure 61 shows the scope measurement of cutoff frequency of 4 Hz

(filter length = 1,600). This filter length produces the slowest response
time but provides the best rejection of 50/60 Hz AC noise.
Delay
Rise time
Figure 61: Scope Measurement for Filter Length = 1600
6.4 Tension Measurement Calibration

If your measuring system is for tension application, copies of the
Tensiometer Setup Data Sheet and Tensiometer Application Data Sheet
(Form 858 or 859) for your system are contained in Part A of the Tension
Measurement System Manual. The data on these two sheets are derived
from the information given on the installation drawing and/or supplied by
your company. Use the data on these sheets during setup of the input
channels using the UAP or FPI.
Note: You must check the data on the sheets against the
system being built or installed at the time of system
calibration. If the data do not correspond to the
installed system, either you or KELK must create
new sheets. This can be done using the
procedures as described in 6.6.2.2 or 6.6.2.3 and
then printing the sheets.

6.4.1 Tensiometer Setup Data Sheet

The tensiometer setup data sheet (Figure 62) is generated at the factory
for your application using information on load cell calibration cards and
Form 858 or 859. This data sheet provides the following data:
 Load cell model number

 Rated capacity (C) and Unit of Measurement
 Sensor position; for example, operator side or drive side
 Load cell serial number for each sensor
 Full scale sensitivity (S)
 Shunt resistance at calibration (used at factory, note that this

may not be the same value as the application shunt resistor)
 Output with calibration shunt resistor (Oc)
 Application shunt resistor to be selected for this application

Other data on the setup data sheet not listed above are generated
automatically by the UAP or need manual input. For example, single
lead resistance measured (RL). Enter the data from the tensiometer
setup data sheet into the UAP or FPI during setup of the Input
Channels.

Figure 62: Typical Tensiometer Setup Data Sheet
The Application Wizard (Form 858 or 859) must also be used to

determine the Utilization Factor (UF) and the new Calibration Target Load
(CTL). See the next sub-section 6.4.2 for more details.
When the UF and CTL are determined, they are applied to the DSP2 in
order to calibrate each sensor channel. As a result, the DSP2 outputs a
signal which represents tension.
Note: For applications involving variable wrap angles, the

Calibration Target Load is determined using the
system geometry that results in the largest force on
the sensor.

6.4.2 Tensiometer Application Data Sheet

KELK generates the tensiometer application data sheet (Form 858 or
859) for the customer’s system in the factory. This is done by inputting
application wrap angles and specific system parameters, as given on the
system installation drawing or from customer-supplied data, into the
Application Wizard of the User Access Program (UAP).
Note that the Application Wizard is only active if the ‘Tension’ application
and ‘Normal’ selections are selected as indicated in the tensiometer setup
data sheet (Figure 62). The Application Wizard help you to calculate the
Utilization Factor (UF) and the wrap angle compensation (WAC) tables
based on your inputs and selection. For fixed angle tensiometers, the
Application Wizard generates a Form 858 as shown in Figure 63.
When the Application Wizard is initiated, it opens an application wizard
window (Form 858). The window, which displays a comprehensive
legend on the right side, permits the following:
 Selection of tensiometer format from a library of system types
 Selection of strip to roll geometry from a library of known

applications
Figure 63: Example of Form 858 for Fixed Angle Systems

 Accurate determination of wrap angle using the selected strip to

roll condition and dimensional parameters
 Calculation of the following:
 The maximum normal and parallel forces (Fn and Fp) due to
tension that are applied to the measuring system
 The maximum force on the load cell at maximum rated tension

(Pmax)
 The constant of proportionality between tension and the

resulting force on the load cell (K)
 The Utilization Factor (UF).

For variable angle system, the Application Wizard generates a Form 859
which also includes look-up tables based on user input. Figure 64 shows
a look-up table for a system with one variable angle and one fixed angle.
Figure 65 shows a look-up table for a system with two variable angles.
Figure 64: Form 859 with WAC Tables for One Variable Angle System

The look-up tables are used for wrap angle compensation to calculate
system gain compensation factors. It also lets you select the source of
the wrap angle inputs. Refer to sub-sections 6.4.3 and 7.7 for more
details on Wrap Angle Compensation.
If the system changes, you can use the UAP to update the system
information and generate new Form 858 or 859 as described in
procedures 6.6.2.2 or 6.6.2.3.
Figure 65: Form 859 with WAC Tables for Two Variable Angle Systems
6.4.3 Wrap Angle Compensation

The Calibration Target Loads supplied with Tensiometer Load Cell
Assemblies can be used without compensation for fixed strip entry and
exit angles, as specified on their tensiometer setup data sheet.
Compensation is required if one or both angles change.

For each angle that changes (entry, exit or both), a lookup table,
containing a series of 21 coefficients equally spaced between the
minimum and maximum values of a wrap angle value, is entered during
setup. During rolling, the DSP2 uses this table to determine the
appropriate Scaling Factor for the current wrap angle and adjusts the load
signals to output the correct strip tension.
During Setup, you must also select the applicable Wrap Angle input mode
from the following list:
 Off (if WAC is not required)

 Manual (if wrap angle values are to be entered through UAP)
 FieldBus (if input is from the FieldBus connection)
 Analog Input 1 (if channel 1 input is from the Auxiliary Analog
Input board)
 Analog Input 2 (if channel 2 input is from the Auxiliary Analog
Input board).
FieldBus or Analog Input is used when the wrap angle is continuously
changing during the process. Manual is used when changes are
infrequent and can setup using the UAP. Refer to sub-section 7.7 Wrap
Angle Compensation for more details.
If the Auxiliary Analog board is installed, it provides two Auxiliary Analog
Inputs. Input 1 (Analog 1) is normally used for the strip entry angle, and
Input 2 (Analog 2) for the exit angle. These can be reversed; make sure
that the lookup tables and inputs always correspond.
The WAC Look-up Tables are supplied using Form 859. KELK uses the
Application Wizard in the User Access Program to generate these forms.
The tables are based on the rolling geometry specified by the customer.
Each table contains 21 data points so that there are 20 equal intervals
between minimum and maximum wrap angle input. Using the wrap angle
inputs, the DSP2 interpolates linearly between table data points to
determine the corresponding coefficients, W1 and W2. These two
coefficients are combined to formulate the Compensation Factor applied
to the sensor signal to maintain the correct tension output.

6.5 Pre Power-up Check

Before turning on the DSP2, check that:
 The sensors and wiring are installed properly and connected to

the correct Sensor Ports;
 If used, the wrap angle sensors and wiring are properly installed
and connected to the Auxiliary Analog Inputs;
 All Analog Outputs, Logic I/O, Ethernet cable(s) and Fieldbus

cables are correctly installed;
 Any equipment that responds automatically to the outputs is not

active.
Caution: Before and during setup and sensor configuration,

the Digital and Analog Outputs and the Load
Alarms may be inaccurate. Ensure that they are
not connected to any active mill control system as
this may cause the production of off-specification
product or mill damage.
6.6 Setup and Configuration - User Access Program

This section contains setup and configuration procedures in the following
sub-sections. For more information about the UAP and the menu system,
refer to Section 4 User Access Program.
6.6.1 Set Up UAP-to-DSP2 Communications

The UAP program must be installed on a PC or laptop that has the
following minimum hardware and software requirements:
 500 (MHz) or faster 32-bit (x86) or 64-bit (x64) processor

 512 MB of RAM
 10 MB of available space on the hard disk
 1280 x 1024 video adapter
 Network card (100 Mbps or higher)
 Windows XP or Windows 7 operating system
 Java Runtime Environment later than version 7 installed.
The UAP communicates with the DSP2 through the Ethernet network. To
establish communication with the DSP2 electronics unit, you must identify

the IP address in both the UAP and DSP2 in accordance with the
procedures in the following sub-sections.
6.6.1.1 Install UAP on a PC

The UAP application and a copy of this DSP2 User’s Manual in Portable
Document Format (PDF) are supplied by KELK. To install the UAP:
1. Install the UAP application supplied by Kelk on your laptop or PC.
 Double-click the setup installation file (UAP DSP2.exe).
 On the User Access Program Setup window that opens, click

Next.
 Click Next to select the Default Installation (English). If alternate

language is preferred, select Optional Installation, then click
Next.
 When a pop-up message informs you UAP is already installed,

click OK to start uninstall the existing version. Click Yes to
confirm removal of the UAP at the next message. When a
confirm message appears indicating that the UAP was removed,
Click OK.
 When the installation is complete, click Finish.
2. Verify that a shortcut icon appears on the desktop.

6.6.1.2 Modify IP Address of the DSP2 and PC

1. Power on the DSP2 and wait for the load display to appear.
2. Press Menu to view the 3. SYSTE

IP address setting under MSETUP
SYSTEM
the SYSTEM Submenu.  EN0IP EADDRESS
4.
▪ 192.009.001.075
3. If necessary, change the EN0 IP address or EN1 IP address to a new

address specified by your network administrator or by enabling
DHCP.
 To edit the IP address or enable DHCP to generate an IP address,

refer to 6.7.1 Configure Ethernet Ports.
 Restart the DSP2.
4. Connect an Ethernet cable from your laptop or PC to the Ethernet

switch of DSP2 cabinet or directly to the J10 EN0 or J11 EN1
connection at the back of the DSP2.
5. Make sure that your laptop PC can communicate over the network
with the DSP2. Consult the network administrator and change the IP
address of the laptop if necessary.
6.6.1.3 Add DSP2’s to the UAP
1. Double-click the (UAP DSP2) shortcut on the desktop.

2. On the DSP2 UAP window that appears, open the Device Properties
window (Figure 66) by clicking Device under the main menu bar and
selecting Add. Also, you can bring up the Device Properties window
by pressing Ctrl, Shift, and A keys at the same time.
3. On the Device Properties window, enter the applicable data in the
following fields:
 Name — a name for the DSP2; for examples: DSP2_# and

location name F1, F2, R1, or Furnace_exit (no spaces)
 IP Address — IP address of the DSP2 as specified by the

network administrator or by DHCP
 Channel A — optional descriptive name to identify sensor

location. For example, Operator side
 Channel B — optional descriptive name for identification; for

example, Drive side.

Figure 66: Add Device to UAP
4. Click OK.
5. Verify that the device name (for example, DSP2_unit1) with a Setup
icon and a Diagnostics icon appear on the Navigation panel as shown
below.
Navigation
panel
6. To add more DSP2’s (with different IP address) to the UAP, repeat

the previous procedure (6.6.1.2) and this procedure (6.6.1.3).

6.6.2 Set Up Input Channels

Depending on the application of the measuring system and the available
input data, you can set up the input channels using procedures in the
following sub-sections:
6.6.2.1 Roll Force or Pressure Application

To set up input channels for roll force or pressure application:
1. Click Setup at the navigation panel.
2. Verify that the main panel on the right shows the screen of Input
Channels tab.
3. Click Normal on the Load Cell Data Entry field of Strain Gage
Interface Board Parameter (Figure 67).
4. Select Roll force or Pressure as applicable on the Application field
for the measuring system. If you select Tension, refer to sub-section
6.6.2.2 or 6.6.2.3.
Step 4
Step 5
Step 7
Step 6
Figure 67: Setup – Input Channels

Note: When you change a selection or value, it is highlighted

in yellow as well as the tab/field it is within. This shows
that it is a pending change. Highlights are removed
after these changes are applied to the device.
5. Refer to the Load Cell Calibration Card for Sensor A or B and enter
the applicable data for the following fields:
 Model No.
 Rated Capacity (C) and unit of measurement (click the ▼ arrow

and select the applicable unit of measurement from the list).
 Digital filter bandwidth: If you want to change this value, refer to

6.3 Signal Filtering for more information.
 Load cell excitation: Enter the default value of 10 V.
Note: Change the default value only for conditions such

as low sensitivity of load cell, low response, small
wrap angle, high overload protection, or high
input noise. Please consult with KELK before
changing this value.
 Zero accumulation fault: Enabled (default) or Disabled. If

enabled, channel fault will be indicated when accumulative load
exceeds ±20% of full scale. If disabled, channel fault will be
indicated only at input saturation.
6. Refer to Load Cell Calibration Card of Sensor A and enter the
following data in the table for column of Channel A:
Note: To edit or enter a value in the table, double-click the

existing value or an empty field of the table.
 Serial Number
 Shunt resistor at calibration
 Output with calibration shunt resistor (OC)
 Single lead resistance measured (RL):

 Enter the calculated value of RL in accordance with the

procedure in 6.1.1 Measure Interconnect Cable Resistance.
After you enter a new value, the calculation of cable
compensation factor (Cf) changes automatically.
7. Click the Recalculate CTL button. This will recalculate the CTL
shown in the table (Figure 67).
 Verify that calibration target load (CTL) is within 20 to 150%
 Ideally, the CTL should be within 50 – 100%. To adjust the CTL

within this range, do step 8 as necessary.
8. If necessary, refer to Figure 68 and adjust the CTL as follows:
 Click on the existing value of Application shunt resistor on

table column for Channel A.
 On the displayed selection list, select a resistor value ranging

from 50kΩ – 800kΩ. Note that the lower the resistor value, the
higher will be the recalibrated CTL.
 Click Recalculate CTL button again.
Figure 68: Setup – Adjust CTL Using Application Shunt Resistor

9. Repeat steps 6 to 8 for

entering applicable
values on Channel B Toolbar
column of the table.
10. Click the Apply Changes Apply
Changes
icon on the toolbar as icon
shown in Figure 69 or
select Device > Apply
Changes on the menu
bar. Figure 69: Toolbar of DSP2
UAP
11. Click Yes on the pop-up window to confirm Apply Changes.

13. When a caution message appears, click OK to confirm run
configuration.
14. Wait for the configuration to complete and the display return to the
device main screen.
6.6.2.2 Tension Application – Fixed Wrap Angles

To set up input channels for tension application with fixed wrap angles,
refer to Tensiometer Setup Data Sheet and Form 858 (DSP2
Tensiometer Application Data) in the Tension Measurement System
Manual and follow these steps:
2. Verify that the main panel shows the screen of Input Channels tab.
3. Select Normal on the Load Cell Data Entry field of Strain Gage
Interface Board Parameter.
4. Select Tension on the Application field (Figure 70).
5. Enter the applicable data from the Tensiometer Setup Data Sheet on
the following fields:
 Model No.
 Rated Capacity (C) and unit of measurement — click the ▼

arrow and select the applicable unit of measurement from the
list.
 Digital filter bandwidth — if you want to change this value, refer

to 6.3 Signal Filtering for more information.

 Load cell excitation — enter the default value of 10 V.
Note: Change the default value for Load Cell

excitation only for conditions such as low
sensitivity of load cell, low response, small wrap
angle, high overload protection, or high input
noise. Please consult with KELK before
changing this value.

exceeds 20% of full scale. If disabled, channel fault will be
indicated only at input saturation (exceeds 200%).
6. Refer to Load Cell Calibration Card of Sensors A and B, enter the

following data on the table columns of Channel A and Channel B:
Step 4
Step 5
Step 7
Step 6
Figure 70: Setup Tension Application

Note: To edit or enter a value in the table, double-click

the existing value or an empty field of the table.
 Serial No.
 Shunt resistor at calibration
 Output with calibration shunt resistor (OC)
 Single lead resistance measured (RL):
 Application shunt resistor

7. Click the Application Wizard button.
8. Refer to Form 858 of your measuring system, do the following steps
on the Application Wizard window (Figure 71):
a. Verify that the values shown on CA and CB fields are the value of
Rated Capacity that you entered in step 5.
Note: As an example of this procedure, the L.H.

and R.H. Wrap angle (Fixed Angle) are
selected for steps b and c.
b. Use the ▼or ▲arrow on the top-left graphic (Figure 71) to select
the correct tensiometer format as specified in your Form 858.
Notice that as you view the different selections, the required data
fields for the selections are also changed.
c. Use the ▼or ▲arrow on the tope-right graphic to select the
correct tensiometer format from a library of system type.

Step b Step c
Step e
Step a
Step f
Figure 71: Form 858 - Application Wizard for Tension Application with Fixed Wrap
Angle
d. Enter the applicable data in the required data fields. For this
example, confirm that α angle on the left field and β angle on the
right field are correct on-site as specified on Form 858. Enter
values or new values as required.
e. Use the ▼or ▲arrow on the center graphic to select the correct
strip-to-roll geometry as specified in Form 858.
f. Enter the rated tension value data and unit of measurement for
the selected strip-to-roll geometry.
g. Confirm that the rated tension and direction of strip travel (Figure
72) are correct as specified on Form 858 on-site. Enter values or
new values as required.
h. Enter the angle of mounting inclination.
i. Click Calculate.
j. Verify that the calculated value for Utilization Factor (UF) is within
the range of 0.25 – 10.0. If the value is outside this range,
recheck all steps and make the necessary changes.

Step g
Step i Step k
Step h
Step j
Figure 72: Calculation for UF in Application Wizard
k. Click Apply. This will close the Application Wizard.

