DSP2 Manual PDF

ROLLMAX
DIGITAL SIGNAL PROCESSOR

MODEL DSP2
USER’S MANUAL
MANUAL # 90348 Rev F2

March 2008
© 2003 George Kelk Corporation
GEORGE KELK CORPORATION

48 Lesmill Road
Toronto, Ontario
CANADA
M3B 2T5
Tel (416) 445-5850

Fax (416) 445-5972
E-mail kelkcorp@kelk.com
KELK Table of Contents
TABLE OF CONTENTS
Warranty
Precautions
Part 1 About this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Part 2 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Hardware Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.3 Signal Processing, Load Outputs and Alarms . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.4 Auxiliary Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.4.1 Single Sensor Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.4.2 Auto Zero . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.4.3 Auto Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.4.4 Wrap Angle Compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.4.5 Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.4.6 Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.4.7 Lockout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.5 Setup and Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.6 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.7 Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.7.1 Sensor Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.7.2 Auxiliary Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.7.3 Analog Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.7.4 Fieldbus Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.7.5 Serial Communications Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.7.6 Front Panel Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.7.7 Logic Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Part 3 User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.2 User Access Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.3 Front Panel Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.3.1 Display and Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.3.2 Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Part 4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.2 Cabinets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.3 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.3.1 AC Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.3.2 Sensor Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.3.3 Auxiliary Analog Input Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.3.4 Analog Output Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.3.5 Logic I/O Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.3.6 Serial Communications (SCI) Wiring . . . . . . . . . . . . . . . . . . . . . . . . 44
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Part 5 Setup and Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.2 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.3 Signal Processing, Limits and Scaling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.4 Signal Filtering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5.5 Wrap Angle Compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
5.6 Pre Power-up Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
5.7 Setup and Configuration - User Access Program . . . . . . . . . . . . . . . . . . . . . 57
5.8 Setup and Configuration - Front Panel Interface . . . . . . . . . . . . . . . . . . . . . . 57
5.8.1 Input Channels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
5.8.2 Analog Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5.8.3 Load Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5.8.4 Wrap Angle Compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
5.8.5 Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
5.8.6 FPI Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5.8.7 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Part 6 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
6.2 Load Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
6.3 Load Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
6.4 System Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
6.5 Single Sensor Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
6.6 Auto Zero . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
6.7 Auto Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
6.8 Wrap Angle Compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
6.9 Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
6.10 Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
6.11 Lockout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Part 7 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
7.2 Electronics Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
7.3 Channel Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
7.4 User Initiated Error Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
7.5 Unexpected Load Measurements and Alarms . . . . . . . . . . . . . . . . . . . . . . . . 80
7.6 Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
7.6.1 System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
7.6.2 Interconnecting Cable Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
7.6.3 Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
7.7 Load Simulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
7.8 Fault History Recording via the User Access Program . . . . . . . . . . . . . . . . . 85
7.8.1 System Status Logger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
7.8.2 Start-Up codes and Start-Up Counter . . . . . . . . . . . . . . . . . . . . . . . . 86
Part 8 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
8.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
8.2 Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
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8.3 Printed Circuit Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

8.4 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Part 9 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
9.1 Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
9.2 Sensor Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
9.3 Auxiliary Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
9.4 Analog Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
9.5 Logic Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
9.6 Logic Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
9.7 Serial Communications Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
9.8 Fieldbus Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
9.9 Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
9.10 Physical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
9.11 User Access Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Appendix A Serial Communications Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
A.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
A.2 Setup and Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
A.3 Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
A.4 Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
A.4.1 Data Formats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
A.4.2 Memory Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Appendix B Fieldbus - Ethernet (Modbus/tcp) Protocol . . . . . . . . . . . . . . . . . . . . . . 104
B.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
B.2 Setup and Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
B.2.1 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
B.2.2 Terminations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
B.2.3 Node Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
B.2.4 Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
B.3 Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
B.4 Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
B.4.1 Data Formats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
B.4.2 Memory Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Appendix C Fieldbus - Profibus Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
C.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
C.2 Setup and Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
C.2.1 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
C.2.2 Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
C.2.3 Node Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
C.2.4 Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
C.3 Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
C.4 Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
C.4.1 Data Formats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
C.4.2 Memory Map . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
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Appendix D Recommended Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

Appendix E User Access Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
E.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
E.2 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
E.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
E.4 DSP2 Communication Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
E.4.1 Connection to DSP2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
E.4.2 UAP Communications Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
E.4.3 Connect to DSP2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
E.5 Using the UAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
E.5.1 Not connected to a DSP2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
E.5.2 Connected to a DSP2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
E.5.3 Data Entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
E.5.4 Applying Data to the DSP2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
E.5.5 Configuration via the UAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
E.5.6 Printing Data from the UAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
E.5.7 Save File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
E.6 UAP Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
E.6.1 DSP2 Main Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
E.6.2 Navigation Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
E.6.3 DSP2 (name); Operations Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
E.6.4 DSP2 Setup Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
E.6.5 Setup Sub-Menu Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
E.6.6 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
E.7 Example of DSP2 Setup and Configuration Summary Printout . . . . . . . . . 129
Appendix F Tensiometer Calibration Information Sheets, Forms 858 and 855 . . . . 133
F.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
F.2 Form 858 Tensiometer Application Data Sheet . . . . . . . . . . . . . . . . . . . . . . 134
F.2.1 Fixed Wrap Angle (Form 858) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
F.2.2 Variable Wrap Angle Systems (Form 859) . . . . . . . . . . . . . . . . . . . . 135
F.3 Form 855 Tensiometer Calibration Data Sheet . . . . . . . . . . . . . . . . . . . . . . 138
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iv
KELK Warranty
WARRANTY
The KELK Rollmax Digital Signal Processor, Model DSP2, is warranted against
defects in materials and workmanship for one year from the date of installation or
eighteen months from the date of shipment, whichever occurs first. This warranty
is independent of the KELK Rollmax Load Cell Five Year Conditional Warranty.
Should the equipment prove defective during the warranty period, KELK’s
obligation is limited to repair or replacement at our factory or, at our option, at the
premises of our designated local agent. Should the customer not wish to return
the product to the KELK factory or local agent for repair or replacement, KELK
will, if feasible, perform the necessary work at a suitable location in the
customer’s premises free of any charges for replaced materials or components
providing that he agrees to pay KELK’s standard hourly service rates for site and
travel time, plus transportation costs and living expenses at cost.
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

KELK Precautions
PRECAUTIONS
Intended Use
The Rollmax Digital Signal Processor, Model DSP2, is intended for use only with
factory calibrated KELK strain gage sensors in load measuring systems. Do not
use the DSP2 in a manner not expressly described in this manual or approved by
authorized KELK personnel or their agents. The outputs and the alarms will be
unpredictable, both the DSP2 and the equipment to which it is connected may be
damaged and the protection provided by the DSP2 may be impaired.
Installation, Setup and Configuration
The DSP2 must be installed, setup and configured as specified in Part 4,

Installation, and Part 5, Setup and Configuration. If not properly installed, setup
and configured, the outputs and alarms will be unpredictable, both the DSP2 and
the equipment to which it is connected may be damaged and the protection
provided by the DSP2 may be impaired.
Accessibility
The DSP2 enclosure is tool accessible and should only be opened by qualified
service personnel. Always disconnect the DSP2 from the power source before
removing the cover. Do not reconnect power until the cover has been replaced
and secured. The only permissible user service, the replacement of printed circuit
boards, does not require the application of power while the cover is removed.
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KELK Precautions
Warnings and Cautions
The DSP2 is marked with IEC 61010 symbols to warn the user of items requiring
particular attention for safety reasons.
!? Caution, refer to accompanying documents.
? Caution, risk of electric shock.
Protective Conductor Terminal.
Cautions are included in this manual to advise of hazards to which equipment

may be exposed.
Persons undertaking the installation, commissioning, operation and service of the