9. Verify that the calculated values are shown in Utilization Factor (UF)
fields of sensor A and Sensor B (Figure 73).
10. Click Recalculate CTL and verify that new values are within 50 –
100% on the Calibration target load (CTL) fields.
11. Adjust the value of application shunt resistor if 20 > CTL > 150%.
12. Click the (Apply Changes) icon on the toolbar or select Device >
Apply Changes on the menu bar.
13. To confirm Apply Changes, click Yes on the pop-up window.
15. When a caution message appears, confirm run configuration by
clicking OK.
device main screen.

Step 10
Step 9
Step 10
Figure 73: Recalculate CTL with New UF Value
6.6.2.3 Tension Application – Variable Wrap Angles

To set up input channels for tension application with variable wrap angles,
refer to the Tensiometer Setup Data Sheet and Form 859 (DSP2
Tensiometer Application Data) in the Tension Measurement System
Manual and follow these steps:
1. Follow steps 1 through 7 of previous procedure in 6.6.2.2 Tension
Application – Fixed Wrap Angle. Enter applicable data as shown in
Figure 74.
2. On the Application Wizard window (Figure 75), Verify that the values
shown on CA and CB fields are the value of Rated Capacity that you
entered in the previous step.
Note: As an example of this procedure, the Variable

Pass Line and Underwind Variable Coil
Diameter are selected for steps 3 and 4.

Figure 74: Set up Tension Application for Variable Wrap Angles
3. Use the ▼or ▲arrow on the top-left graphic to select the correct
tensiometer format as specified in Form 859. Notice that as you view
the different selections, the required data fields for the selections are
also changed.
4. Use the ▼or ▲arrow on the tope-right graphic to select the correct
tensiometer format from a library of system type.
5. Enter the applicable data as in the required data fields as shown in
Figure 75.
6. Use the ▼or ▲arrow on the center graphic to select the correct strip-
to-roll geometry as specified in the Form 859.
7. Enter the applicable data and unit of measurement for the selected
strip-to-roll geometry.

Step 4
Step 3
Step 6
Step 2
Step 7
Figure 75: Application Wizard for Tension Application with Variable Wrap Angles
8. Confirm that the rated tension and direction of strip travel are correct
(Figure 76) as specified in the Form 859. Enter values or new value
as necessary.
9. Enter the angle of mounting inclination.
10. Click Calculate.
11. Verify that:
 A table, which contains data for WAC Inputs and WAC Table
Coefficients, is displayed on the Application Wizard and the
Form number change from 858 to 859.
 The calculated data, including the value of Utilization Factor

(UF) is displayed on the bottom of the Wizard.
 Make sure that UF is within the range of 0.25 – 10.0. If the

value is outside this range, recheck all steps and make the
necessary changes.

Steps 12 and l3
Step 8
Step 9 Step 10 Step 14
Step 11
Figure 76: Form 859 with WAC Tables for Variable Wrap Angles
12. Click the ▼ arrow under Channel 1, select, from the drop-down list,
an applicable input data source for Wrap Angle Compensation (WAC):
 Off (if no input is required)

 Manual (if wrap angle values are to be input from the UAP)
 FieldBus (if input is from the FieldBus connection)
 Analog 1 (if channel 1 input is from the Auxiliary Analog Input
board)
 Analog 2 (if channel 2 input is from the Auxiliary Analog Input
board)

Note: If you select Manual from

step 12 above, you can
use WAC Input under
the Operation submenu
to specify the input
counts and coiler
diameter.
13. Click the ▼ arrow under Channel 2 and select the applicable input
source (same as step 12).
14. To apply the WAC data and UF value, click Apply. This will close the
Application Wizard.
15. Verify that the calculated values are shown in the Utilization Factor
(UF) fields of sensor A and Sensor B (Figure 77).
16. Click Recalculate CTL and verify that new values are within 50 –
100% on the Calibration target load (CTL) fields.
17. Adjust the value of application shunt resistor if 20 > CTL > 150%.
18. Click the (Apply Changes) icon on the toolbar or select Device >
Apply Changes on the menu bar.
21. When a caution message appears, confirm run configuration by
clicking OK.
device main screen.

Step 16
Step 15
Step 16
Figure 77: Complete Setup of Tension Application
6.6.2.4 Setting Up Applications in Expert Mode

You can use the expert mode to set up the input channels for any
applications if the values of the application shunt resistor and calibration
target load (CTL) are known. For example, Application Engineering of
KELK may provide the shunt resistor value and the CTL with the
applicable drawings for some custom application.
To set up the input channels for any application in expert mode:
2. Verify that the main panel shows the screen of Input Channels tab.
3. Select Expert on the Load Cell Data Entry field of Strain Gage
Interface Board Parameter (Figure 78).
4. Refer to the Load Cell Calibration Cards or Tensiometer Setup Data
Sheet for Sensor A or B, enter the data on the following fields:

 Model Number.
 Rated Capacity (C) and unit of measurement — click the ▼
arrow and select the unit of measurement from the list
 Digital filter bandwidth — if you want to change this value, refer
to 6.3 Signal Filtering for more information.
 Load cell excitation — enter the default value of 10 V.
Note: Change the default value only for conditions

such as low sensitivity of load cell, low
response, small wrap angle, high overload
protection, or high input noise. Please consult
with KELK before changing this value.

exceeds ±20% of full scale. If disabled, channel fault will be
indicated only at input saturation.
5. Enter the following data on the table columns of Channel A and
Channel B:
 Application shunt resistor

 Calibration target load (CTL).
6. Apply the changes now or wait until you finish other setups and
configurations.
Figure 78: Set up Input Channels in Expert Mode

6.6.3 Specify Analog Outputs

You can set up the installed Analog Outputs (maximum of 6) to output A,
B, A+B or A-B in voltage or current mode.
To set up the Analog Outputs:
2. Select the Analog outputs tab on the main panel on the right (Figure 79).
Note: The DSP2 can have a maximum of three Analog

Output boards. Each board has two analog
outputs. Only installed boards are enabled for
configuration. Therefore, if a board is not installed,
two analog outputs on the UAP are grayed out.
3. Click the ▼ arrow on the Source field for Output 1 and select the
applicable source (OFF, A, B, A+B or A-B) from the drop-down list.
4. Click the ▼ arrow on the Mode field for Output 1 and select the applicable
mode (Voltage 0–10 V / Voltage 10 V, 0–20 mA or 4–20 mA) from the
drop-down list.
Figure 79: Setup – Analog Outputs

5. Enter an applicable value on the Scaling factor field. Valid range is

1.0 to 999.9%. For more information about scale factor, refer to 6.2.3
Analog Outputs and Output Scaling.
6. Repeat steps 3 through 5 for Output 2 through Output 6 as required.
7. Apply the changes or wait until you finish other setups and
configurations, before applying changes together.
6.6.4 Configure Load Alarms

You can configure up to four Load Alarms to indicate when a load level
exceeds a set threshold. To configure the Load Alarms:
2. Select the Load Alarms tab on the main panel on the right (Figure
80).
3. Click the ▼ arrow on the Source field of Relay 1and select the
applicable source [OFF, A, B, SUM (A+B) or DIF (A-B)] from the drop-
down list.
Figure 80: Setup – Load Alarms

4. Enter an applicable value in the Threshold field. Valid range is 0.1–

150.0%. For more information about threshold and example, refer to
6.2.4 Load Alarms and Threshold Limits.
5. Enter an applicable value in the Time field. Valid range is 001–999 ms.
The Time parameter is the amount of time for which the load must
exceed the threshold before the alarm is set to ON. It is also the
amount of time after the load has fallen below the threshold, before the
alarm is set to OFF.
6. Repeat steps 3 through 5 for Relay 2 through Relay 4 as required.
configurations, before applying changes together.
6.6.5 Set Up Communication Ports

You can change the settings for networking communications ports. An
optional Modbus/TCP board may be installed. If a board is not installed in
the Field-bus location, the fields of Fieldbus J9 communication are
unavailable (grayed out).
To configure communication ports:
2. Select the communication tab on the main panel (Figure 81).
3. Enter the new IP address, Netmask, and Gateway for Ethernet J10
and Ethernet J11 as applicable.
Figure 81: Setup – Communication Ports

4. If an Ethernet Modbus TCP board is installed in the FieldbusJ9 slot

and Modbus fields are enabled, enter the applicable Address (IP),
Netmask and Gateway.
5. Click the Apply Changes icon on the toolbar as shown in Figure 69 or
select Device > Apply Changes on the menu bar
continue.
Note: If you change the IP address of the Ethernet port

that the UAP is currently connected, the network
communication with the DSP2 will be disconnected.
To reconnect with the DSP2 with the new IP address:

1. Right-click on any empty space of the Navigation Panel and select
Properties or select Device > Properties from the menu bar.
2. On the Device Properties window that opens, enter the new IP
address in the IP Address field and click OK.
3. Verify that UAP reads the device again and reconnect with the DSP2.

6.6.6 Configure the FPI Display

You can configure the load display on the FPI to display up to eight load
values. For more information about the FPI settings, refer to 4.4.5 FPI
Display. To configure the FPI display:
2. Select the FPI Display tab on the main panel on the right (Figure 82).
Figure 82: Setup – FPI Display
3. On the First pair field of Live Display

block, click the ▼ arrow to display the
list shown on the right.
4. Select one of eight choices on the list.
The selected choice will display the
specified value(s) on the first two lines
of the front panel LED display.
5. On the Second pair field of Live Display block, click the ▼ arrow and
repeat the above step. Make sure the selection is different from the
live display of the first pair.
The selected choice will display the specified value(s) on the third and
fourth lines of the front panel LED display.
6. Enter an applicable value from 1.0000 – 99999999 in the Full scale
field. Note that the decimal point is movable. For examples: 1.0000,
10.000, 100.00, 1000.0 and 10000.
7. Click the ▼ arrow on the Load unit field and select the applicable unit
of measurement from the list.
Note: Changing the load units does not affect Full Scale
load number. Load unit is only for display.
8. Click the ▼ arrow on the Auxiliary indicator field and select the
applicable choice as shown on the following list.
9. The default setting for heart beat is Enable. If you want to disable the
heart beat on the FPI, click the ▼ arrow and select Disable.
select Device > Apply Changes on the menu bar.
12. Click Yes on the Operation is successful message.
6.6.7 Set Up IBA

If your site does not use the ibaPDA application, skip this procedure. For
site that uses ibaPDA, configure the IBA Process Data Acquisition (PDA)
module so that a remote PDA server can connect to the DSP2 and collect
data for logging and analysis.
To set up IBA:
2. Select the IBA tab on the main panel on the right (Figure 83).
3. Enter the IP address of the IBA PDA server in the Server IP Address
field.
4. Enter 10 ms in the Logging rate field.
5. Enable Generic Index and/or Custom index on the Modules pane as
applicable:
 To enable Generic index, click Enable or check box (Figure 84).

Verify that a check mark is in the check box and the second
column (Generic) of the mapping table is visible.
 To enable custom index, click Enable or check box on the

custom index line as shown in Figure 84. Verify that a check
mark is in the check box and the third column of the mapping
table is visible.

Figure 83: Setup – IBA
Figure 84: IBA with Generic and Custom Indexes Enabled

6. Note that the mappings for generic and custom modules are defined
as shown in the following table. Generic modules are view only.
Generic Modbus Custom Modbus
Description Description
Module Input R Module Input R
00 0 Load A % 00 0 Load A %
01 1 Load B % 01 1 Load B %
02 2 Status of Logical Outputs 02 2 Status of Logical Outputs
03 3 Sum A+B % 03 3 Sum A+B %
04 4 Difference A-B % 04 4 Difference A-B %
05 12 Electronics Status 05 10 Timer Counter High Word
06 13 Channel A Status 06 11 Timer Counter Low Word
07 14 Channel B Status 07 20 Load A # High Word
08 15 Electronics Temperature 08 21 Load A # Low Word
09 20 Load A # High Word 09 22 Load B # High Word
10 21 Load A # Low Word 10 23 Load B # Low Word
11 22 Load B # High Word 11 24 Sum A+B # High Word
12 23 Load B # Low Word 12 25 Sum A+B # Low Word
13 24 Sum A+B # High Word 13 26 Difference A-B # High Word
14 25 Sum A+B # Low Word 14 27 Difference A-B # Low Word
15 26 Difference A-B # High Word 15 32 WAC 1 Input
16 27 Difference A-B # Low Word 16 33 WAC 2 Input
17 41 FPI Keypad Code 17 53 SGIB A Temperature
18 48 SGIB A Status 18 54 Not Used
19 56 SGIB B Status 19 61 SGIB B Temperature
20 49 SGIB A Arm 1 Voltage 20 62 Not Used
21 50 SGIB A Arm 2 Voltage 21 100 A_1K High Word
22 51 SGIB A Excitation Voltage 22 101 A_1K Low Word
23 52 SGIB A Excitation Current 23 102 B_1K High Word
24 57 SGIB B Arm 1 Voltage 24 103 B_1K Low Word
25 58 SGIB B Arm 2 Voltage 25 132 Calculated bridge resistance A High Word
26 59 SGIB B Excitation Voltage 26 133 Calculated bridge resistance A Low Word
27 60 SGIB B Excitation Current 27 134 Calculated bridge resistance B High Word
28 140 Zero Accumulator A High Word 28 135 Calculated bridge resistance B Low Word
29 141 Zero Accumulator A Low Word 29 205 AO1 Status
30 142 Zero Accumulator B High Word 30 211 AO2 Status
31 143 Zero Accumulator B Low Word 31 240 CPU Load
Table 6: IBA Mappings for Generic and Custom Modules

7. When the Generic and/or the custom index are enabled, you can also
change the default index number of 16 and 17 to other numbers.
Changing Index numbers are applicable only if the ibaPDA client is
logging more than one DSP2’s and you want to specify different index
numbers for each DSP2.
Note: If you change the default index number in the

DSP2, you must also update the TCP/IP Module
Index in the iba I/O Manager according to the next
procedure in sub-section 6.6.7.1.
6.6.7.1 Update TCP/IP Module Index in ibaPDA

The following procedure assumes that you have changed the Module
number for generic index from 16 to 20. To update the TCP/IP Module
Index in ibaPDA.
1. Start the ibaPDA client from a remote PC or laptop. Make sure it
connects with the DSP2 unit.
2. Select Configure > I/O Manager from the menu bar of the ibaPda
client window.
3. On the iba I/O Manager window that opens, select TCP/IP Modbus
Server on the Navigation panel.
4. Verify that the connections show that the new connection for Module
Index is now 20 as shown in Figure 85.
Figure 85: TCP/IP Modbus Server

5. Select DSP2 Generic Module (16) under TCP/IP Modbus Server.

6. Click the General tab (Figure 86).
7. Click on the Module Index number under TCP/IP and change the
number from 16 to 20 as shown in Figure 86.
8. Click OK. Click OK again to confirm Applying new I/O configuration.
Figure 86: Changing TCP/IP Module Index Generic Module (16)
6.6.7.2 Modify Custom Module

If applicable, you can modify the index of the custom module. Table 7
lists the additional input registers for the custom index.

Modbus Modbus
Description Description
Input R Input R
48 SGIB_A_Status 89 A_1k_P Low Word
56 SGIB_B_Status 90 B_1k_P High Word
Chan 'A' Input Scale Factor
75 91 B_1k_P Low Word
A_scl (Wsc)
Chan. 'B' Input Scale Factor
76 92 SUM_1k_P High Word
B_scl (Wsc)
77 WAC compensation coef. W1 93 SUM_1k_P Low Word
78 WAC compensation coef. W2 94 DIF_1k_P High Word
80 A_1kF_P High Word 95 DIF_1k_P Low Word
81 A_1kF_P Low Word 96 A_1kF High Word
82 B_1kF_P High Word 97 A_1kF Low Word
83 B_1kF_P Low Word 98 B_1kF High Word
84 SUM_1kF_P High Word 99 B_1kF Low Word
85 SUM_1kF_P Low Word 217 AO3 Status
86 DIF_1kF_P High Word 223 AO4 Status
87 DIF_1kF_P Low Word 229 AO5 Status
88 A_1k_P High Word 235 AO6 Status
Table 7: Additional Input Registers for Customer Index
To replace customer modules with other Modbus input registers, use the
following example that replaces modules 27 and 28 (Modbus input
registers 134 and 135) with input registers 217 and 223:
1. Double-click the mapping field of a custom module number 27, enter
217 or use the Up arrow to set the number to 217. Press Enter.
2. Double-click the mapping field of a custom module number 28, enter

223 or use the Up arrow to set the number to 223. Press Enter.


select Device > Apply Changes on the menu bar.
Note: If you made changes to the custom index, you must

also update the iba I/O Manager of the ibaPDA
client to reflect your changes according to the next
procedure in 6.6.7.3.
6.6.7.3 Update Custom Module in ibaPda I/O Manager

To update the iba I/O Manager settings for DSP2 Custom Module:
1. Start the ibaPDA client from a remote PC or laptop. Make sure it
connects with the DSP2.
2. Select Configure > I/O Manager from the menu bar of the ibaPda
client window.
3. On the iba I/O Manager window that opens (Figure 87), select DSP2
Customer Module (17) under TCP/IP Modbus Server.
4. Click the tab.