DSP2 must pay careful attention to these Warnings and Cautions.
Electrostatic Damage
Electrostatic discharge (ESD) can damage static

sensitive components used in the DSP2. To prevent
ESD, follow the guidelines given in Part 8,
Maintenance, when handling, removing and installing
printed circuit boards.
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March 2008
KELK About This Manual
PART 1 ABOUT THIS MANUAL
Information is provided for installing, operating and servicing the Rollmax Digital Signal
Processor, Model DSP2, as part of a KELK Roll Force, Pressure or Tension Measuring
System in metals rolling mills, or KELK Load Measuring System in metals and ore
processing applications.
Users of this manual must pay particular attention to the Precautions section at the front
of the manual and to all Warnings and Cautions contained herein.
If additional technical assistance is required, contact KELK at the address given on the
title page or our designated agent.
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.
DSP2 90348 Rev F2

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KELK Description
PART 2 DESCRIPTION
2.1 Features
The Rollmax Digital Signal Processor, Model DSP2, Figure 2.1, is a principal component
of KELK load measuring systems. It complements KELK strain gage sensors, providing
optimum performance in metal rolling, temper, and skin pass mills, metal and ore
processing, and other demanding industrial applications.
Figure 2.1 Rollmax Digital Signal Processor, Model DSP2
KELK measuring systems employ strain gage technology to ensure fast response,
excellent linearity and low hysteresis, and to permit the design and construction of very
robust sensors incorporating a one piece load sensing element.
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KELK Description
The DSP2 supports two sensors; it features:
Sensor excitation and signal conditioning

Individual, sum and difference load measurement, with Analog and Digital outputs
Load level and rate-of-change-of-load alarms
Wrap Angle Compensation (WAC) for varying wrap angle tension measuring
applications
Single Sensor Operation

Auto Zero
Auto Calibration
Self Test
Lockout - to control user access
Menu driven setup and configuration. No manual hardware adjustments are required.
Continuous monitoring of the measuring system, including the DSP2 and the sensors
Load Simulation
2.2 Hardware Configuration
The DSP2, Figure 2.2, comprises:
A Signal Processor Board containing the digital signal processing electronics and
Logic I/O’s.
Two Strain Gage Interface Boards, providing sensor excitation and analog signal
processing, one for each sensor.
One Analog Output Boards, with two user configurable outputs.
A Power Supply.
A Front Panel User Interface Assembly.
Plus optional boards, installed as required to suit the application:
One or two additional Analog Output Boards, for a maximum of six Analog Outputs.
A Fieldbus Card for the high speed transmission of digital data using Ethernet
(Modbus/TCP) or Profibus protocols.
An Auxiliary Analog Input Board for inputting analog wrap angle data in varying
wrap angle tension measuring applications.
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KELK Description
Figure 2.2 DSP2 Configuration
The DSP2 is housed in a 19 inch rack mounting enclosure.
The power switch, fuse and all connections are located on the rear panel.
2.3 Signal Processing, Load Outputs and Alarms
Basic on-line signal processing for roll force, pressure, fixed wrap angle tension and load
measuring applications is shown in Figure 2.3. Signal processing for variable wrap angle
tension measuring applications is shown in Figure 2.4. Only one Analog Output and one
Load Alarm are shown - all Analog Outputs (up to six) and all Load Alarms (up to 4) can
be independently configured as the user pleases.
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KELK Description
For roll force, pressure, fixed wrap angle tension and load measuring applications:
1. Zero offsets are applied to the sensor signals.
2. Gain adjustments are applied to yield Channel A and Channel B loads.
3. The sum (A+B) load and difference (A-B) load are calculated to complete the Load
Measurement Set. Only one Load Measurement Set is shown; however, there are
two. One includes user configurable signal filtering and is the source for the 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 Fieldbus Interface.
through the Analog Outputs. Each output can be configured for load A, B, A+B
or A-B, for scaling factor and for voltage or current format.
5. The Load Alarms can be configured for load level or rate-of-change-of-load, for load
A, B, A+B or A-B, for threshold and for response time.
The zero offsets (Step 1) and gains (Step 2) are applied in two stages:
During analog signal processing - to coarse levels, set by the DSP2 during
Configuration to provide optimum resolution following A/D conversion.
(Configuration is performed during installation to calibrate the measuring system
and apply tare weight compensation.)
During subsequent digital signal processing - to fine tune the offsets and gains for
any adjustments introduced by Auto Calibration and Auto Zero.
The Load Measurement Set is also accessible, at a rate suitable for monitoring and data
logging purposes, through the Serial Communications Interface.
For tension applications, with varying wrap angles, signal processing is as described
above except that a scaling factor is applied following gain adjustment to compensate for
the changes in the angles. The scaling factor is calculated using lookup tables, entered
during setup, and sensor or manual inputs of wrap angle magnitude.
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KELK Description
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 Load
Channel B Load Normal operation
Single Sensor A
Operation Invoked
Load Measurement Set
Channel A + Channel A -
Channel A Channel B
Channel B Channel B
Output Scale Threshold

Fieldbus Interface
Alarm
Load
Serial Analog Output
or
Communications A, B, A+B or A-B
Rate-of-Change-of-Load
Interface A,B, A+B or A-B
Figure 2.3 Basic Signal Processing - Roll Force, Pressure and Fixed Wrap Angle
Tension Measuring Applications
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KELK Description
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
Wrap Angle Input 1 Wrap Angle Input 2
Lookup Table 1 Lookup Table 2
Wrap Angle Wrap Angle

Wrap Angle Scaling Factor
Scaling Factor Scaling Factor
Channel A Channel B
Channel B Load Normal operation
Load Load
Single Sensor A
Operation Invoked
Channel A + Channel A -
Channel A Channel B
Channel B Channel B
Output Scale Threshold

Fieldbus Interface
Alarm
Load
Serial Analog Output
or
Communications A, B, A+B or A-B
Interface A,B, A+B or A-B
Figure 2.4 Basic Signal Processing - Variable Wrap Angle Tension Measuring
Applications
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KELK Description
2.4 Auxiliary Functions

2.4.1 Single Sensor Operation
Single Sensor Operation, otherwise known as load doubling, connects both Channel A
and B registers in the Load Measurement Set to the same sensor channel. User initiated,
it provides an output on both channels in the unlikely event of a sensor or Strain Gage
Interface Board failure.
2.4.2 Auto Zero
Auto Zero compensates for small changes in tare weight, without affecting other
measuring system settings. User initiated, it adjusts the fine offsets to set both channel
outputs to zero and indicates if a detected offset falls outside a range of ± 20% of the
defined channel input range.
2.4.3 Auto Calibration
Auto Calibration allows the user to ensure that the load measuring system has remained
in calibration. It fine tunes the zero offsets and gains to set the outputs of both channels
to zero and recalibrate the system.
2.4.4 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.
2.4.5 Self Test
The Self Test is performed automatically each time the DSP2 is turned on. It can also be
initiated manually. Temporarily freezing the Digital and Analog Outputs, it includes
more extensive testing than is possible during normal system operation but undertakes no
corrective actions.
2.4.6 Reset
When initiated, Reset has the same effect as turning on the system. The system is
initialized and normal operation commenced.
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KELK Description
2.4.7 Lockout
Lockout prevents changes being made to the system setup and the use of Configuration,
Reset and Simulation. Single Sensor operation, Auto Zero and Auto Calibration and
Self Test are not locked out.
2.5 Setup and Configuration
The DSP2 can be setup and configured with the User Access Program or through the
Front Panel Interface. No hardware adjustments are required. The interfaces are
described in Part 4. Setup and Configuration are described in Part 5.
2.6 Diagnostics
The DSP2 monitors measuring system performance, both continuously during on-line
operation and in response to Self Test and other auxiliary functions. System status is
annunciated:
For operational purposes, by Logic Outputs (Section 2.7.7) and through the user and
communications interfaces as described in Section 6.4.
For troubleshooting purposes, through the user and communications interfaces as
described in Section 7.1.
2.7 Interfaces
The interfaces, and their functions, are listed in Table 2.1.
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KELK Description
Function Interface
Input, Output, Control, Indicator
Auxiliary Analog Inputs
Serial Communications
User Access Program
Front Panel Interface
Disabled by Lockout
Analog Outputs
Logic Outputs
Logic Inputs
Sensor Ports
Fieldbus
Inputs
Sensors x
Wrap Angle Input - On-line Mode x x
Load Outputs (For mill control) x x
Load Alarm Indication x x x x x
Operations
Load Monitoring and Display x x x x
Status Indication - Electronics Healthy x x
System Fault x x x
Channel A Fault x x x
Channel B Fault x x x
Single Sensor Op. x x x
Single Sensor Operation - Invoke x x x x x
- Revoke x x x
Auto Zero x x x x x
Auto Calibration x x x x x
Wrap Angle Input - Off-line Mode x x x x
Self Test x x x
Reset x x x
Lockout x x
Setup and Configuration x x x
Diagnostics
System Status x x x x
Calibration Data x x
Wrap Angle Compensation x x
Load Simulation x x x
Hardware and Firmware Data x
Table 2.1 Interfaces
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KELK Description
2.7.1 Sensor Ports

The Sensor Ports connect directly to the Strain Gage Interface Boards, which provide
sensor excitation, signal amplification and conditioning, and A/D conversion.
2.7.2 Auxiliary Analog Inputs

The Auxiliary Analog Input Board has two, group isolated, voltage inputs. It is installed
if wrap angle sensor data are to be input in analog format.
2.7.3 Analog Outputs

Up to three Analog Output Boards may be installed. Each contains two group isolated
outputs which can be independently configured as a ± 10 V, 4 - 20 mA or 0 - 20 mA
output to represent a percentage of an individual load (Channel A or B), the sum of the
loads (A+B) or the difference between the loads (A-B).
2.7.4 Fieldbus Interface

The Fieldbus Interface, available in Ethernet (Modbus/TCP) or Profibus protocol:
Gives access to the Load Measurement Set at a rate suitable for mill control.
Provides access for monitoring and controlling the DSP2.
Allows wrap angle data to be input.
The Ethernet (Modbus/TCP) and Profibus Interfaces are described in Appendices B and
C, respectively.
2.7.5 Serial Communications Interface

The Serial Communications Interface:
Provides access for monitoring and controlling the DSP2.

Allows wrap angle sensor data to be input in off-line mode Wrap Angle Compensation.
RS232 and RS485 modes are available. All DSP2’s employed in a mill can be connected
in RS485 mode to the mill computer.
The load data output over this interface are intended for data logging and monitoring purposes
only. For mill control, the higher output rate of the Fieldbus Interface is required.
The Serial Communications Interface is described in Appendix A.
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KELK Description
2.7.6 Front Panel Interface
The Front Panel Interface provides access for system setup, monitoring and control. It
comprises an alpha-numeric display, keypad, and status indicators. It is described in
Section 3.3.
2.7.7 Logic Inputs and Outputs
Logic Inputs are provided for the initiation of 6 functions:
Self Test.
Auto Calibration.
Auto Zero.
Single Sensor A Operation.
Single Sensor B Operation.
Lockout.
The functions are initiated by a user supplied voltage pulse or external contact closure.
There are 8 Logic Outputs:
System Fault - mechanical Form C relay; de-energized to indicate a measuring

system fault or loss of electrical power. The user can select the contact sense.
Channel A Fault - normally open, Form A, solid state relay; closure indicates a
fault condition.
Channel B Fault - normally open, Form A, solid state relay; closure indicates a
fault condition.
Single Sensor Operation - normally open, Form A, solid state relay; closure
indicates Single Sensor Operation.
4 load level, or rate-of-change-of-load, user assignable Load Alarms - normally
open, Form A, solid state relays; closure indicates user selected threshold has been
exceeded.
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KELK User Interface
PART 3 USER INTERFACE
3.1 Introduction
The user can setup, configure, monitor and control the measuring system:
with a Laptop or PC using the User Access Program (UAP), or

At the Front Panel Interface (FPI).
All functions are accessible through both interfaces.
3.2 User Access Program
The User Access Program (UAP) operates in a Windows environment and is menu
driven. It is supplied on a CD for installation on a user supplied PC or laptop.
Refer to Appendix E for details.
Two communication modes, RS232 or RS485, are available. Only one can be in use at
any time.
Load data output over this interface are intended for data logging and user monitoring
purposes only. For mill control, the higher output rate of the Fieldbus Interface is
required.
The UAP has a simple hierarchical structure:
Title Page
Operations Panel
Setup
Input Channels
Analog Outputs
Load Alarms
Wrap Angle Compensation
Communications
Front Panel Displays
Diagnostics Status Screen
Configuration Data
Hardware Identification
Factory Calibration
Simulation
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KELK User Interface
The Operations Panel displays the system operational condition and provides access to all
DSP2 control functions described in Part 6.
The Setup Summary Panel is the entry point for Setup and Configuration, described
in Part 5.
The Diagnostics Panel provides detailed fault identification for troubleshooting purposes,
load simulation and system test, described in Part 7.
On screen help is available.
3.3 Front Panel Interface
MENU ESC CAL
ENTER
ZERO
Figure 3.1 Front Panel
The Front Panel Interface comprises:
An alpha-numeric display and keypad to provide access for system setup,

configuration and control, using simple menu driven procedures.
System Status Indicators:

Electronics Healthy.
System Fault.
Channel A Fault.
Channel B Fault.
Single Sensor Operation.
Four Logic Output (Load Alarm) Indicators.
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KELK User Interface
3.3.1 Display and Keypad
In this manual, all references to keys are in upper case, e.g. ENTER and all displayed
menu items, parameters and functions are in bold print e.g. LoadDisp.
The display contains eight alpha-numeric characters.
The keypad contains nine keys:
ENTER To navigate the menu, edit a variable parameter and initiate a diagnostic process.
ESC To navigate the menu.
←→ To navigate the menu and edit a variable parameter.
↑↓ To edit a variable parameter and initiate a diagnostic process.
MENU To return to the menu entry point from any location in the menu.
ZERO To initiate Auto Zero. This key is independent of menu operation.
CAL To initiate Auto Calibration. This key is independent of menu operation.
3.3.2 Menus
The menu has a hierarchical structure. The complete menu is illustrated in Figure 3.2. It
comprises the Main Menu, illustrated in Figure 3.5, which leads to lower level menus,
Figures 3.6 to 3.15. Note: In this version of the manual, there are no figures
designated 3.3 and 3.4.
The Self Test, Configuration and Reset functions in the Main menu (Figure 3.5) and the
parameters in the Load Display menu (Figure 3.6) are discussed in Part 6, Operation.
The parameters in the Setup menus (Figures 3.7 to 3.13) are discussed in Part 5, Setup
and Configuration.
The parameters in the Diagnostics (Figure 3.14) and Calibration (Figure 3.15) menus are
discussed in Part 7, Troubleshooting.
When the signal processor is first switched on, BootDSP2, then Reset is displayed for
several seconds and is automatically followed by WAIT!!! which is then automatically
followed by KELKDSP2, the menu entry point. Then, if there is no user intervention
for a user selected time interval, a user selected default parameter, or series of parameters,
is displayed.
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KELKDSP2 LoadDisp Setup Diagnose Reset N Config_N Self_T N
KELK
March 2008