5. Click on the applicable field that you want to change the name of the
signal. For this example, click field 27 as shown in Figure 87.
6. Type in a new name and click OK.
7. On the Applying new I/O configuration window, click OK.

Figure 87: Iba Screen for DSP2 Custom Module (17)
6.6.8 Change Logic I/O Settings

Usually the factory settings for logic inputs and outputs are sufficient for
most systems. Do not change the factory settings unless it is necessary
to customize your system.
To change a factory setting for input or output signal:
1. Click Setup at the navigation panel. Select the I/O Settings tab on
the main panel on the right (Figure 89)
2. Click the ▼ arrow on an applicable field of the signal that you want to
change; select the appropriate choice.
 For Alarm 1-4, the choice is Closed on Fault or Open on Fault.
 For Zero, 2xA input trigger, 2xA input trigger, Self-test input
trigger and Calibration input trigger, the choice is On Rising
Edge or On Falling Edge.
 For Lockout input trigger, the choice is Lock On Open Input or

Lock On 24V Applied.
 For System Fault, Channel A Fault and Channel B Fault, the

choice is Closed On Fault or Open On Fault.
configurations.

Figure 88: Setup – IO Settings
6.6.9 Apply Changes and Run Configuration

When all the setups and configuration are done, make sure that you apply
the changes and/or run the configuration. Note that some operations of
Apply Changes also run the Configuration operation after the changes.
To apply changes to any DSP2:
1. Select the applicable device on the navigation panel. For example,
select DSP2_unit 1 as shown in Figure 89. Click the Apply Changes
icon on the toolbar as shown below or select Device > Apply
Changes on the menu bar.
Apply
Changes
Toolbar
icon
Figure 89: Apply Changes Icon on Toolbar


4. If the following message appears, click OK to confirm run
configuration.
Figure 90: Confirmation Message
device main screen.
The UAP will prompt you to run Configuration when:
 CTL is changed
 Excitation is changed
 New load cell is installed
 Zero accumulation exceeds 20% of full scale.
To run configuration any time:

1. Select the applicable device on the navigation panel.
2. Select Device > Run Configuration on the menu bar.
Figure 91: Run Configuration
3. On the confirmation message that appears (Figure 91), confirm Run

Configuration by clicking OK.
device main screen.
6.6.10 Verify Setup and Load Output

After the setup and configuration are done, verify that the setup and load
output (analog and digital) are correct using the load simulation. Check
also that output to the mill control system are correct.
Caution: Make sure that the Mill Control System is not active for
production until you have verified that the setup and configuration
are correct
1. Connect the Mill Control System/Programmable Logic Controller

(PLC) to the DSP2.
2. Using one of the available output (analog or digital), connect the
laptop of mill control system or PLC and confirm that the Mill Control
System communicates with the DSP2.
3. Select Diagnostic on the navigation panel of the UAP and then click
the Simulation/Test tab (Figure 92)
Figure 92: Simulation/Test Tab
4. Select Simulation A & B on the Simulation Option field (Figure 93).
Note: For steps 5 and 6, the input field A and B accept negative
values for simulating negative voltage or current lower than 4
mA, Graphic/bar will stop at 0.
5. Enter a percentage in the Load Simulation field of channel A or click

and hold the channel A slider and move it up or down to a new value.

6. Enter a different percentage in the Load Simulation field of channel B

or click and hold the channel B slider and move it up or down to a new
value.
7. Make sure the values entered for channels A and B do not trigger any
Load Alarms as it is shown in Figure 94.
8. Verify that the entered values correspond to the values shown on the
Measurement graphs and displayed on the FPI.
9. On the terminal blocks for logic I/O and analog output (refer to sub-
sections 5.3.3

Logic I/O Wiring and 5.3.4 Analog Output Wiring for details), measure
the analog outputs. Verify that the measurements correspond to the
simulated load values.
10. Verify that the loads displayed on the laptop of mill control system
also correspond to the simulated load values.
Step 8
Step 4
Step 5 Step 6
Step 7
Figure 93: Simulation A & B Settings

Figure 94: Simulated Load for Load Alarms
11. Adjust the simulated loads of channel A and/or channel B, so that they
trigger the load alarm(s) as shown in the example of Figure 94Figure
94.
12. Verify that the values of simulated loads are shown on the FPI and
that the applicable System Status LEDs on the FPI are ON.
13. On the terminal block of logic I/O (TB12), measure the outputs of
channel A Fault and/or Channel B Fault. Verify that the
measurements indicate the applicable channels that cause the load
alarms.
14. Verify also that the applicable load alarms displayed on the laptop of
mill control system.
15. Select Shunt A & B on the Simulation Option field (Figure 95). This
option applies the calibration shunt resistors to both channels.
16. Verify that the levels of the load outputs on the Measurement field
correspond to the Calibration Target Loads (including any corrections
included for interconnecting cable resistance) entered during setup.
Note: If you navigate away from the Simulation/Test tab,

simulation is stopped and the DSP2 returns to
normal mode.

CTL A CTL B
Figure 95: Simulated Load with Shunt Resistors Applied
6.6.11 Save Configuration

After all setups and configurations are done and verified, make sure that
you save the configuration of the device(s) on the hard disk as a backup.
The configuration file has a file extension of kcm and is stored in a
DSP2_UAP folder under your user’s name folder.
To save the device configuration:
1. Click File > Save or Save All on the Menu bar.
Note: Select Save All if the UAP has more than one
device.
2. On the Save KCM window that appears, type a descriptive name in

the File Name field (Figure 96).
3. If you want to save the file to:
 the desktop; click the desktop icon (Figure 96)
 another location; click the up-one-level icon and navigate to your

designated location

 a new folder; click the create-new-folder icon and enter a new

folder name. Select the new folder to continue.
Figure 96: Save Configuration
4. Click Save

6.7 Setup and Configuration - Front Panel Interface

This section and sub-sections contain setup and configuration procedures
using the FPI. For details about the navigation and the menu system,
refer to Section 3 Front Panel Interface.
To access the Setup menu, press the MENU button on the FPI and then
the down arrow key (↓). Then, in the System submenu, use the  or 
key to navigate to other setup submenus as shown in Figure 97.
SETUP
 ANALOG OUTPUTS Analog
A01 SOURCE Outputs
▪ OFF
SETUP
 SYSTEM
System
EN0 IP ADDRESS submenu
▪ 192.009.001.075
SETUP
 FPI
 FPI
 submenu
1ST ROW PAIR
▪ CHANNEL A&B (%) 
SETUP
 SGIB A SETTINGS SGIB A
SHUNT Settings
▪ 50 kOhm
SETUP
Alarms
 ALARMS
submenu
ALARM 1 SOURCE
▪ OFF

SETUP
SGIB B
 SGIB B SETTINGS Settings
SHUNT
▪ 50 kOhm
SETUP Logic I/O
 LOGIC IO FACTORY  Factory
ALARM 1 POLARITY Settings
▪ CLOSED ON ALARM
SETUP
 SGIB COMMON SETTI SGIB
APPLICATION Common
▪ Roll Force Settings
SETUP
System
 SYS INFO Information
NAME
▪ sn18
Figure 97: Setup Submenus

Note: The Lockout logic input is set to disable in the factory

so that all configurable parameters can be edited on
the Front Panel Interface. After completing the setup
and configuration, you may want to lockout the FPI
so that no one can change the settings. To enable
the lockout feature, refer to sub-section 7.10.
6.7.1 Configure Ethernet Ports

You can configure the two Ethernet ports (EN0 and EN1) so that a remote
applicable such as UAP, ibaPDA, or mill control program can
communicate with the DSP2.
To configure Ethernet port settings:
 Verify the Ethernet port connections and check with the network
system administrator what IP addresses are assigned to EN0 and
EN1 of the Electronic Unit.
 Refer to Figure 98 for navigation.
 Enter the applicable values for the parameters. Usually, you only
need to change the IP addresses or enable DHCP (Dynamic Host
Configuration Protocol).
If you need to change/edit a parameter setting:
1. Press the down arrow key (↓) so that the active indicator is on the
parameter line.
2. Press ENTER so that the parameter line is in editing mode with a
blinking ░ symbol.
3. Enter the required value using  and  keys to select digit, and ↑
and ↓ keys to increment or decrement digit.
4. To change EN0 DHCP or EN1 DHCP settings, use the ↓ ↑ key to
select Enable.
5. To exit edit mode, press ENTER.
6. Restart the DSP2.
7. If you have enabled EN0 DHCP or EN1 DHCP, make sure the
adapter(s) is connected to a DHCP server and verify that:
 The message EN0 DHCP Waiting… and/or EN1 DHCP

Waiting… appear on the FPI during the initialization process.
Note: While the system is processing DHCP, the front

panel is still functional and lets you configure the
DSP2.

 If DHCP is successful for the EN0 or EN1 adapter, the front panel
switches to live load display. Go to step 8.
 If after one minute, another blinking message DHCP Aborted…

appears for 5 seconds on the front panel before returning to live
load display, this indicates that the adapters cannot complete the
DHCP operation. Check the network setting or contact the
network administrator. Disable DHCP as necessary.
8. On the FPI, press MENU and note the new IP address of EN0 or EN1.
SETUP SETUP
SYSTEM SYSTEM
 EN0 IP ADDRESS  EN1 IP ADDRESS
▪ 192.009.001.075 ▪ 011.011.000.136
 
 
SETUP SETUP
SYSTEM SYSTEM
 EN0 NETMASK  EN1 NETMASK
▪ 255.255.255.000 ▪ 255.255.255.000
SETUP SETUP
SYSTEM SYSTEM
 EN0 GATEWAY  EN1 GATEWAY
▪ 000.000.000.000 ▪ 000.000.000.000
SETUP SETUP
SYSTEM SYSTEM
 EN0 MAC ADDRESS  EN1 MAC ADDRESS
▪ XX:XX:XX:XX:FF:FF ▪ XX:XX:XX:XX:FF:FF
SETUP SETUP
SYSTEM SYSTEM
 EN0 DHCP  EN1 DHCP
▪ Disable ▪ Disable

 

Figure 98: System Submenus

9. Use the new IP address to set up communication with the UAP

according to the procedure in 6.6.5 Set Up Communication Ports.
Refer to sub-section 4.4.4 Communication for more details about
DHCP.
6.7.2 Set Up Input Channels

To set up the input channels using the FPI, you need to access three
setup submenus:
 SGIB A Settings — A setup submenu for Strain Gage Interface

Board (SGIB) of sensor A
 SGIB B Settings — A setup submenu for Strain Gage Interface

Board (SGIB) settings of sensor B
 SGIB Common Settings — A submenu for settings that are

applicable to both SGIB A and SGIB B.
Refer to the following sub-sections for the setup information.
6.7.2.1 SGIB A Settings and SGIB B Settings

Navigate to the SGIB A Settings submenu (as shown in Figure 97), refer
to Figure 99 and set up the following parameters:
 SHUNT (Calibration shunt resistor)
 Make sure that you select the value corresponding to that on

the Sensor Calibration Cards or Tensiometer Application Data
Sheet. This value along with the CTL value is used during
Sensor Configuration.
 CTL (Calibration Target Load)
 Set to the value to that defined on the Load Cell Calibration

Cards or Tensiometer Setup Data Sheet as applicable.
 Use new CTL value with resistance correction. Refer to
6.1.2 Calculate CTL with Resistance Correction for
procedure.
 The value must be in the range 20.00 to 150.00% (02000
to 15000). This value along with the Shunt is used during
sensor configuration.
Note: If you enter any value outside this range, the

ENTER key will not allow you to exit the edit
mode.

When you are done with the SGIB A Settings, navigate to the
SGIB B settings submenu. Set up the parameters the same way
as the SGIB A settings.
SETUP  SETUP
SGIB A SETTINGS  SGIB A SETTINGS
 SHUNT  CTL
▪ 50 kOhm ▪ 09499 %
↓↑ ↓↑
SETUP SETUP
SHUNT CTL
 50 kOhm  09499 %
ENTER ENTER
SETUP SETUP
SHUNT CTL
 ░0 kOhm  ░9499 %
↓↑
50 kOhm, 100 kOhm, Enter the required value
150 kOhm, 200 kOhm, using  and  keys to
250 kOhm, 300 kOhm, select digit, and ↑ and ↓
350 kOhm, 400 kOhm, keys to increment or
450 kOhm, 500 kOhm, decrement digit. 2 – 4
550 kOhm, 600 kOhm, Valid range is 02000 to
650 kOhm, 700 kOhm 15000 (20.00–150.00)%
750 kOhm, 800 kOhm
ENTER ENTER
Figure 99: SGIB A Settings
6.7.2.2 SGIB Common Settings

Navigate to the SGIB Common Settings submenu (as shown in Figure
97), refer to Figure 100 and set up the following parameters that are
applicable to both SGIB boards:
 Application:
 Select Roll Force for force measuring system, Tension for
tension measuring system or Pressure for pressure measuring
system.

 Single Sensor (source of sensors):

 Default setting is A & B for normal operation of Sensor A to
be connected to Channel A and Sensor B to be connected
to Channel B.
 Select 2*A for Sensor A to be connected to both Channels.
 Select 2*B for Sensor B to be connected to both Channels.
Note: Selection of 2*A or 2*B will set the system to

Single Sensor Operation. Use these options
only if a sensor, or input channel has failed
and a load signal is required on both channels.
↓ and
SETUP SETUP
ENTER
SGIB COMMON SETTI SGIB COMMON SETTI
 APPLICATION APPLICATION
▪ Roll Force  ░oll Force
↓↑
 Roll Force
 ENTER
 Tension
 and ↑
 Pressure
SETUP ↓ and SETUP

SGIB COMMON SETTI ENTER SGIB COMMON SETTI
 SINGLE SENSOR SINGLE SENSOR
▪ A & B  ░ & B
↓↑
 A & B
ENTER
 2 * A
and ↑
 2 * B
Figure 100: SGIB Common Settings
Note: To switch from 2*A to 2*B or vice versa, select

A & B first.

6.7.3 Specify Analog Outputs

You can set up the installed Analog Outputs (maximum of 6, AO1–AO6)
to output A, B, A+B or A-B in ±10V, 0 to 10V, 4–20 mA or 0–20 mA mode.
To set up the parameters of the Analog Outputs (AO1–AO6), navigate to
the Analog Outputs submenu (as shown in Figure 97). Then, refer to
Figure 101 and set up the following three parameters for each Analog
Output:
SETUP ↓ and SETUP ↓↑  OFF

ANALOG OUTPUTS ENTER ANALOG OUTPUTS
 AO1 SOURCE AO1 SOURCE  A
▪ OFF  ░FF  B
 SUM
  DIF

SETUP ↓ and SETUP

ANALOG OUTPUTS ENTER ANALOG OUTPUTS ENTER
 AO1 MODE AO1 MODE
and ↑
▪ VOLTAGE  ░ OLTAGE
↓↑
  Voltage
  0–20 mA Current ENTER and ↑
 4–20 mA Current
↓ and
SETUP ENTER SETUP
ANALOG OUTPUTS ANALOG OUTPUTS
 AO1 FSL AO1 FSL
▪ 0010 %  ░010 %


Enter the value using 
SETUP and  keys to select
ANALOG OUTPUTS digit, and ↑ and ↓ keys to
 AO2 SOURCE increment or decrement
▪ OFF digit.
Valid range is 0010 to
9999 (1.0–999.9 %).


Analog Outputs for
AO2 to AO6 are the ENTER and ↑
same as AO1
Figure 101: Analog Outputs

1. Source:
 Select OFF if you want to disable the analog output.
 Select A (sensor A), B (sensor B), SUM (A+B), or DIF (A-B) as

applicable.
2. Mode:
Note: The analog output connections are different for

voltage and current modes as indicated in sub-
section 5.3.4 Analog Output Wiring. Make sure that
the mode selection is appropriate for the connection;
if it is not, the analog output will be incorrect.
 Select ±10V, 0-10V, 0–20 mA Current or 4–20 mA Current as

applicable.
For A, B and SUM (A+B), the zero point is at 0 V in the voltage

mode (0–10V), 0 mA in 0–20 mA mode and 4 mA in 4–20 mA
mode. For DIF (A-B), the zero point is at 0 V in the voltage mode
(10V), 10 mA in 0–20 mA mode and 12 mA in 4–20 mA mode.
6.7.4 Configure the FPI Display

You can configure the load display on the FPI to display up to eight
values. To configure the FPI display, navigate to the FPI submenu (as
shown in Figure 97). Then, refer to Figure 102 and set up the following
parameters:
1. 1ST Load PAIR - select one of 8 display options as shown in Figure
102
2. Refer to 3.2.2.5 FPI Submenu for more information
3. 2ND Load PAIR - select a different display option (not the same
option as 1ST Load PAIR)
4. Load Unit - enter an applicable unit of measurement for the measuring
application
5. Heart Beat - enable or disable the Heart Beat on the FPI. Default is
enable.
When you are done, press MENU to display load measurements and
verify the settings are correct.