Ver 1.10 Reset N Config N Self_T N

Status TareLoad WAC Cal_Disp Load_Sim Reset Y Config Y Self_T Y
DSP2 90348 Rev F2

Sim__OFF SimA_100 SimB_100

W1in0999 W2in1000 Wf01.000 Sim__OFF SimA099 SimB099

Sim_Shnt

Atar+022 Btar-010 ChannelA ChannelB Sim_User

Bhz01021 Bhg01021 Bz-00032 Bg_60002 Bex00402
FltA0FF0 FltB0F00 FtlEl_0F Temp30.1 Ahz01021 Ahg01021 Az-00222 Ag_60002 Aex00402
InpChSet AnaChSet RelaySet ComunSet WAC User Int

AnaOut 1 AnaOut 2 AnaOut 6 Relay__1 Relay__4 FS#200.0 DMT_1800 DCT_02.0 DispMenu

FS#1000. DMT_1800 DCT_02.0 Items 1
Out1_OFF O1_V_10_ O1Scl100 Rel1_OFF R1md__Ld R1T100.0 R1Tim010

Out1_OFF O1_V_10_ O1Scl100 Rel1_OFF R1md_Ld R1T100.0 R1Tim 010 WAC__1_ WAC__2_

Figure 3.2

Out1__A_ O1mA4-20 Rel1__ A_ R1md_Rt+

Out1__B_ O1mA0-20 Rel1__B_ R1md_Rt- W1Sc_OFF W1in0999 W1_Table

16

Out1A+B_ Rel1A+B_ W1Sc_OFF W1in1000

Out1A-B_ Rel1A-B_ W1Sc_Man 11 T9999 121T9100

W1Sc_Ain 11 T9050 121T9050

AppForce Shnt100k A CTL B CTL Filtr001 InpA&Bon
W1Sc_Fbs

AppForce Shnt_50k AT099.99 BT099.99 Filtr999 InpA&Bon

Serial FieldBus
Complete Menu
App_Tens Shnt100k AT099.99 BT099.99 Inp__2xA

Addr_254
App_Pres Shnt150k Inp__2xB
LEGEND

Addr_254
Shnt200k
MENU ORIGIN ( KELKDSP2 ) OR RETURN
MENU
Shnt250k ComRS232 Addr_254 Baud9600 TO MENU POSITION FROM DEFAULT.

Addr_254 NAVIGATE BETWEEN MENU LEVELS,
Shnt300k ComRS232 Baud 9600 ENTER ACCEPT EDIT, INITIATE PROCESS.

Shnt350k ComRS485 Baud _19k

UNDO PREVIOUS SELECTION OR
ESC
NAVIGATION.
Shnt400k Baud _38k NAVIGATE WITHIN MENU LEVEL
EDIT PARAMETER.
Baud _57k EDIT PARAMETER.
A/B BarG Channel A Channel B Sum CAL INITIATE AUTO-CALIBRATION.

Σ/∆ BarG Diff

Α+ Σ+ ZERO INITIATE AUTO-ZERO.
Β+ ∆− A%+ 98.1 A#+1902. B%+102.1 B#+2042. Σ%+ 99.1 Σ#+4004. ∆%- 3.9 ∆#+ 79.
User Interface
KELK User Interface
Menus are navigated using the ENTER, ESC, ←, → and MENU keys.
ENTER To move to a lower level in the menu structure or select a parameter or

function.
ESC To undo the previous menu selection and return to the higher level in the
menu structure.
←→ To cycle between available items on the same level within the menu
structure.
MENU To return:
from any location in the menu to KELKDSP2.
from the default display, to the last accessed point in the menu.
The variable parameters in the Setup menu are edited using the ENTER, ←, ↑, ↓, → and
ESC keys.
To edit a variable parameter:
1. Navigate to the parameter.
2. Press ENTER, part of the parameter flashes.
3. There are two types of variable parameter:
When a selection is to be made from a range of available options, use the ↑ or ↓

key to select the desired option. Press ENTER to enter it into memory. The
display stops flashing.
When a value is to be entered, set it within the prescribed range using the ← and
→ keys to cycle between the digits and the ↑ and ↓ keys to scroll the digits. Press
ENTER to enter it into memory. The display stops flashing. If the value is out of
range, it will not be accepted; the value must be set within the prescribed range
and the ENTER key pressed again.
If ESC is pressed during an edit, the edit is abandoned and the setting already in memory
is retained and displayed. The display stops flashing.
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KELK User Interface
If MENU is pressed during an edit, the edit is abandoned and the setting already in
memory is retained. The display returns to the menu entry point, KELKDSP2, and stops
flashing.
Functions are initiated with the ENTER, ↑ and ↓ keys. To initiate a function:
1. Navigate to the function.
2. Press ENTER, the “N” part of the function flashes.
3. Press either ↑ or ↓ to change “N” to “Y”.
4. Press ENTER to initiate the process. After completing the process, the “Y” reverts to
“N” and the display reverts to the normal illumination level.
5. WAIT!!! is displayed until the process is completed.
6. "Y" reverts to "N" (not flashing).
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KELK User Interface
ENTER
KELKDSP2 VER XXX Installed Software Version
ESC
Load Display Menu

LoadDisp
For displaying measured loads
Setup Menu
Setup
For entry of user selected parameters
Diagnostics Menu
Diagnose
For accessing diagnostics data
Reset N For initiating a Reset
Config N For initiating Configuration
Self T N For initiating a Self Test
Navigate using left and right arrow keys.

To enter a submenu, press ENTER.
To return to KELKDSP2 from anywhere in any menu, press MENU.
Figure 3.5 FPI Main Menu
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KELK User Interface
ENTER Bar Graphs

LoadDisp A/B ====
ESC Channels A & B
Bar Graphs
Σ/∆ ====
A+B & A-B
ENTER Channel A Load

ChannelA A% XX.XX
ESC % Full Scale
Channel A Load
A# XX.XX
User Designated Units
ENTER Channel B Load

ChannelB B% XX.XX
ESC % Full Scale
Channel B Load
B# XX.XX
ENTER Channel A + Channel B

Sum Σ% XX.XX
ESC % Full Scale
Channel A + Channel B
Σ# XX.XX
ENTER Channel A - Channel B

Diff ∆% XX.XX
ESC % Full Scale
Channel A - Channel B
∆# XX.XX
Navigate between parameters
using left and right arrow keys.
Figure 3.6 FPI Load Display Menu
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KELK User Interface
ENTER
Setup InpChSet Input Channels
ESC
AnaChSet Analog Outputs
RelaySet Load Alarms
ComunSet Communications
WAC Wrap Angle Compensation
User Int FPI Display
Navigate between features using left and right arrow keys.

To enter a feature menu, press ENTER.
Figure 3.7 FPI Setup Menu
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KELK User Interface
ENTER Application
InpChSet AppForce
ESC Roll Force, Tension or Pressure
Calibration Shunt Resistor

Shnt 50k
50, 100, 150, 200, 250, 300, 350, or 400 kOhm
ENTER Sensor A Calibration Target Load

A CTL ATXXX.XX
ESC Range 020.00 to 150.00 %
ENTER Sensor B Calibration Target Load

B CTL BTXXX.XX
ESC Range 020.00 to 150.00 %
Filter
FiltrXXX
Range 001 to 999
Source
Inp A&B
A&B, 2xA or 2xB
Navigate between parameters using left and right arrow keys.
To set - Press ENTER. Select from available options using up and down arrow keys.
Press ENTER.
To set - Press ENTER. Enter required value using left and right arrow keys to select
digit, and up and down arrow keys to increment digit. Press ENTER.
Figure 3.8 FPI Setup - Input Channels
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KELK User Interface
ENTER ENTER Source

AnaChSet AnaOut 1 Out1 A
ESC ESC Off, A, B, A+B or A-B
Mode
O1 V 10
± 10 V, 4 - 20mA, 0-20mA
Output Scale Factor

O1Scl XXX
Range 001 to 999
AnaOut 2 to
Same as AnaOut 1
AnaOut 6
Figure 3.9 FPI Setup - Analog Outputs
ENTER ENTER Source

RelaySet Relay 1 Rel1 A
ESC ESC Off, A, B, A+B or A-B
Mode - Load Level or

R1md Ld
Threshold
R1TXXX.X
Range 001.0 to 150.0
Time
R1TimXXX
Range 001 to 999 ms
Relay 2 to
Same as Relay 1
Relay 4
Press ENTER.
Figure 3.10 FPI Setup - Load Alarms
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ENTER ENTER Mode

ComunSet Serial ComRS232
ESC ESC RS232 or RS485
Address
Addr XXX
Range 001 to 254
Baud Rate
Baud9600
9600, 19K, 38k or 57k
ENTER Address
Fieldbus Addr XXX
ESC Range 001 to 254
Press ENTER.
Figure 3.11 FPI Setup - Communications
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ENTER ENTER Source - Off, Manual,

WAC WAC 1 W1Sc OFF
ESC ESC Analog or Fieldbus
Wrap Angle Value

W1inXXXX
Range 0000 to 1000
W1Table W1 Table
Table Entry # 1
11 TXXXX
Range 0000 to 9999
Table Entry # 2
12 TXXXX
Range 0000 to 9999
Table Entry #21

121TXXXX
Range 0000 to 9999
WAC 2 Same as WAC 1
To set - Press ENTER key. Select from available options using up and down arrow keys.
Press ENTER Key.
To set - Press ENTER key. Enter required value using left and right arrow keys to select
digit, and up and down arrow keys to increment digit. Press ENTER Key.
Figure 3.12 FPI Setup - Wrap Angle Compensation
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ENTER Scale Factor

User Int FS#XXX.XX
ESC Range 1.000 to 9999
Time Out
DMT XXXX
Range 0015 to 1800 Seconds
Display Time
DCT XX.X
Range 02.0 to 25.0 Seconds
ENTER Live Display menu

DispMenu Items N
ESC size. 8 maximum.
To set - Press ENTER. Enter required value using left and right arrow keys to
select digit, and up and down arrow keys to increment digit. Press ENTER.
Scan to view parameters selected for automatic display using left and
right arrow keys.
To add a parameter for automatic display:
- navigate to the desired parameter at any location in the menu,
- press up arrow key,
- press down arrow key,
- press up arrow key.
To remove a parameter from automatic display:
- select parameter at this location using up and down arrow keys,
- press up arrow key,
- press down arrow key,
- press up arrow key.
Figure 3.13 FPI Setup - FPI Display
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ENTER ENTER Hex sum of Channel A

Diagnose Status FltAXXXX
ESC ESC Status Messages
Hex sum of Channel B

FltBXXXX
Status Messages
Hex sum of Electronics

FltEl XX
Status Messages
Temp XX.X Internal Temperature oC
ENTER Channel A tare load as % of

TareLoad Atar XXX.X
ESC Sensor Capacity
Channel B tare load as % of

Btar XXX.X
Sensor Capacity
ENTER
WAC W1inXXXX Wrap Angle Value W1
ESC
W2inXXXX Wrap Angle Value W2

WfXX.XXX
Scale Factor
Cal Disp Calibration Menu
ENTER Enable Simulation

Load Sim Sim OFF
ESC Off, Shunt or User
Navigate between functions using left and right arrow keys. Channel A
SimA XXX
To set - Press ENTER. Select from Range 000 to 150 %
available options using up and down arrow
keys. Press ENTER. Channel B
SimB XXX
Range 000 to 150 %
To set - Press ENTER. Enter required
value using left and right arrow keys to
select digit, and up and down arrow keys to
increment digit. Press ENTER.
Figure 3.14 FPI Diagnostics Menu
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ENTER ENTER
Cal Disp ChannelA Ahz XXXX Coarse (Hardware) Offset
ESC ESC
Ahg XXXX Coarse (Hardware) Gain
Az XXXXX Fine (Software) Offset
Ag XXXXX Fine (Software) Gain
Aex XXXX Excitation Current
ChannelB Same as Channel A
Navigate between parameters using left and right arrow keys
Figure 3.15 FPI Calibration Menu
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KELK Installation
PART 4 INSTALLATION
4.1 Introduction
KELK load measuring systems are designed, and have been proven over many years, to
provide excellent performance in the demanding environments of the metals industry.
However, to achieve their full potential for high accuracy and long service life, they must
be properly installed.
Following installation, the system must be setup and configured before being placed in
on-line service, see Part 5.
Caution
! If the system is not properly setup and configured, the
Digital and Analog Outputs and the Load Alarms are
unpredictable and their use for mill control purposes
may cause the production of off-specification product
or mill damage.
If power is 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 the production of
off-specification product or mill damage.
The Rollmax Digital Signal Processor, Model DSP2, must be installed:
In an operating environment with the characteristics specified in Section 9.10.

Ensure that sufficient clearance is provided for cooling. If free standing, a
minimum clearance of 6 mm (0.25 in) above the bench or desk surface is required.
Do not place anything on top of DSP2. If mounted in a cabinet or other enclosed
space, ensure that the temperature adjacent to the DSP2 does not exceed 40 oC
(104 oF) and provide adequate clearance for air flow. Mount a minimum of
75 mm (3 in.) above heat generating equipment.
So that the user has easy access to the power cord and switch.
With a minimum of 75 mm (3 in.) clearance behind the unit for cabling.
The DSP2 and any cabinet in which it is installed, together with all connecting wiring
must be installed in compliance with all applicable codes, regulations and standards.
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4.2 Cabinets
For rolling mills, grinding mils and other heavy industrial applications, the DSP2 should
be installed in a 19 inch rack mounting cabinet providing appropriate environmental
protection, such as the KELK floor standing and wall mounting models.
When installing a cabinet:
Use the lifting lugs provided on the top of the cabinet for ease of handling.
Provide sufficient clearance for the door to open. A standard KELK cabinet
requires 1450 to allow the rack to be fully opened for service.
Secure floor mounting cabinets to the floor or wall to prevent tipping. This is
particularly important for cabinets with swing out racks. KELK Floor Mounted
Cabinets are supplied with four holes in the base for M 12 or ½ in. bolts.
Secure wall mounting cabinets to a wall or other supporting structure. KELK