SETUP ↓ and SETUP  CHANNEL A&B (%) & (#)

FPI ENTER FPI
↓↑
 CHANNEL A&B (%)
 1ST ROW PAIR 1ST ROW PAIR
▪ CHANNEL A&B (%) …  ░ CHANNEL A&B (%)…  CHANNEL A&B (#)
 CHANNEL A&B BAR
  SUM & DIF (%) & (#)

 SUM & DIF (%)
SETUP ↓ and SETUP ↓↑  SUM & DIF (#)
FPI ENTER FPI  SUM & DIF BAR
 2ND ROW PAIR 2ND ROW PAIR
▪ SUM & DIF (%)  ░ UM & DIF (%)


Shows setting only.
SETUP
FPI Setting can be OFF, ENTER and ↑
 AUX INDICATOR
ALARM1, ALARM2,
▪ ALARM1
ALARM3, ALARM4 or
ANY ALARM


SETUP
FPI Shows setting only.
 FSL FORMAT Setting can be
▪ 10000 changed using the
UAP.


SETUP
↓ and SETUP
lb, kg, N, kN, MN
FPI ENTER FPI
↓↑ t (SI), ton (US)
 LOAD UNIT LOAD UNIT psi, bar, MPa
▪ lb  ░b

 ENTER and ↑
SETUP ↓ and SETUP ↓↑

FPI ENTER FPI  Enable
 HEART BEAT HEART BEAT
 Disable
▪ Enable  ░nable
Figure 102: FPI Submenu

6.7.5 Configure Load Alarms

You can configure the Load Alarms (maximum of 4) to indicate when a
load level exceeds a set threshold.
To configure the Load Alarms, navigate to the Alarm submenu (as shown
in Figure 97). Then, refer to Figure 103 and enter the applicable
value/selection for the following parameters of each Load Alarm:
↓ and SETUP
SETUP ENTER
ALARMS ALARMS
ALARM 1 SOURCE
 ALARM 1 SOURCE
▪ OFF  ░FF
↓↑
 ENTER OFF, A, B,

and ↑ SUM, or DIF
↓ and
SETUP ENTER SETUP
ALARMS ALARMS
 ALARM 1 THRESHOLD  ALARM 1 THRESHOLD
▪ 1500 % ▪ ░500 %
ENTER Enter the value using  and  keys


and ↑ to select digit, and ↑ and ↓ keys to
 increment or decrement digit.
Valid range is 0001 to 1500.
↓ and
SETUP ENTER SETUP
ALARMS
ALARMS
 ALARM 1 TIME
 ALARM 1 TIME
▪ 001 ms
▪ ░01 ms


ENTER Enter the value using 
and ↑ and  keys to select
digit, and ↑ and ↓ keys to
Parameters for increment or decrement
Alarm 2 to Alarm digit.
4 are the same as Valid range is 001 to
Alarm 1 999 ms.
Figure 103: Alarms Submenu

1. Source:
 Select OFF if you want to disable the load alarm.
 Select A (sensor A), B (sensor B), SUM (A+B), or DIF (A-B) as

applicable.
2. Threshold:
 Enter the applicable threshold in the range of 0001–1500 (actual

value is divided by 10 = 0.1 – 150.0%).
 For more information about threshold and example, refer to

6.2.4 Load Alarms and Threshold Limits.
3. Time:
 Enter the applicable time in the range of 001–999 ms. The Time
parameter is the time for which the load must exceed the
threshold before the alarm is set to ON. It is also a time after the
load has fallen below the threshold, before the alarm is set to
OFF.
6.7.6 Change Logic I/O Factory Settings

Usually the factory settings for logic inputs and outputs are sufficient for
most systems. Do not change the factory settings unless it is necessary
to customize your system.
To change any of the factory settings:
1. Navigate to the Logic I/O Factory submenu (as shown in Figure 97).
2. Use the down arrow key (↓) to access the first parameter ALARM 1
POLARITY.
3. Refer to Figure 104 below and change the applicable polarity settings
of the logic inputs or outputs.

↓ and ↓ and SETUP

SETUP ENTER ENTER LOGIC IO FACTORY …
LOGIC IO FACTORY …  IN SELF TEST POL …
 ALARM 1 POLARITY ▪ ON RISING EDGE
▪ CLOSED ON ALARM
Use ↑ or ↓ to 
 select Closed on

 Alarm or Open ↓ and
on Alarm. ENTER SETUP
Displays of Alarm 2 to To return to the LOGIC IO FACTORY …
Alarm 4 Polarity, same previous screen,  IN LOCKOUT POLAR …
as Alarm 1 Polarity press ENTER ▪ LOCK ON OPEN INP…
and ↑. Use ↑ or ↓ to
select Lock on
Open Input or
↓ and Lock by 24V
ENTER Applied.
SETUP
LOGIC IO FACTORY … To return to the
 IN ZERO POLARITY previous SETUP
▪ ON RISING EDGE screen, press LOGIC IO FACTORY …
ENTER and ↑.  OUT CHANNEL A FA …
▪ CLOSE ON FAULT
Use ↑ or ↓ to
SETUP select On
LOGIC IO FACTORY … Rising Edge
↓ and SETUP
 IN CALIBRATION P … or On Falling
ENTER LOGIC IO FACTORY …
▪ ON RISING EDGE Edge.
 OUT CHANNEL B FA …
To return to ▪ CLOSE ON FAULT
the previous
screen, press
ENTER and ↑.
SETUP
LOGIC IO FACTORY … SETUP
 IN 2XA POLARITY LOGIC IO FACTORY …
▪ ON RISING EDGE  OUT SYSTEM FAULT …
Use ↑ or ↓ to
▪ CLOSE ON FAULT
select Close
On Fault or
Open On Fault.
SETUP To return to the

previous SETUP
LOGIC IO FACTORY …
screen, press LOGIC IO FACTORY …
 IN 2XB POLARITY ENTER and ↑.
▪ ON RISING EDGE  OUT SINGLE SENSO …
▪ CLOSE ON FAULT

 

Figure 104: Logic I/O Factory Settings

6.7.7 Initiate Configuration

After you are done with all setup changes, initiate the configuration
operation before placing the DSP2 on-line. The configuration operation
applies the Calibration data and zeroes each channel.
Caution: If the measuring system is not configured after

parameter changes, it is not calibrated. The
Digital and Analog Outputs and the Load Alarms
are inaccurate. Using an un-calibrated system
for mill control may cause the production of off-
To initiate the configuration operation:

1. Press the MENU key when the display panel is in load display mode.
2. Refer to Figure 105 and initiate a configuration operation.
3. Wait for the operation to complete and the LED display returns to load
display mode.
Setup menu ↓↑
SETUP
SYSTEM OPERATIONS
EN0 IP ADDRESS  CONFIGURATION
▪ 192.009.001.075
▪

 ENTER
DIAGNOSTICS
ELECTRONICS OPERATIONS
No error CONFIGURATION
▪  ░NO
▪

 ↓↑
OPERATIONS
CONFIGURATION OPERATIONS
CONFIGURATION
▪  ░YES
▪
ENTER
Figure 105: Initiate Configuration

System Monitoring and Controls
7 System Monitoring and Controls

The DSP2 provides the following functions for system monitoring and controls:
 Load displays
 Load alarms
 System status
 Single sensor operation
 Zero operation
 Calibration
 Self-test
 Reset
 Load simulation
 Lockout.
7.1 Load Display

Measured loads are displayed in the LCD display panel of the FPI (Figure 5) and
the device main panel of UAP (Figure 23). To set up the display options of the
FPI, refer to 3.2.2.5 FPI Submenu or 4.4.5 FPI Display.
During normal operation (both Sensor A and Sensor B are operational), the sum
() and difference () loads in the FPI display are that:
 % = (A% + B%)/2
 % = A% - B%
 # = A# + B# for roll force measuring applications
= (A# + B#)/2 for pressure and tension measuring applications
 # = A# - B#
During a single sensor operation (only 2 x Sensor A or 2 x Sensor B is
operational), the sum () and difference () loads in the FPI display are that:
 % = A% (or B%)
 % = 0
 # = 2A# (or 2B#) for roll force measuring applications
= A# (or B#) for pressure and tension measuring applications
 # = 0

7.2 Load Alarms

Load alarm conditions (when set load levels are exceeded) are indicated by:
 Auxiliary status indicator on the DSP2 front panel and the load alarm
indicator on the device main panel of UAP
 Logic output relays as described in sub-section 5.3.3 Logic I/O Wiring
 Alarm messages at the Modbus and Profibus Interfaces. Refer to Section

11 Fieldbus Interfaces and Setups for more details.
7.3 System Status

The DSP2 continuously monitors the signal processing electronics, sensor
excitation currents and signals, Auxiliary Analog Inputs, Fieldbus Interface and
internal temperature. System status is indicated by:
 System indicators on the DSP2 front panel and on the device main panel
of UAP. There are indicators for Electronics Healthy, System Fault,
Channel A Fault, Channel B Fault, Single Sensor and Load
Alarm/Auxiliary. Note that:
 The update rate of system status indicators on the front panel is 1 ms

(1 kHz).
 The update rate of system status indicators on the UAP is about 250
ms.
 Logic Output relays for System Fault, Channel A Fault, Channel B Fault
and Single Sensor Operation. Refer to sub-section 5.3.3 for more details.
The update rate is 10 ms for logic inputs and 100 ms for logic outputs.
 Status messages at the Modbus, Profinet and Profibus Interfaces. Refer

to Section 11 Fieldbus Interfaces and Setups for more details. The update
rate of status messages for Fieldbus is 1 ms (1 kHz).
If a fault is indicated, refer to Section 9 Troubleshooting for suggestions to

resolve the fault condition.
If a System Fault, Channel A Fault or Channel B Fault is indicated, the UAP may
disallow running the Calibration or Zero operation. However, you can still run
Self-test or Configuration.
7.4 Single Sensor Operation

The single sensor operation, also known as load doubling, connects both
Channel A and B registers in the Load Measurement Set to the same
sensor channel.

Note: The single sensor operation is not initiated

automatically if a senor or channel fault is detected,
user intervention is required.
To initiate the single sensor operation, use any of the following methods:
 FPI — refer to SGIB Common Settings in sub-section 3.2.2.3 or

sub-section 6.7.2.2
 UAP — select the (single sensor) icon on the toolbar or

select Operations > Single Sensor from the menu bar. Select
2*A or 2*B and click OK.
 Contact closure at the Single Sensor A or the Single Sensor B

Operation Logic Input. Single Sensor Operation latches on; it is
not stopped when the external contacts are opened. Refer to
sub-section 5.3.3 for more details.
Modbus, Profinet and Profibus Interfaces — refer to Section 11 Fieldbus
Interfaces and Setups for more details.
When the DSP2 is in single sensor operation:
 The sum load (A+B) is twice the selected sensor load and the
difference load (A-B) is zero.
 The Single Sensor indicator on the front panel is illuminated.
 The single sensor indicator on the main device screen of the

UAP is illuminated.
 The Logic Output relay for Single Sensor Operation closes.
To stop the Single Sensor Operation and return to normal operation of

two sensors, use one of the following methods:
 FPI - refer to SGIB Common Settings in sub-section 3.2.2.3 or

sub-section 6.7.2.2
 UAP - select Operations > Single Sensor from the menu bar.
 Select A&B and click OK.
 Confirm operation by clicking Yes.
7.5 Zero
The zero operation adjusts the fine offset of both channels to set their outputs to
zero. Usually, this operation (command) is used to compensate for small
changes in tare weight.

The Zero command will adjust the outputs to zero provided that Load A or B does
not exceed ± 20% of the Full Scale (fault condition 1). If this limit is exceeded
then Zero out of range fault will be triggered for one or both channels. The ±
20% limit was designed to protect against accidental zeroing during operation. In
case of tare weight change of ± 20% you must run Configuration to zero the
system or disable this feature.
The DSP2 also accumulates offset changes every time Zero is performed
successfully. If accumulated offset reaches the limit of ± 20% then Zero out of
range fault is triggered (fault condition 2). This second fault condition was
designed to track, from the original configuration, imbalance of the Load Cell
Bridge due to overload or other conditions. Accumulated offset fault can be
enabled or disabled using the UAP > Input Channels page.
If Zero command is being initiated and either fault condition 1 is true then the
following warning message appears to stop the Zero operation:
If fault condition 2 is true then the following warning message appears to stop the
Zero operation:
If either error message occurs, KELK recommends that you investigate the
cause, the rest is OK.
 To determine the magnitude of the offset, refer to Sub-section 9.7.1.

 To continue operation, initiate the Configuration operation again to
establish a new zero reference. Refer to 6.7.7 Initiate Configuration or
6.6.9 Apply Changes and Run Configuration.
 To initiate the zero operation, use any of the following methods:
Caution: During the zero operation, the Digital and

Analog Outputs and the Load Alarms continue
to function normally. Ensure they are not used

for mill control as this may cause the production

of off-specification product or mill damage.
 FPI — press the ZERO key on the front panel.
 UAP — click the (zero) icon on the toolbar or select

Operations > Zero from the menu bar. Confirm operation by
clicking Yes.
 Modbus, Profinet and Profibus Interfaces — refer to Section 11

Fieldbus Interfaces and Setups for more details.
 Logic I/O — close the contact at the Zero Logic Input. Refer to
sub-section 5.3.3 for more details.
If the new zero offset exceeds the allowable limit, a fault condition will be
indicated. Refer to Section 9 Troubleshooting for suggestions to resolve
the fault condition.
7.6 Calibration
The calibration operation ensures that the measuring system sensor
configuration has remained in calibration. It zeroes both channels by
adjusting their fine offsets. Then, using the sensor calibration data
entered during setup, scales both channels by adjusting their fine gains.
The calibration operation is for routine system checking and fine-tuning.
It will not reconfigure the sensors following a sensor replacement. If you
have replaced a sensor, set up the input channels with the updated
sensor data and run the Configuration again.
If the Load A or B has exceeded ± 20% during the calibration routing, the
following warning message appears and the calibration operation
stopped:
The DSP2 also accumulates offset changes every time Zero is performed
successfully. If accumulated offset reaches the limit of ± 20% then Zero
out of range fault is triggered (fault condition 2). This second fault
condition was designed to track imbalance of the Load Cell Bridge due to
overload or other conditions. Accumulated offset fault can be enabled or
disabled using the UAP > Input Channels page.

If fault condition 2 is true then the following warning message appears to

stop the Zero operation:
To initiate calibration, use any of the following methods:
Caution: During the calibration, the Digital and Analog

Outputs and the Load Alarms continue to
function normally. Ensure they are not used for
mill control as this may cause the production of
off-specification product or mill damage.
 FPI — press the CAL key on the front panel.
 UAP — select the (calibration) icon on the toolbar or select

Operations > Calibration from the menu bar. Confirm
operation by clicking Yes.
 Modbus, Profinet and Profibus Interfaces — refer to Section 11

Fieldbus Interfaces and Setups for more details.
 Logic I/O — close the contact at the Calibration Logic Input.

Refer to sub-section 5.3.3 for more details.
If a new fine gain or zero offset exceeds the allowable limit of 20%, a fault
condition is indicated. Refer to Section 9 Troubleshooting for suggestions
to resolve the fault condition.
7.7 Wrap Angle Compensation

Inputs for Wrap angle compensation of tension measuring system can be
set up in the application Wizard (Form 859) as shown in Figure 106. For
setup information, refer to sub-section 6.6.2.3 Tension Application –
Variable Wrap Angles for details. For more information about wrap angle
compensation, refer to 6.4.3 Wrap Angle Compensation.

Figure 106: Application Wizard - WAC Input Selection
 If the WAC inputs are set to FieldBus, update the wrap angle
value through the Fieldbus Interface.
 If the WAC inputs are set to Analog1 and Analog 2, the inputs
are automatic. Make sure the Auxiliary Analog board is installed
in the DSP2 and it supplies the applicable 0-10V or ±10V for two
analog inputs.
 If the WAC Inputs are set to Manual, update the wrap angle
value using the UAP. Refer to the procedure below.
To update the Wrap Angle value manually from the UAP:
1. Select the (wrap input) icon on the toolbar or select Operations

> Wrap Input on the menu bar.
2. On the Wrap Angle Compensation window that opens, enter the
counts into the Input1 and Input 2 fields. Make sure each count value
is within the range of 0 to 1000.
3. Click OK.
7.8 Self-Test
Self-test temporarily stops the digital and analog outputs and runs a
series of tests to calibrate and verify system operation. Note that:
 All parameters are restored after the self-test is complete.