Wall Mounted Cabinets are supplied with four holes in the rear mounting flanges
for M 12 or ½ in. bolts.
! Warning
If a cabinet is not properly secured, it may tip or fall,

injuring personnel and damaging the cabinet and its contents.
All conduit entries should be caulked to exclude dust.
4.3 Wiring
All connections to the DSP2 are on the rear panel, Figure 4.1.
Detailed drawings 43057 and 42945 (or a customer specific equivalent) are included at
the end of this manual to illustrate DSP2 cabinet installation and connection wiring.
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Figure 4.1 DSP2 Connections
All signal wiring connected to the DSP2 must be from SELV (Separated Extra Low
Voltage) sources in accordance with IEC 61010-1 annex H, Safety requirements for
electrical equipment for measurement, control and laboratory use.
Warning
! Connecting to other than SELV sources may cause the

application of an excessive voltage to the DSP2 if a
source malfunctions.
All connections, except for the Fieldbus, are described in this section. The Fieldbus
connection is described in Appendices B and C.
If the DSP2 is installed in a cabinet, a power outlet should be provided in the cabinet and
all signal wiring should be connected via terminal blocks mounted in the cabinet.
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4.3.1 AC Power Wiring
The DSP2 must be connected to a power source with the characteristics specified in
Section 9.9. It adjusts automatically to the voltage range, typically 120 or 240 VAC, to
which it is connected. It must be properly grounded.
The DSP2 is supplied with a power cable and plug. The power cable connections are
shown in Figure 4.2.
Figure 4.2 Power Wiring
4.3.2 Sensor Wiring
For a new measuring system, recommended wiring practices and instructions are included
in the documentation supplied with the system.
For existing systems, it is strongly recommended that the sensor wiring be checked
against KELK recommendations and serviced, if necessary, to ensure optimum system
performance.
Sensor wiring must be rated at least 300V. Terminations must be clean so as not to
introduce contact resistance or leakage to ground. Cables must be run to avoid exposure
to power cables and other potential sources of electromagnetic interference. Good wiring
practices and a dry environment are essential. Typical sensor wiring is shown in
Figure 4.3. Connector pinouts are listed in Table 4.2.
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Figure 4.3 Sensor Wiring
DSP2 TERMINAL BOARD SIGNAL

CONNECTOR-PIN CONNECTION
J1-1 TB11-1 Sensor A +Excitation
J1-2 TB11-2 Sensor A -Excitation
J1-3 TB11-3 Sensor A +Signal
J1-4 TB11-4 Sensor A -Signal
N/C TB11-5 Sensor A Shield
J2-1 TB11-6 Sensor B +Excitation

J2-2 TB11-7 Sensor B -Excitation
J2-3 TB11-8 Sensor B +Signal
J2-4 TB11-9 Sensor B -Signal
N/C TB11-10 Sensor B Shield
Table 4.1 Sensor Connectors
1. The sensor cable hose assemblies must be free of damage and kinks.
2. At the junction box:
The sensor cables should be terminated in a vapour proof junction box. The
junction box should be mounted on a vertical surface, with the sensor cable/hose
entries at the bottom, in a location that precludes the accumulation of mill fluids
and provides good accessibility, e.g. on top of the mill stand.
Open the junction box and inspect all connections. Replace all dirty and corroded
terminal blocks and lugs. Ensure that there are no frayed wires to cause
momentary shorts to ground.
Ensure that the box and all internal components are dry. If moisture is seen or
suspected, dry with alcohol.
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Ensure that the cable shields are electrically isolated from the box ground.
Check the cable entry points; reseal, if necessary.
When replacing the junction box cover, ensure that the gasket is properly
positioned. Tighten the bolts sequentially, in two steps (snug, then tight) to
prevent distortion or damage of the cover and gasket.
3. Check the wiring from the junction box to the DSP2:
The minimum wire gage must be:
18 AWG (1.0mm2) for up to 90m (300 ft) runs,

16 AWG (1.5mm2) for up to 150m (500 ft) runs,
14 AWG (2.5mm2) for up to 240m (800 ft) runs.
A four conductor twisted (in pairs or all together) shielded cable, with insulating
jacket, is recommended.
16 AWG (1.5mm2) cable is available from KELK, Part Number 28280.
The preferred routing is through metal conduit. However, the cable may, after
leaving the junction box in a conduit, be run in low signal cable trays. When run
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.
4. With the interconnecting cable not connected to the DSP2, check the sensor and
interconnecting cable wiring for:
Continuity. Using an Ohmmeter with a resolution of 0.1 Ohm, measure the input
resistance between the green and black conductors and the output resistance
between the red and white conductors. The measured values should be within
1 Ohm of those given on the Calibration Card supplied with the sensor, plus the
resistance of the interconnecting cable.
The resistance of the interconnecting cable can be determined by direct

measurement or from:
Wire Gage Resistance - each conductor

14 AWG (2.5mm2) 0.0084 Ohm/m (0.0026 Ohm/ft.)
16 AWG (1.5mm2) 0.0133 Ohm/m (0.0041 Ohm/ft.)
18 AWG (1.0mm2) 0.0209 Ohm/m (0.0064 Ohm/ft.)
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Leakage resistance. Measure leakage resistance between any conductor and the
cable shield, between any conductor and ground, and between the cable shield
and ground. The result should be greater than 100 megOhms in each case.
Caution
! Do not use an insulation tester with test voltages in
excess of 50V. Higher voltages may damage the sensor.
If any problems are encountered, test the interconnecting and sensor cables,
Sections 7.6.2 and 7.6.3.
4.3.3 Auxiliary Analog Input Wiring
Analog wrap angle sensor signals are input through the Auxiliary Analog Inputs. Wiring is
shown in Figure 4.4. Connector pinouts are listed in Table 4.2. Connecting cables must
be rated at least 300V. The following cables, or their equivalents, are recommended:
One cable for 2 channels - Belden 8723, 22 AWG. 2 twisted pairs, individually
shielded, or
Separate cables per channel - Belden 9451, 22 AWG. 1 twisted pair, shielded.
Note 22 AWG is equivalent to 0.33-0.38mm2.
Figure 4.4A Auxiliary Analog Input Wiring
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Figure 4.4B Auxiliary Analog Input Circuit

J3-1 TB16-1 Auxiliary Analog Input Ground
J3-2 TB16-2 Voltage In 1
J3-3 N/C
J3-4 TB16-4 Voltage In 2
J3-5 TB16-5 Auxiliary Analog Input Ground
Table 4.2 Auxiliary Analog Input Connector
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4.3.4 Analog Output Wiring
There are two analog outputs in each connector. Each output can be connected for
voltage or current, both are shown in Figure 4.5. An output must not be connected for
both current and voltage at the same time. Connector pinouts are listed in Table 4.3.
Connecting cables must be rated at least 300V. The following cables, or their
equivalents, are recommended:
2 channels - Belden 8723, 22 AWG. 2 twisted pairs, individually shielded, or

2 x 1 channel - Belden 9451, 22 AWG. 1 twisted pair, shielded.
Figure 4.5A Analog Output Wiring: Voltage Mode
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Figure 4.5B Analog Output Wiring: Current Mode
Figure 4.5C Analog Output Circuit
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J6-1 TB13-1 Voltage Out 1
J6-2 TB13-3 Current Out 1
J6-3 TB13-2, 4, 8, 10 Return 1 & 2
J6-Case TB13-6 Shield

J5-3 TB14-2 Return 3 & 4

J4-3 TB15-2, 4, 8, 10 Return 5 & 6
Table 4.3 Analog Output Connectors
4.3.5 Logic I/O Wiring
Logic I/O wiring is shown in Figure 4.6. Connector pinouts are listed in Table 4.4.
Connecting cables must be rated at least 300V. The following cables, or their
equivalents, are recommended:
14 signals plus power - Belden 9736, 24 AWG. 17 twisted pairs, individually

shielded, or
14 x 1 channel - Belden 9501, 24 AWG. 1 twisted pair, shielded.
Note 24 AWG is equivalent to 0.21-0.24mm2.
For the logic inputs:
A user supplied voltage or contact closure can be used, see Figure 4.6b.
Before connecting to the Lockout logic input, remove the factory installed jumper.
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For the logic outputs:
A user supplied voltage is required, see Figure 4.6c. Do not use the DSP2
15 VDC supply; this might overload the supply.
The System Fault relay is de-energized for a fault condition.
Figure 4.6A Logic I/O Wiring
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Figure 4.6B Logic Input Circuit
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Figure 4.6C Logic Output Circuits
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J8-19 TB12-19 15 Volt Return
J8-37 TB12-37 15 Volt Return
J8-18 TB12-18 +15 Volt
J8-36 TB12-36 +15 Volt
J8-17 TB12-17 +Spare 2
J8-35 TB12-35 -Spare 1
J8-16 TB12-16 +Spare 2
J8-34 TB12-34 -Spare 1
J8-15 TB12-15 +Lockout
J8-33 TB12-33 -Lockout
J8-14 TB12-14 +Self Test
J8-32 TB12-32 -Self Test
J8-13 TB12-13 +Single Sensor B Operation
J8-31 TB12-31 -Single Sensor B Operation
J8-12 TB12-12 +Single Sensor A Operation
J8-30 TB12-30 -Single Sensor A Operation
J8-11 TB12-11 +Auto Calibration
J8-29 TB12-29 -Auto Calibration
J8-10 TB12-10 +Auto Zero
J8-28 TB12-28 -Auto Zero
J8-9 TB12-9 Logic Output 4
J8-5 TB12-5 Single Sensor Operation
J8-23 TB12-23 Single Sensor Operation
J8-4 TB12-4 Channel B Fault
J8-22 TB12-22 Channel B Fault
J8-3 TB12-3 Channel A Fault
J8-21 TB12-21 Channel A Fault
J8-2 TB12-2 System Fault (N.O.)
J8-20 TB12-20 System Fault (COM)
J8-1 TB12-1 System Fault (N.C.)
Table 4.4 Logic I/O Connector
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4.3.6 Serial Communications (SCI) Wiring
The serial communications wiring is shown in Figures 4.7A and 4.7B.
The Com 1 (SCI) connector pinouts are listed in Table 4.5.
Figure 4.7A Serial Communications Wiring; RS232
Figure 4.7B Serial Communications Wiring; RS485
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RS232 RS485
J7-1 No Connection No Connection
J7-2 TB17-2 TXD -TXD
J7-3 TB17-3 RXD -RXD
J7-5 TB17-5 Serial Common Serial Common
J7-7 TB17-7 No Connection +RXD
J7-8 TB17-8 No Connection +TXD
Table 4.5 Com 1 (SCI) Connector
Figure 4.8 RS485 Customer Connection Information
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KELK Setup and Configuration
PART 5 SETUP AND CONFIGURATION
5.1 Introduction
Before being placed into service, the measuring system must be setup and configured.
This must always be done when:
A) the system is initially installed
B) the DSP2 is changed
C) sensors are changed
D) the Calibration Target Load is changed.
Setup is the entering of sensor calibration data and the setting of all user selectable
options and parameters. The calibration data are taken into memory and are used by the
DSP2 to set system gain during Configuration. All other entries are immediately and
automatically used by the DSP2 in its operations.
Configuration is user initiated and applies data entered during Setup to calibrate the
measurement system. It must only be performed under static load conditions, i.e., with a
fixed tare load, and no active load, applied.
Configuration sets the load outputs to zero and calibrates the system. It first sets the
analog offsets and gains, then adjusts the digital offsets and gains for optimum system
accuracy.
The DSP2 is normally setup and configured through the User Access Program (UAP).
While the Front Panel Interface (FPI) can be used for this purpose, it is primarily intended
for ongoing system monitoring and service, including setup adjustments. Instructions for
using these interfaces are given in Part 3, User Interface.
A clear understanding of the effects of calibration, scaling, signal filtering and, if

applicable, wrap angle compensation on the Digital and Analog Outputs and the Load
Alarms is essential in order to properly setup and configure the system. Read Sections
5.2 to 5.5 before proceeding with Setup and Configuration.
It is recommended that the Pre Power-up checks given in 5.6 be carried out prior to
proceeding with Setup.
Caution
If the measuring system is not properly setup and configured, the
Digital and Analog Outputs and the Load Alarms are unpredictable
and use of the system for mill control purposes may cause the
production of off-specification product or mill damage.
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5.2 Calibration
Each sensor is calibrated against a high precision, traceable standard at KELK. Sensor
output is measured from zero to full load (Sensor Capacity). Then, with no load applied,
a high accuracy Shunt Resistor is temporarily placed across one arm of the sensor’s strain
gage bridge to unbalance it. The signal produced by this resistor, expressed as a
percentage of Sensor Capacity, is the sensor’s Calibration Target Load. It is in the range
20.00 to 150.00 %.
Each sensor is supplied with a Calibration Card listing:

Model number.
Serial number.
Bridge (one or two).
Sensor Capacity.
Sensitivity - sensor output, in millivolts per volt of applied excitation, at Sensor
Capacity.
The value of the Shunt Resistor.
Output with Shunt Resistor, in millivolts per volt.
Calibration Target Load.
Input Resistance.
Output resistance.
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 (see Section 5.3) for each channel represents 100% of sensor capacity. The
sensor Calibration Target Load is used to directly calibrate the load measuring system.
In tension measuring systems, the magnitude of load applied to the sensor is dependent on
strip tension and the angles at which the strip approaches and leaves the tensiometer roll.
These wrap angles must be accurately known as they are factored into the calibration of
the system. KELK computes Calibration Target Loads for the tensiometer, based on the
mill and strip geometry defined by the user. They are listed in a Tensiometer Calibration
Data Sheet Form 855 supplied with each tensiometer; refer to Appendix F. Individual
sensor calibration cards are supplied also. Typically, such systems are calibrated such
that Full Scale Input for each channel represents 100% of rated tension (not sensor
capacity). Additional compensation is required in varying wrap angle applications, as
discussed in Section 5.5.
Caution
If a tensiometer is operated in a geometry different from that specified on the
Calibration Data Sheet, the Digital and Analog Outputs and the Load
Alarms will be unpredictable and use of the system for mill control purposes
may cause the production of off-specification product or mill damage.
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The Shunt Resistor value and Calibration Target Loads (from the Calibration Cards for
roll force, pressure and load measuring applications, and from the Calibration Data Sheets
for tension measuring applications) are entered into the DSP2 during setup. Then, during
Configuration, the DSP2 computes and sets the analog and fine gains to be applied to the
sensor signals to provide a calibrated output.
The Calibration Target Loads given on Calibration Cards and Calibration Data Sheets are
determined with only the sensor cables connected directly to the calibrating electronics.
Installation in the mill normally involves the use of long interconnecting cables. Each
Calibration Target Load must be corrected to compensate for the effect of this additional
resistance.
1. Determine the resistance of one conductor of the interconnecting cable by

measurement or using:
Wire Gage Resistance
14 AWG (2.5 mm2) 0.0084 Ohm/m (0.0026 Ohm/ft.)