 If any fault conditions are detected during the self-test, the status
messages with the timestamps are displayed in the status list
table on the Device Main Panel of the UAP.
To initiate the self-test, use any of the following methods:
 FPI — refer to 3.2.4 Operations Menu and select SELF TEST.
 UAP — select the (self-test) icon on the toolbar or select

Operations > Self-Test from the menu bar. Confirm operation
by clicking Yes.
 Logic I/O — close the contact at the Self-Test Logic Input. Refer
to sub-section 5.3.3 for more details.
Caution: During the self-test, the Digital and Analog

Outputs and the Load Alarms are temporarily
frozen. Ensure that they are not used for mill
control as this may cause the production of off-
If a fault condition is indicated, refer to Section 9 Troubleshooting for

suggestions to resolve the fault condition.
7.9 Reset
The Reset operation is a soft reset and reinitializes the internal software.
Caution: During reset, the Digital and Analog Outputs and

the Load Alarms are temporarily frozen.
Ensure that they are not used for mill control as
this may cause the production of off-
To initiate a reset from the UAP:

1. Select Device > Reset from the menu bar.
2. Confirm operation by clicking Yes.
7.10 Lockout
When lockout is enabled, it prevents:
 making any change to a setup parameter
 initiation of a Configuration operation

 initiation of a Reset and Simulation/Test.
Jumpers and software setting in the UAP control the lockout feature. The
lockout input trigger is set in the I/O Settings tab of the Setup Panel
(Figure 37). The jumpers at terminals TB12 15-16 and TB12 32-33
(Figure 60) controls the lockout according to the following table:
Lockout input triggers Jumpers Lock

Lock by 24V Plugged Yes
Unplugged No
Lock by open input Plugged No
Unplugged Yes
The default setting is set to no lock (jumper for lock by open input is
plugged in). This allows users to have full access to all operations of
UAP and FPI. If you want to limit users to make any further changes, set
the lock to yes according to the above table.
Note: Lockout cannot be accessed over the Fieldbus.

Maintenance
8 Maintenance
The DSP2 requires no routine maintenance. Service is required only if a failure occurs. Other
components such as load cells or sensors require periodic inspection.
8.1 Replacing a Fuse

Following is the procedure to replace the fuse found inside the Power
Entry Module on the rear panel.
Note: DSP2 EU version B can have by design one of the two styles of
Power Entry modules: the TE Connectivity or the Schaffner power entry.
Both types of modules are shown below.
1. Set the power switch to OFF and unplug the power cord from the rear
of the DSP2 (Figure 108).
2. Insert a small blade screwdriver or similar tool in the small notch of
the fuse holder near the power socket and gently pry away the fuse
holder (Figure 107).
3. Remove the fuse holder from the slot.
4. Remove the fuse from fuse holder and examine it. Discard the fuse if
it’s broken or blown.
5. Insert a new fuse of same size and rating in the same location of fuse
holder as the original fuse (refer to Section 10 for part number of the
fuse).
6. Insert the fuse holder back into the slot.
7. Connect the power cord back to the power socket and set the power
switch to ON.

Maintenance
Figure 107: Fuser Holder, Power Socket and Power Switch

Maintenance
8.2 Replacing the DSP2

To remove the DSP2:
1. Make sure that the configuration of the DSP2 to be replaced has been
saved to a file and note the IP address of the DSP2.
Note: Saving the DSP2 configuration is necessary so that

you can load the configuration to the new unit
without setting up the DSP2 again. To save the
configuration, refer to 6.6.11 Save Configuration.
2. Carefully open the DSP2 cabinet and set the power switch on the
back of the DSP2 to OFF.
3. Remove all cables, including the grounding strap from the rear
connection panel.
Note: The Grounding Strap (*08562) from the rack’s side

rail self-tapping screw is connected to the ground
stud on the rear connection panel as shown in
Figure 108.
4. From the front of the cabinet, remove the four mounting screws that
attached the DSP2 to the 19-inch mounting rack. Save the screws for
DSP2 re-installation.
5. Carefully remove the DSP2 from the mounting rack.
6. Pack the DSP2 unit properly in accordance with the procedure in sub-
section 8.3 and return the unit to KELK.
Figure 108: DSP2 Rear Panel Connections

Maintenance
To install the new DSP2:

1. Carefully unpack the DSP2 received from KELK.
2. Inspect the unit and make sure there is no damage.
3. Mount the DSP2 to the 19-inch rack with four mounting screws.
4. Connect all applicable cables and grounding strap back to the rear
connection panel.
5. Set the power switch on the back of the DSP2 to ON.
6. Start the UAP and establish communication with the DSP2 in
accordance with the procedure in sub-section 6.6.1.2 Modify IP
Address of the DSP2 and PC.
7. Start UAP from your PC or laptop. Refer to the applicable procedures
below to load configuration from the saved configuration file to the
new DSP2.
 4.6.1 Load Device Configurations from a Configuration File
 4.6.2 Load Setup Data from a Configuration File to a Device
8. Click the Apply Changes icon on the toolbar as shown below or select
Device > Apply Changes on the menu bar.
Apply
Changes
Toolbar
icon
Figure 109: Apply Changes Icon on Toolbar
 To confirm Apply Changes, click Yes on the pop-up window.
 When an Operation is successful message appears, click

OK.

Maintenance
 If the following message appears, confirm run configuration by

clicking OK.
Figure 110: Confirmation Message
 Wait for the configuration to complete and the display return to

the device main screen.

Maintenance
8.3 Packing the DSP2 or Sensors for Returning to Factory

If you do not have the original packing materials, use the following
guidelines to pack the DSP2 or sensor to be returned to the factory:
 To avoid hand contact, transport products in static-safe

containers, such as bags, or boxes.
 Protect all electrostatic-sensitive parts and assemblies with

conductive or approved containers or packaging.
 Always be properly grounded when touching a sensitive

component or assembly.
 Do not throw, drop or otherwise roughly handle the DSP2.
 Pack the unit tightly with protective packing material to avoid any
movement during transit.
We recommend that products, all plastics, bubble shooting, foam, etc.,
used for packaging should have dissipative properties. Do not use
insulative packaging. Since conductive plastics and foams present a
certain second order of static discharge hazard, avoid their use unless it
is necessary. Static dissipative packaging is much more effective at
preventing damage than conductive packaging.
Note: KELK reserves the right to refuse all warranty claims

if the equipment returned to the factory is damaged
because of improper packing or handling.

Troubleshooting
9 Troubleshooting
This section provides information about fault conditions and status messages. It gives you the
corrective actions to solve or correct these fault conditions or faults. In addition, troubleshooting
procedures are provided to help you to isolate the components that cause the faults.
Troubleshooting is for qualified technicians who have received training on the DSP2. If your
company does not have trained technicians, please contact KELK or KELK OEM agent.
9.1 Viewing Fault Condition and Status

The DSP2 system monitors four types of fault conditions:
 Electronics fault — a hardware fault or a hardware detected fault

 Measurement channel faults — an error was detected on
Channel A or Channel B that may influence the quality and
accuracy of the measurement data
 System fault — a composite fault indication that includes both
measurement channel and electronic faults
 Analog output fault — a fault that is detected from the analog

output board to the customer PLC or mill control system.
The fault conditions are indicated by:
 System Status LEDs on the Front Panel Interface
 Status Indicators on the Device Main Panel of the UAP (Figure

111)
 Logic Outputs
 Status codes over the Fieldbus interface
The detected faults for electronics and measurement channels are

identified in:
 UAP — Status list table on the Device Main Panel (Figure 111)
and the Status tab of the Diagnostics panel as shown in Figure
112
 FPI — the Diagnostics submenu as shown in Figure 113.
 Fieldbus interface — Refer to bitmapped messages in sub-

sections 11.1 Ethernet Modbus/TCP Communication and Setup,
11.2 Profibus Communications & Setup and 11.3 Profinet
Communications & Setup for more details.
The detected faults for analog output are identified in the Diagnostics
submenu of UAP and through the bitmapped message over the Fieldbus
interface.

Troubleshooting
Figure 111: Status Indicators and Status List Table on Device Main Panel
Figure 112: Diagnostics Submenu

Troubleshooting
If there is error message, possible

message can be:
 SGIB A not calibrated
DIAGNOSTICS
 SGIB B not calibrated
 ELECTRONICS
No error  SGIB A board not recognized
▪  SGIB B board not recognized
 WAC board not recognized

 IBA network logging error

 Excessive internal temperature
DIAGNOSTICS
 CHANNEL A If there is channel
No error A error(s), see list
▪ below.
DIAGNOSTICS
CHANNEL B
  SGIB alarm
 ▪ detected 

DIAGNOSTICS
↓↑
 CHANNEL B
SGIB alarm Other channel A or B messages:
▪ detected  SGIB alarm detected
 Configuration verification failed
Error  No response to shunt resistor
status  Error calculating bridge resistance
 Zero out of range
DIAGNOSTICS  Channel data not valid
If there is SGIB
 SGIB A A error(s), see  Load simulation active
No error list below.  Signal off
▪
 SGIB reset detected


DIAGNOSTICS ↓↑ DIAGNOSTICS 
 SGIB B SGIB B 
Input Saturation  Input Saturation
▪ ▪
 Error Other SGIB A or B messages:

 status  Input saturation
 Excitation voltage out of range
DIAGNOSTICS  Excitation current out of range
 TEMPERATURE
43.5˚ C
 Arm1 voltage out of range
▪  Arm2 voltage out of range
 5V power supply out of range
 15V power supply out of range
Figure 113: Example of Error Messages in Diagnostics Submenu

Troubleshooting
9.2 Troubleshooting the DSP2

The DSP2 monitors its hardware and signal processing. If an electronics
fault is detected, the 'Electronics Healthy' LED on the FPI and UAP go out
indicating a fault condition. In addition, the System Fault indicator is
illuminated. You can view the fault status of electronic fault using the FPI,
the UAP or via the Fieldbus option as described in sub-section 9.1.
For troubleshooting information using the LEDs on the Modbus-TCP refer
to section 11.
Use the following table for description and corrective action for a given
message of electronics fault or symptoms.
Issue Message / Description / What to check / corrective action

Number symptoms possible cause
9.2.1 No display There is no power  Check that the power switch of

on the FPI to the DSP2 electronics unit (EU) is set to ON.
of the EU Electronics Boards
or the fuse in the
 Check cabinet power wiring to the
electronics unit. Make sure main power
EU has blown.
is available in the cabinet.
 Check power cable connections from
the cabinet to the back of the EU; make
sure the connections are secure and
the cable is not damaged.
 Check and replace blown fuse in EU.
Refer to procedure in sub-section 8.1.
 If the above steps do not fix the
problem, the fault is within the EU.
Replace the DSP2 or return the DSP2
to KELK for repair.
9.2.2 SGIB A not The installed SGIB Run configuration from either the FPI or
calibrated A in this unit was using the UAP.
not configured.  If using the UAP, refer to procedure in
sub-section 6.6.9 Apply Changes and
9.2.3 SGIB B not The installed SGIB
Run Configuration.
calibrated B in this unit was
not configured.  If using the FPI, refer to procedure in
sub-section 6.7.7 Initiate Configuration.
9.2.4 SGIB A The SGIB A board Notify KELK to check that:
board not was not detected or  The board is installed correctly in the
recognized wrong board type first two slots (J1 and J2) and not in the
was detected. third slot (J3).
9.2.5 SGIB B The SGIB B board  Correct SGIB board is used. If wrong
board not was not detected or board is found, replace with correct
recognized wrong board type board.
was detected.

Troubleshooting
Issue Message / Description / What to check / corrective action

Number symptoms possible cause
9.2.6 WAC board The WAC board Notify KELK to check that:
not was not detected or  The WAC board (auxiliary analog input
recognized wrong board type board) is installed correctly in the third
was detected. slot (J3) and not slot 1 or 2 (J1 and J2).
 Incorrect SGIB board (different serial
number) is installed. If incorrect board
is found, replace with correct board.
9.2.7 IBA network IBA server and  Check the IP address of the PC that
logging DSP2 are not runs the IBA PDA server software.
error (FPI) communicating or
the IP address of
 Verify that server PC is connected to
or the EU directly or through the network.
IBA server was
Network
incorrect.  Verify that the server IP address and
logging
logging rate are correctly set up as
error – IBA described in sub-section 6.6.7 Set Up
(UAP)
IBA.
9.2.8 Excessive The internal  Check that the temperature adjacent to
internal temperature of the the unit (if the unit is installed in a
temperature DSP2 exceeds cabinet, the temperature inside the
70°C (158°F). cabinet) does not exceed 40ºC (104ºF).
This alarm indicates  Check that air flow around the unit is
that the ambient not restricted.
temperature around
 Check the status message one hour
the DSP2 is too
after taking corrective action to ensure
high.
that it was effective.
Table 8: Electronics Fault Troubleshooting
9.3 Troubleshooting Channel and SGIB Faults

Measurement Channel and SGIB Faults are detected either by the
continuously running diagnostic routine of the DSP2 or by user initiated
operations such as Configuration, Self-Test, Zero, Calibration and Load
Simulation. The DSP2 monitors the results of these operations and posts
a warning message upon detected problems.
When a channel or SGIB fault occurs, the System Fault LED and the
appropriate Channel Fault LED on the FPI are illuminated. In addition,
the corresponding logic output is triggered. You can view the fault status
message through the FPI, the UAP or via the Fieldbus option as
described in sub-section 9.1.
Use the following two tables for description and corrective action for a
given message of channel and SGIB fault.

Troubleshooting
Item Message Description / possible cause What to check / corrective action

Number
9.3.1 Channel A This fault is detected during Note: This fault may show up
data not valid Configuration and indicates that temporary in the UAP during
there is no valid input from the Configuration. This is normal.
specified channel.
 Reset the electronic unit.
Possible cause can be a
communication problem
 If other sensor related fault message
occurs, follow corrective action of
9.3.2 Channel B between the Strain Gage
that message.
data not valid Interface Board (SGIB) and the
processor board or a faulty  If problem persists, contact KELK for
SGIB. further troubleshooting.
9.3.3 Channel A This fault is detected either by a  Make sure that the load cell is
error calculating self-test or configuration connected.
bridge resistance operation. It indicates that the
DSP2 cannot estimate the value
 Check for other SGIB message(s)
that also appeared on the
of the bridge connected to the
diagnostics menu of FPI or UAP
specified channel (SGIB board).
(see sub-section 9.1).
9.3.4 Channel B
error calculating  If excitation voltage out of range or
bridge resistance excitation current out of range
message appears, follow the
corrective action of that message to
resolve the fault.
 Run the configuration operation.
9.3.5 Channel A This fault is detected when  Run Configuration to reset the
zero out of range either one of the two conditions accumulated offset to zero and clear
are violated: the fault message.
1. Maximum load that Zero or
Calibration can cancel is Note: In case of a major tare weight
±20%. change, hardware zero will be
adjusted during
9.3.6 Channel B 2. If zero accumulation fault is Configuration.
zero out of range set to enable, maximum
accumulated load previously  If problem persists, contact KELK.
cancelled by Zero or
Calibration is also ±20%.
This condition does not
applies if zero accumulation
fault is set to disable.
Possible causes: load drift, tare
load change or sensor damage.
9.3.7 Channel A This fault is detected during Contact KELK for further
no response to Configuration, Calibration and troubleshooting to isolate the fault in
shunt resistor Load Simulation. It indicates a the SGIB.
fault in the SGIB of the specified
9.3.8 Channel B channel.
no response to
shunt resistor

Troubleshooting
Item Message Description / possible cause What to check / corrective action

Number
9.3.9 Channel A This fault is detected during Self-  Make sure that there is no active
configuration Test, Configuration or load applied to the measuring
verification failed Calibration. It indicates system at the time when
verification of load cell Configuration, Calibration and Self-
configuration parameters failed Test are run.
9.3.10 Channel B for the specified channel.
 Warm up the measuring system
configuration (DSP2 and load cell) by running it at
verification failed least 30 minutes.
 Run the configuration operation
again.
 If problem persists, contact KELK.
9.3.11 Channel A This intermittent fault indicates  Ensure that DSP2 cabinet is
SGIB reset that SGIB configuration properly closed and does NOT
detected parameters have been corrupted house transformers, wireless
by extremely high levels of transceivers or other equipment not
Electromagnetic Interference supplied by KELK.
(EMI). The DSP2 system reacts
9.3.12 Channel B
by automatically restoring the
 If the problem persists, consider
SGIB reset moving the cabinet to another
parameters to their correct
detected location away from possible sources
values.
of EMI.
9.3.13 Channel A The DSP2 monitors the SGIB Check also for other fault messages:
SGIB alarm fault condition continuously.  Input saturation
detected This status for a specified
channel indicates one or more of  15 V or 5 V power supply out of
the SGIB alarms messages range
have also detected.  ARM1 or ARM2 voltage out of range
9.3.14 Channel B  Excitation current or voltage out of
SGIB alarm range Check for any other SGIB
detected messages that occurs.
Follow the corrective actions of the
SGIB fault message that lists on the
Table 10: SGIB Alarm Troubleshooting.
Table 9: Channel Fault Troubleshooting

Troubleshooting
Issue Message Description / possible cause What to check / corrective action

Number
9.3.15 Channel A The input to the specified Incorrect setup of channel

input saturation channels is too high or low measurement:
causing saturation.  Check all setup parameters. If
Saturation not caused by a mill they are incorrect, set up the
operating condition indicates applicable channel with correct
9.3.16 Channel B either: values.
input saturation
 Incorrect setup of
measurement channel such Interconnecting cable or sensor fault:
that the full scale input is too  Run the system test according to
low for the mill operating sub-section 9.7.1 System Test.
condition.
 Follow with the interconnect cable
 Interconnecting cable fault or (sub-section 9.7.2) and sensor
Sensor fault. (sub-section 9.7.3) tests, as
required.
9.3.17 Channel A
15V power supply
out of range The 15V power supply for the Contact KELK support to check for
specified channel is out of internal problem on the specified
9.3.18 Channel B range. strain gage interface board (SGIB).
15V power supply
out of range
9.3.19 Channel A
5V power supply
out of range The 5V power supply for the Contact KELK support to check for
specified channel is out of internal problem on the specified
9.3.20 Channel B range. strain gage interface board (SGIB).
5V power supply
out of range
9.3.21 Channel A or Monitored ARM1 voltage for the  Check specified sensor
Channel B specified channel is out of connections. Make sure that all
ARM1 voltage out range. cable connections are connected
of range properly.
 Run the system test according to
sub-section 9.7.1.
9.3.22 Channel A or Monitored ARM2 voltage for the (sub-section 9.7.2) and sensor
Channel B specified channel is out of (sub-section 9.7.3) tests.
ARM2 voltage out range.  If the problem persists, check the
of range load cell excitation in the input
channels tab of the UAP. Make
sure the value is set to the default
10 V or a specific value
recommended by KELK.

Troubleshooting
Issue Message Description / possible cause What to check / corrective action

Number
9.3.23 Channel A Monitored excitation current for  Run the system test according to
excitation current the specified channel is out of sub-section 9.7.1.
out of range range.
Possible causes are poor sensor (sub-section 9.7.2) If the problem
connections, sensor failure, persists, contact KELK as
excitation supply failure, short required.
9.3.24 Channel B circuit across the load cell bridge
excitation current  If the problem persists, check the
or a new sensor with different
out of range load cell excitation in the input
bridge resistance is used.
9.3.25 Channel A Monitored excitation voltage for  Run the system test according to
excitation voltage the specified channel is out of sub-section 9.7.1.
out of range range.
Possible causes are poor sensor (sub-section 9.7.2) and sensor
connections, sensor failure, (sub-section 9.7.3) tests, as
excitation supply failure or short required.
9.3.26 Channel B circuit across the load cell
 If the problem persists, check the
excitation voltage bridge.
load cell excitation in the input
out of range
9.3.27 Channel A This intermittent fault indicates  Ensure that DSP2 cabinet is
SGIB reset that SGIB configuration properly closed and does NOT
detected parameters have been corrupted house transformers, wireless
by extremely high levels of EMI. transceivers or other equipment
The DSP2 system reacts by not supplied by KELK.
9.3.28 Channel B
automatically restoring the
SGIB reset
parameters to their correct
 If the problem persists, consider
detected moving the cabinet to another
values.
location away from possible
sources of EMI.
Table 10: SGIB Alarm Troubleshooting

Troubleshooting
9.4 Checking Analog Output Fault

When a fault occurs on the analog output, the fault status can be viewed only in the
Status tab of the Diagnostic Panel or via the Fieldbus.
Use the following table for description and corrective action for a given error message of
analog output.
Issue Message Description / What to check / corrective action

Number possible cause
9.4.1 Voltage Voltage output  Inspect cabling from analog output

output fault for the specified board (J6 for A01 and A02, J5 for
(A01 – A06) analog output A03 and A04, J4 for A05 and A06) to
board is out of the PLC of mill control system for
range. damage. Make sure all cable
connections are secure.
 Verify that the output of ±10 VDC
meets the requirement of going into a
resistive load of 2 kΩ minimum with
10% over range capability.
 If the problem persists, contact KELK.
9.4.2 Current Current output for  Inspect cabling from analog output
output fault the specified board (J6 for A01 and A02, J5 for
(A01 – A06) analog output A03 and A04, J4 for A05 and A06) to
board is out of the PLC of mill control system for
range. damage. Make sure all cable
connections are secure.
 For 4-20 mA settings, verify that the
output meets the requirement of
going into a resistive load not
exceeding 500Ω with 5% over range
capability.
 For 0-20 mA setting, verify that the
output meets the requirement of
going into a resistive load not
exceeding 500Ω with 5% over range
capability.
9.4.3 Over The temperature  Refer to message “excessive internal

temperature on the specified temperature” in Table 8: Electronics
fault analog output Fault Troubleshooting for corrective
(A01 – A06) board is too high. actions.
Table 11: Analog Output Fault Troubleshooting

Troubleshooting
9.5 Interpreting User Initiated Error Conditions

Use the following table for description and corrective action for a user
initiated error condition.
Note: While a user initiated operation (for examples:

simulation, single sensor, calibration, zero or self-
test) is active, the corresponding LEDs (Channel A
Fault, Channel B Fault and Single Sensor) on the
FPI can be illuminated also.
Issue Message Description / possible What to check / corrective

Number cause action
9.5.1 Channel A Load simulation is active This message will be

Load simulation for this channel. cancelled when the load
active simulation is off or the user
This is a message given
exiting the Simulation/Test tab
9.5.2 Channel B for a user initiated load
of the Diagnostics panel.
Load simulation simulation or testing.
active
9.5.3 Channel A This is a message given This message will be

Internal routine for a user initiated cancelled when the operation
active operation such as is finished.
Configuration, Self-Test,
9.5.4 Channel B Zero and Calibration.
Internal routine
active
9.5.5 Channel A This is a warning given Fix the problem on the other
Signal off for a Single Sensor sensor then return to normal
(other channel (channel B doubled) two-sensor operation.
doubled) operation.
When the system is in normal
9.5.6 Channel B This is a warning given sensor operation, this
Signal off for a Single Sensor message goes off.
(other channel (channel A doubled) To set the system to normal
doubled) operation. sensor operation, refer to the
procedure in sub-section 7.4
Single Sensor Operation.
Table 12: User Initiated Fault Troubleshooting

Troubleshooting
9.6 Correcting Unexpected Loads and Alarms

Tare load and unsatisfactory mill operating condition can affect the load
measurement. If load measurements or alarm levels deviate significantly from
expected values not relating to a tare load or unsatisfactory operating condition,
take the following steps:
1. Make sure that that the system is off-line, do a zero operation using the UAP
or Zero button on the FPI to bring each channel to zero (sub-section 7.5).
2. Run Load Simulation in shunt mode (refer to sub-sections 4.5.5 and 6.6.10
Verify Setup and Load Output)
 For roll force, pressure and tension measuring systems, check that the
DSP2 load displays correspond with the Sensor Calibration Target Loads
(including interconnecting cable corrections).
 For fixed wrap angle tension measuring systems, check that the DSP2
load displays correspond with the Tensiometer Calibration Target Loads
(including interconnecting cable corrections).
 For varying wrap angle tension measuring applications, check that the
DSP2 load displays correspond with the Tensiometer Calibration Target
Loads (including interconnecting cable corrections).
If the displayed loads are correct, erroneous wrap angle compensation

may be causing the problem. Make sure that the WAC lookup tables have
been set up correctly and check the WAC sensor inputs.
 If the displayed loads are incorrect, check that the Shunt Resistor value
and Calibration Target Loads were entered correctly during setup.
Calibration error will affect the Digital and Analog Outputs, the Load
Displays and the Load Alarms. Make the applicable corrections if
necessary and run Configuration again.
 If the displayed loads are correct and an Analog Output is erroneous,

make sure that you enter the correct output scale factor. Any error will
affect only the associated Analog Output.
 If the displayed loads are correct and a load level alarm is not issued at the
expected level, run Simulation (sub-sections 4.5.5 and 6.6.10 to find the
triggering point. If this differs from the expected level, correct the
Threshold setting. Any error will affect only the associated Alarm.
3. If the problem cannot be attributed to any of the above causes, run the Self-
Test, sub-section 7.8. If any fault is reported, refer to sub-sections 9.2 to 9.4.

Troubleshooting
9.7 Doing the Cable and Sensor Tests

The following three tests help you to isolate the faults in the system
components.
Caution: During these tests, the Digital and Analog

Outputs and the Load Alarms are
unpredictable. Ensure that they are not
connected to any active mill control system as
this may cause the production of off-
9.7.1 System Test

For details about sensor connections to the DSP2, refer to Figure 58 for
interconnecting diagram for the 4-wire cable.
To do the system test, take the following steps:
1. Turn the DSP2 OFF.
2. Disconnect the interconnecting cable wires +SIG and -SIG on terminal
block TB11. Refer to the table below for the applicable wire terminals
for channels A and B.
Table 13 TB11 Connection for 4-Wire Interconnecting Cable
3. Turn the DSP2 ON. With a digital voltmeter (DVM), measure the
excitation voltage between +EXC and -EXC wires. Note that:
 The reading should be the same as in the UAP setting. Default

is 10 VDC.
 A low reading of less than 1 VDC indicates overcurrent

protection mode or an excitation supply problem.
4. Set the DVM measurement to millivolts, measure the voltage between

the +SIG and -SIG wires. Record the value and note that:

Troubleshooting
 The normal reading should be less than 0.5 mV per volt of

excitation (mV/V).
 Values above 1 mV/V are unusual and indicate around 100% of

full scale. If the value is higher than 3 mV/V, it may be beyond
the range of the zero control. The problem is most likely with the
load cell, contact KELK.
5. Set the DSP2 to OFF, disconnect the +EXC and -EXC wires (this
completely disconnects the cable from the DSP2). Do the following
tests:
a. Using an Ohmmeter with a resolution of 0.1Ω, take the following
resistance measurements. Verify that the reading is within ±1Ω of
the resistance specified on the calibration card plus the resistance
of the interconnecting cable. High or low readings indicate cable
problems or a damaged sensor.
 Input resistance — measure between the +EXC and –EXC

wires.
 Output resistance — measure between the +SIG and -SIG

wires.
Caution: Do not use an insulation tester (megohmmeter)

with test voltages of more than 50V in the next
step. Higher voltages will damage the sensor.
b. Using a DVM or megohmmeter with a test voltage of less than

50V, take the following measurements. Verify that all readings are
more than 20 MΩ.
 Bridge-to-ground resistance (for example, any sensor wire

to ground)
 Bridge-to-shield resistance (for example, any sensor wire
to the cable shield)
 Shield-to-ground resistance (for example, load cell cable
shield to ground)
Note: A reading of 20 MΩ or less indicates cable

damage or moisture in the sensor, cable assembly
or junction box. Readings below 10 MΩ may be
detrimental to measurement accuracy.
6. If all readings were normal for steps 4 and 5, the excitation supply is
faulty. Contact KELK to replace the Strain Gage Interface Board.

Troubleshooting
7. If any readings were abnormal for steps 4 and 5, the interconnecting

cable assembly or the sensor causes the problem. Continue with the
next two tests to identify the fault.
9.7.2 Load Cell Cable Test

If there are other junction boxes in the cable routing, repeat the following
procedure for each of them:
1. Disconnect the cable at the junction box and the DSP2 terminal block
(TB11).
2. Test all conductors for continuity.
3. Take measurements of the following:
 Resistance to ground of all conductors
 Resistance to the shield of all conductors
 Shield to ground resistance.
4. If any reading for step 3 is 20 MΩ or less, it indicates cable damage or

moisture in the cable. If measured values are below 20 MΩ or if you
find any conductor not to be continuous, replace the cable.
Note: Noisy or erratic sensor signals can be the result of

improper cable routing. Do not run sensor cables
close to power cables or potential sources of
electromagnetic radiation. Use of metal conduits is
recommended.
5. When reconnecting the cable, make sure that:
 All dirty and corroded terminal blocks and lugs are replaced.
 There are no frayed wires to cause momentary shorts to ground.
 The junction box and all internal components are dry. If you
suspect moisture or see moisture on the components, dry them
with alcohol.
 The cable shield is electrically isolated from the box ground.
 The junction box is sealed properly. Check the cover and all
cable entry points, reseal if necessary.
9.7.3 Sensor Test

1. Disconnect the sensor cable from the junction box.

Troubleshooting
2. Repeat tests in step 5 of sub-section 9.7.1 System Test.

3. If a problem is in either the sensor cable or the sensor, remove the
sensor for a complete inspection. Refer to the sensor inspection
procedure in the Load Measuring System Manual or Tension
Measuring System Manual for details.
4. Inspect the full length of the cable for damage.
 If the cable damage is near the entry of the sensor (within 6

inches or 150 mm), replace the sensor or return the sensor to
KELK for service or repair.
 If the cable damage is a distance away from the sensor, repair

the cable using the KELK Splicing kit (Part Number 20311). All
applicable repair instructions are included in the kit.
5. If there is no cable damage, the problem is probably in the sensor.

Return the faulty or damaged sensor to KELK for evaluation and
repair.
Note: One problem with sensors that cannot be

detected by the above tests is strain gage fatigue.
Fatigue manifests itself when a sensor reaches the
end of its life.
Strain gage fatigue can also occur when a sensor is

continuously overloaded locally because of poor
loading conditions. The symptom of this condition
is a progressive zero drift in a direction typically
opposite to the load direction. You can
compensate this condition using the zero control
(hardware and software) until the compensation
circuitry reaches its limit. Then, a sensor
replacement is necessary.

Troubleshooting
9.8 Simulating Loads

Load Simulation is used for checking the DSP2 setup and the load output
(analog or digital) to mill control system interface. Load simulation is
available in the UAP only.
There are two load simulation modes:
 Shunt — shunt resistors are applied to both channels or either

channel A or channel B . The levels of the load outputs will
correspond to the Calibration Target Loads (including any
corrections included for interconnecting cable resistance)
entered during setup.
 Simulate — the load outputs can be set in the range 0% to

150% of individual sensor or tensiometer capacity.
Caution: During Load Simulation, the Digital and Analog

Outputs and the Load Alarms are forced to the
user specified levels until normal operation is
resumed. Ensure that they are not used for mill
control as this may cause the production of off-
specification product or mill damage .
To simulate a load or apply the shunt resistors using the UAP, refer to
sub-sections 4.5.5 Simulation/Test and 6.6.10 Verify Setup and Load
Output for more details.
Note: Do not initiate Calibration, Zero, Self-Test or Run

Configuration operation when load simulation is
active. If you do this, the following warning
message will appear and block the operation.

Troubleshooting
9.9 Interpreting Event Status Log

The contents of the system event log is shown in Figure 114. It contains
the following data:
 Date and time when the event occurs
 Electronics status (ElSt) – contains the same information as

Modbus register 12 or format 16B3
 Channel A status (Ch_A) and channel B status (Ch_B) –

contains the same information as Modbus registers 13 and 14,
or format 16B4
 SGIB A status (SG_A) and SGIB B status (SG_B) – contains the

same information as Modbus registers 48 and 56, or format
16B5
Figure 114: System Status Log
All status codes are four-digit hexadecimal number. Some examples of

status (event) codes are: 0000, 0008, 4000, 001D, 009F etc. Using a
calculator from the Windows operating system, you can convert the four-
digit hex code to binary shown in the examples of Table 14 below:

Troubleshooting
H4 H3 H2 H1
Bits 15–12 Bits 11–8 Bits 7–4 Bits 3–0
Hex Binary for hex Binary for hex Binary for hex
Binary
code code 4000 code 009F code 0011
Bit 0 0 1 1
Bit 1 0 1 0
H1
Bit 2 0 1 0
Bit 3 0 1 0
Bit 4 0 1 1
Bit 5 0 0 0
H2
Bit 6 0 0 0
Bit 7 0 1 0
Bit 8 0 0 0
Bit 9 0 0 0
H3
Bit 10 0 0 0
Bit 11 0 0 0
Bit 12 0 0 0
Bit 13 0 0 0
H4
Bit 14 1 0 0
Bit 15 0 0 0
Table 14: Examples of Binary Equivalent for Hex Codes
To interpret the four-digit hexadecimal code:

1. Convert the hex code into the binary equivalent using the calculator.
2. Enter the binary equivalent in the last column of Table 15. Make sure
the binary are entered on the applicable error status field. For
example: if the error status is for ch_a or ch_b, enter the binary in the
Channel Status fields.
3. Note that the bit that is set to 1 indicating the error status. Some
examples are:
 All codes are 0000 – indicates normal operation, no fault

detected.
 ElSt (Electrons Status) 0008 – bit 3 is set, therefore indicating an

IBA network logging error.
 Ch_A 1000 – bits 12 is set, indicating SGIB alarm detected.

Usually when there is a SGIB A alarm detected error, there is
also error code(s) in SGIB A.

Troubleshooting
 SG_A 009F – bits 7, 4, 3, 2, 1 and 0 are set, which indicating

ARM 2 voltage out of range, ARM1 voltage out of range,
saturation in the last 100ms, excitation voltage out of range and
excitation current out of range are detected in SGIB A.
 SG_B 001D – bits 4, 3, 2 and 0 are set, which indicating ARM 2

voltage out of range, ARM1 voltage out of range, input
saturation and excitation current out of range are detected in
SGIB B.
Name Description Details Binary Equivalent

16B3 Electronics Status Bit 0 - SGIB A board not recognized Bit 0:
(ElSt) Bit 1 - SGIB B board not recognized Bit 1:
or Bit 2 - WAC board not recognized Bit 2:
Bit 3 - IBA network logging error Bit 3:
Modbus Bit 4 - Reserved Bit 4:
register
Bit 5 - Reserved Bit 5:
12
Bit 13 - Excessive Internal Temperature Bit 13:
Bit 14 - SGIB A not calibrated in this unit Bit 14:
Bit 15 - SGIB B not calibrated in this unit Bit 15:
16B4 Channel Status Bit 0 - Channel data not valid Bit 0:
(Ch_A or Ch_B) Bit 1 - Reserved Bit 1:
or Bit 2 - Reserved Bit 2:
Bit 3 - Error calculate bridge resistance Bit 3:
Modbus Bit 4 - Reserved Bit 4:
registers
Bit 5 - Zero out of range Bit 5:
13 and 14
Bit 6 - No response to shunt resistor Bit 6:
Bit 7 - Configuration verification failed Bit 7:
Bit 11 - SGIB reset detected Bit 11:
Bit 12 - SGIB alarm detected Bit 12:
Bit 13 - Load Simulation Active Bit 13:
Bit 14 - Internal Routine Active (Self-Test, Bit 14:
Configuration, Cal, Zero) Bit 15:
Bit 15 - Signal OFF (Other channel doubled)
16B5 SGIB Status Bit 0 - Excitation current out of range Bit 0:
(SG_A or SG_B) Bit 1 - Excitation voltage out of range Bit 1:
or Bit 2 - Input saturation Bit 2:
Bit 3 - ARM1 voltage out of range Bit 3:
Modbus Bit 4 - ARM2 voltage out of range Bit 4:
registers
Bit 5 - 15V power supply out of range Bit 5:
48 and 56
Bit 6 - 5V power supply out of range Bit 6:
Bit 8 - Reserved

Troubleshooting
Name Description Details Binary Equivalent

Bit 15:
Table 15: System Fault Status

Parts Data
10 Parts Data
This section contains the parts lists for the Rollmax DSP2 electronics system that you can order
from KELK.
10.1 Options and Spares

Refer to KELK drawing for the DSP2 product structure and the availability
of spares.
Description KELK Part Number
Fuse (spare) *07054

(1.25 Amp slow blow fuse)
DSP2 - Main Frame Assembly (Spare) 24 models

Includes: DSP2 enclosure, Front (see Figure 115)
Panel Interface, power supply and
processor board.
8 Port Ethernet switch spare *07238
16 Port Ethernet switch spare *08585
ProfiBus Option Kit for FMC2100 PL048476
ProfiNet Option Kit for FMC2100 PL048475
Power cord (IEC Power Cord) *08582
Table 16: Options and Spares
Note: If you want to add an analog input or output option

to an existing system, order also the corresponding
cable assembly for that option.

Parts Data
10.2 DSP2 Order
Figure 115: DSP2 Order Code
10.3 DSP2 Wiring Harness

Wiring harnesses are installed between the DSP2 and the terminal block
assembly in KELK or Customer supplied cabinets. Depending on the
cabinet the harness will be installed in, the harness’s lengths will vary,
either 19.5 in or 24.6 in.
Each standard harness configuration has a discrete part number and
follows the order code structure shown in Figure 116: DSP2 Harness
Order Code:

Parts Data
Figure 116: DSP2 Harness Order Code
To determine which harness to use with the DSP2, refer to Figure 117:
Determining DSP2 Harness Order Code:
Figure 117: Determining DSP2 Harness Order Code
The DSP2 installed in the KELK cabinet, FMC2100 will use DSP2-CBL-*-*-A-B.
The DSP2 installed in the KELK cabinet, WMC12 will use DSP2-CBL-*-*-B-B.

Fieldbus Interfaces and Setups
11 Fieldbus Interfaces and Setups

The DSP2 allows communication of fieldbus interface that uses Profibus, Profinet or
Modbus/TCP protocol. For fieldbus interface of Profibus or Profinet protocol, an Anybus X-
gateway Profibus DP-V1 (Decentralized Periphery) module or Anybus X-gateway Profinet
module is installed in the cabinet. For fieldbus interface of Modbus/TCP protocol, an Ethernet IP
(Modbus-TCP) module is installed in the J9-Fieldbus slot (Figure 118).
Figure 118: Fieldbus Options in the Electronic Unit
Either optional Fieldbus Interface provides the mill control computer with access to:
 Load measurement data at the high rate necessary for mill control.
 Input wrap angle data for varying wrap angle tension measuring applications.
 Monitor and control the DSP2.
This section provides set up information and data mapping of these fieldbus interfaces for your
mill control system.
11.1 Ethernet Modbus/TCP Communication and Setup

The Fieldbus Ethernet Modbus-TCP module implements the
Modbus/TCP protocol that uses the standard Modbus protocol running on
top of TCP/IP. The built in Modbus/TCP server provides access to the
Input- and Output-Data areas via a subset of the functions defined in the
Modbus/TCP specification. All Modbus/TCP messages are exchanged
through TCP port number 502.

11.1.1 Modbus-TCP Module and Indicators

The Ethernet Modbus-TCP module has two standard RJ45 Ethernet
connectors and four status LED indicators as shown in Figure 119.
Figure 119: Modbus-TCP Module
Table 17 shows the pin function of the RJ45 Ethernet connector.
Connector pin Signal Description

1 TD+ Positive transmit data
2 TD- Negative transmit data
3 RD+ Positive receive data
4 NC
No connection
5 NC
RJ45
6 RD- Negative receive data connector
7 NC
No connection
8 NC
Casing PE Protective earth
Table 17: RJ45 Pin Function
Connect the Ethernet cable from the mill control system to the RJ45
connector in J9 of the Ethernet IP module (Figure 118). This module is
for use with twisted pair cables; no external terminator is required.
The four bi-color status LEDs on the module (Figure 119) indicate the
following run-time status and errors (Table 1818):

LED # State Description
1 Off No IP address or in state EXCEPTION

Network
Status LED At least one Modbus message
Green
received
Green, flashing Waiting for first Modbus message
IP address conflict detected,

Red
FATAL ERROR
Red, flashing Connection timeout
2 Off No power
Module
Status LED Green Normal operation
Major fault (including Anybus

Red
EXCEPTION), FATAL
Red, flashing Minor fault
Alternating Firmware update from file system in

green/red progress
3/4 Off No link, no activity

Link/Activity
LED Green Link (100 Mbit/s) established
Green,
Activity (100 Mbit/s)
flickering
Yellow Link (10 Mbit/s) established
Yellow,
Activity (10 Mbit/s)
flickering
Table 18: LED Status Interpretation
11.1.2 Ethernet Settings

The Ethernet Modbus-TCP module can be configured either using the
UAP of the DSP2 or directly via the Ethernet connection according to the
procedures in the following sub-sections.
If your network administrator tells you what IP address, netmask and
gateway to be entered, use the UAP to configure the settings.

11.1.2.1 Configuring Settings using the UAP

To configure the Modbus network setting using the UAP of the
DSP2, see sub-section 6.6.5 Set Up Communication Ports or use
the following procedure.
1. Start the UAP from you laptop and verify that it connect to the
DSP2.
3. Select the Communication tab on the main panel (Figure
120).
4. Enter applicable IP address, subnet and gateway in the
Modbus fields. Make sure that last dot (.) field of IP address
(node Address) is within 1 – 254.
5. Click the Apply Changes icon on the toolbar or select Device
> Apply Changes on the menu bar.
Figure 120: Setup – Modbus Connection

continue.

8. Verify that the DSP2 restarts itself.

9. When an Operation is successful message appears, click
OK.
10. Add the IP address of the Modbus device to the mill system
and verify the mill system can communicate with the Modbus
module.
11.1.2.2 Configuring Settings via the Ethernet connection

You can also configure the Ethernet module through the Ethernet port
using the Anybus IPconfig program. The IPconfig program is available
from downloading from the HMS website:
https://www.anybus.com/support/file-doc-downloads/anybus-support-
tools?orderCode=tools
11.1.3 Processing
The Fieldbus interface for the DSP2 is implemented as two sections of
dual port RAM, one Read and the other Write. Therefore, it is not possible
to implement Read/Write registers directly on the fieldbus and a work-
around is used. All registers that are written by the host are mirrored in
the space read by the host.
The DSP2 cannot determine exactly which variable the host has updated
in the dual port memory so it operates by identifying changes in variable
values sent by the host. Normally, this is completely transparent to the
host but there are two cases where care must be exercised:
 At startup, the current value buffer that used to identify changes,

is set to zero (0). If the host tries to write a zero to a DSP2
variable, the DSP2 takes no action and the variable will remain
at its default power-on value.
 If the host tries to write the same value twice to a DSP2 variable,
the DSP2 takes no action and the variable will remain
unchanged. This is only a problem if the variable has been
changed by the UAP or FPI between the first and second writes.

Functions such as Calibrate and Zero, that are initiated by changing a

register value from 0 to 1 and indicate completion by the DSP2 changing
the value back to zero, must be handled as follows:
 At startup, the value of the host write register will be 0.
 The host must write 1 to the host write register, changing it from
0 to 1 to request a function.
 While the function is in progress, the host will read an active

signal from bit 14 of the channel status read register.
 When the function is completed, this bit will read as inactive (0)
 The host must write 0 to the host write register to enable a

subsequent function request to change value from 0 to 1.
Because the Fieldbus Interface Card is handling host communications
independently, it is not possible to report an invalid data error. If the host
sends invalid (out of range) data, it is ignored by the DSP2.
11.1.4 Data Format for Communications

Table 19 defines the formats of data that have been reconstructed after
transmission. Note that:
 Numeric values are decimal (base 10) unless stated otherwise.
 For bitmapped formats, the condition is enabled (or ON) when

the bit is set and disabled (or OFF) when the bit is clear.
 The nomenclature used for each format reflects the basic type
and size (in eight-bit bytes) of the format. The size of each
format is always an integral multiple of one byte. Regardless of
their size, data are interpreted as "big-endian" (i.e., the least
significant bit is bit 0 and the most significant bit is the highest-
numbered bit for the format).
 For formats that do not use all of available bits, the unused bits
are ignored by the format and are set to zero during
transmission.
Format names are in the form SSS TTT AAA, where:
 SSS is the Data Size in bits. For the DSP2, this is always 16
bits.
 TTT is the Format Type:

I - Signed Integer
U - Unsigned Integer
E - Enumerated

B - Bitmapped
 AAA is Additional Format Information
For signed/unsigned integer types, this is the number of implied

decimal digits:
0 - No decimal digits (no decimal point appears)
1 - One decimal digit (decimal point before last digit)
2 - Two decimal digits (decimal point before last two digits) Etc.
Example: 16I2 is 16 bits, signed integer, 2 decimal points.
Format name example: 16I2 is 16 bits, signed integer, 2 decimal points.
Name Description Details

Signed Integer Types
16I 2 16 bit, signed integer, Example: -123.45 stored as -12345
two decimal digits
Unsigned Integer Types
16U0 16 bit, unsigned integer, Example: 12345 stored as 12345
no decimal digits
16U1 16 bit, unsigned integer, Example: 1234.5 stored as 12345
one decimal digit
Enumerated Types
16E9 Single sensor operation 0-A&B
1-2xA
2-2xB
16E10 Analog output mode of 0 - Voltage
operation 1 - 0-20 mA current
2 - 4-20 mA current
16E12 No/Yes 0 - Disable (no/normal/locked)
1 - Enable (yes/inverted/unlock)
16E13 10V/20V excitation level 0 - 10 V excitation
1 - 20 V excitation
Bitmapped Types
16B0 Logic Outputs Bit 0 - System fault
(System Status Bit 1 - Channel A fault
Indicators and Load Bit 2 - Channel B fault
Alarms) Bit 3 - Single sensor operation
Bit 4 - Load alarm 1
Bit 12 - Electronic healthy

Name Description Details

16B3 Electronics Status Bit 0 - SGIB A board not recognized
Bit 1 - SGIB B board not recognized
Bit 2 - WAC board not recognized
Bit 3 - IBA network logging error
Bits 4 -12: Reserved
Bit 13 - Excessive Internal Temperature
Bit 14 - SGIB A not calibrated in this unit
Bit 15 - SGIB B not calibrated in this unit
16B4 Channel Status Bit 0 - Channel data not valid
Bit 1 - Reserved
Bit 2 - Reserved
Bit 3 - Error calculate bridge resistance
Bit 4 - Reserved
Bit 5 - Zero out of range
Bit 6 - No response to shunt resistor
Bit 7 - Configuration verification failed
Bit 8 - Reserved
Bit 9 - Reserved
Bit 10 - Reserved
Bit 11 - SGIB reset detected
Bit 12 - SGIB alarm detected
Bit 13 - Load Simulation Active
Bit 14 - Internal Routine Active (Self-Test,
Configuration, Cal, Zero)
Bit 15 - Signal OFF (Other channel
doubled)
16B5 SGIB Status Bit 0 - Excitation current out of range
Bit 1 - Excitation voltage out of range
Bit 2 - Input saturation
Bit 3 - ARM1 voltage out of range
Bit 4 - ARM2 voltage out of range
Bit 5 - 15V power supply out of range
Bit 6 - 5V power supply out of range
Bits 8 -15: Reserved
Table 19: Modbus/TCP Data Format
11.1.5 Modbus-TCP Memory Map

The following table defines the data that can be accessed through the
Fieldbus server interface as well as either of the standard two Ethernet
ports. Process variables may be accessed at the Fieldbus memory at 500
Hz; other variables are updated at approximately 45 Hz. It is advised that
the request rate for the servers on the standard Ethernet ports be limited
to 100Hz or less.

Host read Host Write

Min Max Default
address Address Name Format Units
value value value
(hex) (Hex)
Process Variables (Read-Only, Volatile, see note 1 below)
0000 Input A Load 16I 2 % -327.68 327.67 -
0001 Input B Load 16I 2 % -327.68 327.67 -
0002 Status of Logical 16B0 - - - -
Outputs
0003 Input Sum A+B 16I 2 % -327.68 327.67 -
0004 Input Difference A-B 16I 2 % -327.68 327.67 -
System Status Data (Read-Only, Volatile, see note 2 below)
000C Electronics Status 16B3 - - - 0
000D Channel A Status 16B4 - - - 0
000E Channel B Status 16B4 - - - 0
000F Electronics Temperature 16U1 °C -55.0 125.0 -
0010 Last FPI Key Pressed 16U0 0 255
0011 SGIB A Status 16B3
0012 SGIB B Status 16B3
Operational Parameters (Read-Write, Volatile, see note 2 below)
0020 0420 WAC Input W1 16U0 - 0 1000 0
0021 0421 WAC Input W2 16U0 - 0 1000 0
0422 Calibration* 16E12 - - - 0
0423 Zero* 16E12 - - - 0
Configuration Parameters (Read-Write, Non-Volatile, see note 2 below)

0041 0441 Single Sensor 16E9 - - - 0
Operation**
Notes:
1. Process variables are updated by the DSP2 at 500 Hz.
2. The status data, operational parameters and configuration parameters are updated sequentially
by the DSP2 one at a time every 2 ms (about 45 Hz in total).
* Refer to sub-section 11.1.3 Processing above for operation of this function request register.
** Single Sensor Operation (Load Doubling). The field bus interface can change this parameter
from 0 (normal) to 1 (double A) or 2 (double B), however, it cannot change this value if it is
already non-zero. Only the FPI or UAP can clear it.
Table 20: Modbus-TCP Memory Map

11.2 Profibus Communications & Setup

11.2.1 Profibus DP-V1 X-gateway
Profibus is an open serial communication standard that enables data
exchange between different kinds of automation components. The
Profibus protocol family is specified in the IEC 61158 standard. In
Profibus communication, the master station – usually a programmable
logic controller (PLC) – polls the nodes (devices) that respond and take
the actions requested by the master.
The DSP2 is connected to the Profibus network through an Anybus X-
gateway Profibus module. The Anybus X-gateways for Modbus-TCP act
as intelligent links between two industrial networks. On the Modbus-TCP
network, they function as clients (masters) while they function as devices
(slaves) on the PROFIBUS or PROFINET network.

The optional Anybus X- gateway Modbus/TCP implements a 'Profibus DP

Slave'. The Slave interface is intended to be used for communicating with
a Master PLC/monitoring and control station in an industrial environment
(‘DP Master Class 1’ or ‘DPMaster Class 2’).
Data transmission rates from 9.6 kbps to 12 Mbps are achievable via RS
485 twisted pair or fiber optic cables. Up to 126 master and slave devices
can be connected to one network line which extends up to 200 m.
Although the minimum bus cycle time is 2 ms, and increases depending
upon the number of slaves and the transmission rate, the maximum
update rate that can be achieved when using the gateway is 24 ms.

11.2.2 Profibus DP-V1 X-gateway External View

The Profibus DP-V1 X-gateway is equipped with a power connector (A),
SD Card (B), USB Port (C), Status LEDs (D), DIN-rail Connector (E),
Profibus Connector (F), and 2-port switch Modbus-TCP Connector (G) as
it is shown in Figure 121Figure 121.
Figure 121: Anybus X-gateway Modbus-TCP PROFIBUS DP-V1

11.2.3 Profibus DP-V1 Connector

The connector for the Profibus DP-V1 network is found at the lower front
of the module as shown in Figure 121.
The table below shows the pin function of the 9-pin D-sub connector.
Pin Signal Description

Housing Shield Connected to protective earth
1, 2, 7, 9 Not connected -
3 B-Line Positive RxD/TxD according to RS485
specification
4 RTS* Request to Send
5 GND BUS** Isolated GND from RS485 side
6 +5V BUS** Isolated GND from RS485 side
8 A-Line Negative RxD/TxD according to RS485
specification
Notes:
* RTS is used in some equipment to determine the direction of transmission.
In normal applications only A-Line, B-Line and Shield are used.
** +5V BUS and GND BUS are used for bus termination. Some devices, like
optical transceivers (RS485 to fiber optics) might require external power
supply from these pins. In normal applications only A-Line, B-Line and
Shield are used
Table 21: Pin Function of 9-pin D-sub Connector
11.2.4 Profibus DP-V1 Status Indicators

There are eight status LEDs located on the front panel of the X-gateway
module.

X-gateway and Modbus-TCP Network LEDs
1 - Gateway Off Power Off

Status
Alternating Missing configuration
Red/Green
Flashing Green Idle
Green Running
Flashing Red Invalid configuration
Red Fatal error
5 - SD Card Green Accessing SD card
Flashing Red Failure
6 – Modbus- Off Power Off

TCP Status
Green Communicating with Modbus-TCP network
Flashing Red Transaction error or timeout
Red Fatal error
7, 8 – Ethernet Off No link

Link 1, Ethernet
Link 2 Flashing Green Receiving/transmitting Ethernet packets
Profibus DP-V1 Network LEDs
2 Not Used
3 – Profibus DP- Off Power off, not online

V1 Network
Status Green Online, data exchange
Flashing Green Online, clear
Flashing Red (1 Parametrization error

flash)
Flashing Red (2 Configuration error

flashes)
4 – Module Off Power off, not initialized

Status
Green Initialized
Red Exception error

11.3 Profinet Communications & Setup

The Anybus X-gateway Modbus-TCP is a PROFINET device (slave) on
the PROFINET network. The capabilities of the device are: the data
(including both I/O mapped data and parameter data) limits are 256 bytes
input data and 256 bytes output data, including optional control/status
word and live list. The update rate that can be achieved when using the
gateway is 24 ms.
Each of the two network interfaces exchanges data on its network
through two buffers. The X-gateway forwards the data between these
buffers as shown below:
11.3.1 Profinet X-gateway External View

The Profinet X-gateway is equipped with a power connector (A), SD Card
(B), USB Port (C), Status LEDs (D), DIN-rail Connector (E), Profinet
Connectors (F), and 2-port switch Modbus-TCP Connector (G) as shown
in Figure 122.

Figure 122: Anybus X-gateway Modbus-TCP PROFINET Module

11.3.2 Status LEDs

X-gateway and Modbus-TCP Network LEDs
1 - Gateway Off Power Off
Status
Alternating Missing configuration
Red/Green
Flashing Green Idle
Green Running
Flashing Red Invalid configuration
Red Fatal error
5 - SD Card Green Accessing SD card
Flashing Red Failure
6 – Modbus- Off Power Off
TCP Status
Green Communicating with Modbus-TCP network
Flashing Red Transaction error or timeout
Red Fatal error
7, 8 – Ethernet Off No link
Link 1, Ethernet
Link 2 Flashing Green Receiving/transmitting Ethernet packets
Profinet Network LEDs

2 Not Used
3 – Profinet Off Power off, no connection
Network Status
Green Online (Run): Connection established, IO
controller in RUN state
Flashing Green Online (stop): Connection established, IO
controller in STOP state
4 – Profinet Off Power off, or not initialized
Module Status
Green Operating in normal condition
Green, two flashes Used by engineering tools to identify the
device on the network
Red Exception error
Red, one flash Configuration error
Red, two flashes IP address error
Red, three flashes Station name error
Red, four flashes Internal error

11.3.3 Profinet Connectors

The connectors for the Profinet network are found at the lower front part
of the module.
Pin Number Description

1 TX+
2 TX-
3 RX+
4 Not connected
5 Not connected
6 RX-
7 Not connected
8 Not connected
Housing Shield
Table 24: Profinet Connectors
11.3.4 Profinet GSD File

Similar to the GSD file for Profibus, a PROFINET GSD file is a description
of an IO device provided by the device manufacturer. The contents of the
GSD consists of configuration information, parameters, modules,
diagnostic and alarms, and vendor and device identification. The GSD file
to use is GSDML-V2.2-HMS-ABX_ETNM_2P-20150914.xml which can
also be downloaded on the Anybus website.
11.3.5 Data Format for Communications

Table 19 defines the formats of data for Profibus and Profinet interface
that have been reconstructed after transmission. Note that:
 Numeric values are decimal (base 10) unless stated otherwise.
 For bitmapped formats, the condition is enabled (or ON) when

the bit is set and disabled (or OFF) when the bit is clear.
 The nomenclature used for each format reflects the basic type
and size (in eight-bit bytes) of the format. The size of each
format is always an integral multiple of one byte. Regardless of

their size, data are interpreted as "big-endian" (i.e., the least

significant bit is bit 0 and the most significant bit is the highest-
numbered bit for the format).
 For formats that do not use all of available bits, the unused bits
are ignored by the format and are set to zero during
transmission.
Format names are in the form SSS TTT AAA, where:
 SSS is the Data Size in bits. For the DSP2, this is always 16
bits.
 TTT is the Format Type:

I - Signed Integer
U - Unsigned Integer
E - Enumerated
B - Bitmapped
 AAA is Additional Format Information
For signed/unsigned integer types, this is the number of implied

decimal digits:
0 - No decimal digits (no decimal point appears)
1 - One decimal digit (decimal point before last digit)
2 - Two decimal digits (decimal point before last two digits) Etc.
Format name example: 16I2 is 16 bits, signed integer, 2 decimal points.

11.3.6 Data Identification

The following table defines the data that can be accessed through the
Profibus or Profinet interface:
Byte # Byte # Name Format Units Minimum Maximum Default

(Decimal) (Decimal)
Read Write
Process Variables ( Read-Only, Volatile, see note 1 below)
01:02 Input A Load 16I12 % -327.68 327.67
03:04 Input B Load 16I12 % 327.68 327.67
05:06 Status of Logical 16B0 - - -
Outputs
07:08 Input Sum A+B 16I12 % 327.68 327.67
09:10 Input Difference 16I12 % 327.68 327.67
A+B
System Status Data ( Read-Only, Volatile, see note 2 below)
17:18 Electronics Status 16B3 - - - 0
19:20 Channel A Status 16B4 - - - 0
21:22 Channel B Status 16B4 - - - 0
o
23:24 Electronics 32U0 C -55.0 125.0 0
Temperature
25:26 Last FPI Key 16U0 - 0 255 -
Presser
27:28 SGIB A Status 16B3 - - - 0
29:30 SGIB B Status 16B3 - - - 0
Operational Parameters (Read-Write, Volatile see note 2 below)

33:34 01:02 WAC Input W1 16U0 - 0 1000 0
35:36 03:04 WAC Input W2 16U0 - 0 1000 0
05:06 Calibration 16B3 - - - 0
07:08 Zero - - - 0
Configuration Parameters (Read-Write, Volatile see note 2 below)

49:50 17:18 Single Sensor 16E9 - - - 0
Operation*
Notes:
* Single Sensor Operation (Load Doubling). The field bus interface can change this parameter from 0
(normal) to 1 (double A) or 2 (double B), however, it cannot change this value if it is already non-zero.
Only the FPI or UAP can clear it
Table 25: Data Identification

Glossary of Terms and Acronyms
12 Glossary of Terms and Acronyms

The following is a comprehensive list of glossary of technical terms and their definitions to help
you better understand and navigate the confusing world of Load Measuring System. Note that
the list is in alphabetical order.
Term / Acronym Definition / Description
Analog Output Scale Scaling that can be applied to Analog Outputs Data
Factor
Analog Output DC voltage or current output representing Measurement

data
Anybus-S Anybus-S (slave) is a family of certified and proven

interchangeable embedded communication modules
designed for integration into industrial automation
devices that need to communicate with PLC’s or PC’s
via industrial networks
AWG American wire gauge (AWG). It is a standardized wire

gauge system used in North America for the diameters
of round, solid, nonferrous, electrically conducting wire.
Bridge An arrangement of strain gages within a sensor. Strain

gage sensors are a Wheatstone Bridge
Bridge resistance The resistance of the Wheatstone bridge of a force

sensor
Cal Calibration. The operation to scale each channel input

to represent a known and traceable quantity
Calibration The adjustment of system gain against a reference to

define Full Scale Input and provide meaningful
interpretation of the output
Channel Signal conditioning path, input to output, for a single

transducer
Configuration A user activated process that causes the DSP2 to

accept user selected parameters which are then used to
define Full Scale Input, to calibrate and define the zero
reference point for both channels and to zero both
channels
CTL Calibration Target Load
D-sub D-subminiature or D-sub is a common type of connector

with a D-shaped metal shield

DCI See Digital Communications Interface
DHCP Dynamic Host Configuration Protocol. It is a

standardized networking protocol used on IP networks
that dynamically configures IP addresses and other
information that is needed for Internet communication.
DHCP allows computers and other devices to receive an
IP address automatically from a central DHCP server,
reducing the need for a network administrator or a user
from having to configure these settings manually.
Difference output The difference of measurement data from two sensors
Digital A generic term covering serial data communication

Communications interfaces and industrial network interfaces.
Interface Abbreviation: DCI
Digital Value (Load) Internal numeric representation of measurement data.

This may be presented via the front panel display or the
serial interface or the fieldbus interface
DSP2 Digital Signal Processor Model DSP2
DVM Digital Voltmeter
Dynamic Host See DHCP

Configuration
Protocol
EMI Electromagnetic Interference or EMI. It is disturbance

that affects an electrical circuit due to either
electromagnetic induction or electromagnetic radiation
emitted from an external source. The disturbance may
interrupt, obstruct, or otherwise degrade or limit the
effective performance of the circuit.
Excitation supply DC voltage source to be applied to a connected sensor
Force, load Quantity to be measured
FSI Full Scale Input (FSI). See Full Scale Input.
Full Scale Input The input level that corresponds to full scale output as
determined by System Calibration
Full Scale The maximum measurement range as defined by the

maximum value at the output e.g. for analog outputs 10
VDC or 20 mA
Gateway 1. A device that performs a protocol translation at the

Session Layer or higher.

2. Archaic. A TCP/IP router that routes packets
between different network numbers.
IBA Refer to ibaPDA
ibaPDA Process Data Acquisition (PDA) system. It is a PC-

based acquisition and analysis system (data logging
package) for measured values.
IEC International Electrotechnical Commission
Individual output Measurement data from a single sensor
Input range The range of sensor output expressed in millivolts that

can be processed by the DSP2
IP Internet Protocol. The Network Layer protocol in the

TCP/IP stack offering a connectionless internetwork
service. See TCP/IP.
IP (code) Ingress Protection Rating for enclosure or interpreted as

International Protection Rating
IP address An IP (Internet Protocol) address is a unique identifier

for a node or host connection on an IP network. Also
called an Internet address. It is a 32-bit binary number
written as 4 octets separated with periods (dotted
decimal format). See also IP and netmask.
Load cell A transducer that converts an input mechanical force

into an electrical output signal. Refer to definition of
Sensor.
Load doubling A means of isolating measurement data from one input

in the event of a fault condition and using the
measurement data of the remaining good channel to
service the outputs of the faulty channel
Load simulation The measurement data outputs, digital and analog are
forced to a user selectable level; an off-line condition
Lockout The keypad access is restricted or disabled
Logic Input Two state input to identify the reception of externally

generated commands
Logic output Two state output for alarm or condition indication
MAC address The Media Access Control (MAC) address is a 48-bit

unique identifier assigned to a network interface on the

physical network. MAC addresses are 6 bytes long and
are controlled by the IEEE. Also known as a hardware
address or a physical address
Megohmmeter Megohmmeter is also referred to as a megger. It is a

special type of ohmmeter used to measure the electrical
resistance of insulators.
NEMA National Electrical ManUFacturers Association
mV/V Millivolts per volt of excitation. It is the output sensitivity

of the load cell (sensor).
Netmask A netmask is a 32-bit mask used to divide an IP address

into subnets and specify the networks available hosts. In
a netmask, two bits are always automatically assigned.
For example, in 255.255.225.0, "0" is the assigned
network address; and in 255.255.255.255, "255" is the
assigned broadcast address.
Off-line The DSP2 is not processing measurement data.
OLED Organic Light-Emitting Diode. It is a light-emitting diode

(LED) in which the emissive electroluminescent layer is
a film of organic compound, which emits light in
response to an electric current.
On-line The DSP2 is (as considered by the user) processing

measurement data
Profibus Process Field Bus. It is a standard for field bus

communication in automation technology
Scale Factor Scaling that can be applied to Measurement Data before

transfer to the Outputs
Self-Test A self-diagnostic routine within the DSP2
Sensitivity The output sensitivity of the sensor at rated capacity or

application rated capacity, usually expressed in millivolts
per volt of sensor excitation
SGIB Strain Gage Interface Board
Sensor Strain gage force sensor. Other terms: load cell,

tensiometer and pressure transducer
Shunt output: (input The output from the sensor bridge when a shunt resistor
to DSP2) is applied

Shunt resistor A known resistance applied parallel to one arm of the

sensor bridge to force an output for use in system
calibration
Single sensor The selection and indication that load doubling is in

effect. This operation condition to be invoked, manually,
by logic input or via DCI
Sum output The sum of measurement data from a pair of sensors.

For tension and pressure applications the ‘Sum’ is the
average of two Individual measurements
System The word System refers exclusively to the DSP2
System Gain The degree of amplification of each strain gage sensor

Full Scale Input to yield Full Scale Analog Output for a
Scale Factor of 100
Tare correction The means of reducing the output from a sensor under
tare load to a point that is within the zero range of the
DSP2. It is a form of coarse zero correction.
Tare Load A static load applied to the sensor creating an output

from the sensor that is not normally included in the
measurement. In some cases, the output is large,
exceeding the range of zero correction available.
TCP/IP Transmission Control Protocol/Internet Protocol. A

Transport and Network Layer Protocol, respectively,
used by a large number of computers.
Tensiometer Refer to definition of Sensor
UAP Refer to User Access Program
User Access Software supplied on external media for the setup,

Program configuration and monitoring of the DSP2
User Interface Keypad and display media
WAC Wrap Angle Compensation, a process of compensating

for variable geometry conditions affecting the
measurement outcome in tension applications
Zero The operation to zero each channel output within a

specified range
Zero range The percentage of Full Scale Input that can be corrected
to yield Zero
Table 26: Glossary of terms and acronyms

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Rollmax Digital Signal Processor

DSP2 (Version B) User's Manual

 The customer must agree to pay KELK’s standard hourly service

 If feasible, KELK will do the necessary work at a suitable

1 About this Manual ......................................................... 7

2 About the DSP2 ........................................................... 10

3 Front Panel Interface ................................................... 23

4 User Access Program ................................................. 41

90509 Rev B, December 2020 Page 3

4.2.3 Navigation Panel ............................................................... 50

6 Setup and Configuration ........................................... 100

90509 Rev B, December 2020 Page 4

6.3 Signal Filtering ....................................................................... 109

7 System Monitoring and Controls ............................. 172

8 Maintenance ............................................................... 181

9 Troubleshooting ........................................................ 187

90509 Rev B, December 2020 Page 5

9.6 Correcting Unexpected Loads and Alarms ........................... 198

10 Parts Data................................................................... 208

11 Fieldbus Interfaces and Setups................................ 211

12 Glossary of Terms and Acronyms ........................... 231

90509 Rev B, December 2020 Page 6

1 About this Manual

 If additional technical assistance is required, call or contact KELK or our designated

1.1 Intended Use

1.2 Symbols Used in This Manual

90509 Rev B, December 2020 Page 7

Note, Important or Tip

1.3 Safety Information

 Electrical Hazard: Do not apply voltage levels

 Before installing or moving the system, turn off

 Do not use the system in a high-humidity environment. Do not

 Do not disassemble any system components. Do not attempt

90509 Rev B, December 2020 Page 8

1.3.1 Anti-static Precautions

 Wear an anti-static wristband: Wearing an anti-static

 Ground yourself frequently: Before handling any

 Use an anti-static pad: When configuring or working

 Handle electrical component by its edges: When

1.3.2 Electric Safety

 Caution: Carefully route the power cord so it is not a

1.4 Related Publications

Tension Measurement System Manual or Job No. specific

ibaPDA and ibaAnalyzer User’s Manual 90444

Floor Mounted Cabinet Description & Specifications DS.FMC.551

Wall Mounted Cabinet Description & Specifications DS.WMC.552

DSP2 Description & Specifications DS.DSP2.803

Interconnecting Cable DS.INC.555

90509 Rev B, December 2020 Page 9

2 About the DSP2

 Tension measurement in steel, aluminum, paper process lines or other mills

 Force & Pressure measurement in harsh industrial and mining environments.

CE marking and certification

 CE EMC Directive 2014/30/EU, complying with the following Standards:

Restriction of Hazardous Substances Compliant

90509 Rev B, December 2020 Page 10

2.2 Hardware Configuration

Figure 1: DSP2 Configuration

90509 Rev B, December 2020 Page 11