16 AWG (1.5 mm2) 0.0133 Ohm/m (0.0041 Ohm/ft.)
18 AWG (1.0 mm2) 0.0209 Ohm/m (0.0064 Ohm/ft.)
2. Determine Cf, the correction factor:
Cf = 1 + 4 RL
RBR
Where:
RL is the resistance of one conductor of the interconnecting cable.
RBR is the sensor output resistance.
3. Correct the Calibration Target Load:
CTL1 = Cf xCTL
Where:
CTL is the 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
Tensiometer Calibration Data Sheet;
and
CTL1 is the Calibration Target Load corrected for the interconnecting cable
resistance.
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Example:
For a sensor with an output resistance (RBR) of 240 Ohms connected to the signal
processor with 90 meters of 16 AWG (1.5 mm2) interconnecting cable:
RL = 90 x 0.0133 Ohm = 1.2 Ohms
Cf = 1 + 4 x 1.2 = 1.02
240
If the Calibration Card gives a Calibration Target Load of 79.73%, the new
Calibration Target Load is:
CTL1 = 1.02 x 79.73% = 81.32%
5.3 Signal Processing, Limits and Scaling
Channel Input Range definition
The input range for each channel is defined by Calibration (initially carried out during
Configuration). The Calibration routine involves the application of a known resistance to
force an output from the sensor which is applied to the DSP2 input. The value of the
Calibration Target Load entered for each channel defines this input as representing a
percentage of the intended ‘Full Scale Input’. 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. During the Configuration routine the
DSP2 automatically adjusts the input stage gain to maximise the resolution of the input
stage to suit the Full Scale Input plus 20% zero allowance plus 50% over range allowance
plus 5% overhead. This adjustment sets the input saturation at a maximum level of 175%
of FSI; the actual limit is dependent upon the amount of zero allowance utilized at any
given time.
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 that were determined previously by the DSP2
during system setup and Configuration, and any subsequent Auto Zero or Auto
Calibration operation, with the desired tare load applied.
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The application of gains determined previously by the DSP2 during system setup
and Configuration and any subsequent Auto Calibration, based on the sensor
calibration factors (Shunt Resistor value and Calibration Target Loads)
determined during factory calibration.
If the application is Tension Measurement there may be an additional gain
modification factor applied, see Section 5.5.
The Sum Load (Channel A Load + Channel B Load), expressed as a percentage of total
Full Scale Input, and the Difference Load (Channel A Load - Channel B Load), expressed
as a percentage of individual FSI, are computed to complete two Load Measurement Sets,
both comprising A, B, A+B, and A-B. One set includes user configurable signal filtering
and is the source for the digital and analog load outputs. The other is used for the alarms,
and has a separate filter and debounce algorithm.
Within each Load Measurement Set the scaling is fixed at 10000 equivalent to 100% of
the FSI.
The filtered Load Measurement Set is accessible through the Fieldbus Interface and the
Serial Communications Interface.
Front Panel Interface Load Display
The user can select the form of Load display as either bar graph or numeric.
The bar graph displays loads, A and B, or A+B and A-B, each represented as a
percentage of FSI (or total FSI in the case of A+B).
For the numeric display the user can assign a scale factor in the range 1-9999 to define the
full scale value within the resolution of the Load Measurement set, or it can be formatted
to read as a percentage of the FSI. For examble, for a FSI representing 500 T, the display
can be configured to read 0500 (T) or 100.0(%).
Data is derived from the filtered Load Measurement Set, conversion and formatting is
applied, and the result fed to the display.
Analog Output Scaling
The Analog Outputs can be programmed to represent A, B, A+B or A-B and can be
scaled to represent any percentage of the FSI from 1 to 999%. This permits the user to set
these outputs to give the best resolution to meet their needs for example, high resolution
for differential load signals and lower resolution for overload detection. The scale factor,
which can be set from 1-999, indicates the percentage of FSI to be represented by the full
range (10V or 20 mA) of the Analog Outputs.
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Examples:
For normal operation:
Scale factor 100 yields 10V equivalent to 100% FSI
For lower resolution

Scale factor 200 yields 5V equivalent to 100% FSI ((10V equivalent to
200% FSI but user is advised that the limit before saturation of the input
state is 175%)
For higher resolution (for differential signal)

Scale factor 20 yields 10V equivalent to 20% FSI
The load, A, B, A+B or A-B, is read from the filtered Load Measurement Set. An
Output Scale Factor, entered during setup, is applied to yield the Analog Output Load
as a percentage of FSI.
A D/A conversion is executed and the Analog Output Load is output as a voltage or
current signal.
Load and Rate Threshold Limits
Four Logic Outputs can be programmed as Alarms to indicate that a specific load threshold
or rate of change of load threshold has been exceeded. The channel inputs saturate at 175%
of FSI of which 20 % is allocated for zero adjustment. The load threshold that can be
utilized is, therefore, restricted to the range 1-150% of FSI. The Threshold is expressed as
a percentage of: individual FSI for A, B and A-B, total FSI for A+B.
The load, A, B, A+B or A-B, is read from the internally unfiltered Load Measurement Set.
For Rate-of-Change-of-Load Alarms, the load change per millisecond (ms) is

computed.
The load, or load change per millisecond, is compared with a Threshold, entered
during setup.
If the Threshold is exceeded, the Alarm is asserted.
Alarm response time is user selectable. For Load Level Alarms, it is the time the
threshold must be crossed for the Alarm to change state, either to be asserted or
de-asserted. For Rate-of-Change-of-Load Alarms, it is the minimum time for which the
Alarm Logic Output relay is asserted.
See Section 5.8.3 for further details.
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Example:
Application:
Roll force.
Tare load - rolls and chocks.
Sensors
Sensor Capacity: 500 T.
Sensor A Calibration Target Load: 72.63%.
Sensor B Calibration Target Load: 73.18%.
Shunt Resistor: 150 kΩ.
Required Analog Output Full Loads:

A: 400 T.
B: 400 T.
A+B: 800 T.
A-B: 100 T.
Required Alarms:
A equals or exceeds 350 T.
B equals or exceeds 350 T.
The magnitude of A-B, negative or positive, equals
or exceeds 40 Τ.
The rate-of-change-of A+B equals or exceeds
100T/ms.
1. Configuration sets the input gain using the value of shunt resistance and Calibration
Target Load for each sensor to yield a Full Scale Input equivalent to a load of 500T
(sensor capacity). Total FSI is 1000T.
2. Sensor A and B outputs are amplified, digitized, filtered and adjusted to yield
Channel A and Channel B loads. This includes:
The application of zero offsets that were determined previously by the DSP2
during system configuration, and any subsequent Auto Zero, with the desired
tare load applied.
The application of gains determined previously by the DSP2 during system
setup and configuration, based on the sensor calibration factors (Shunt
Resistor value and Calibration Target Loads) as listed above and entered
during setup and configuration.
3. The Sum (Channel A Load + Channel B Load) and Difference (Channel A Load -
Channel B Load) Loads are computed to yield the Load Measurement Sets, both
comprising A, B, A+B, and A-B.
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4. The filtered Load Measurement Set is accessible through the Fieldbus Interface for
mill control purposes.
5. For Analog Outputs A and B:
A and B are read from the filtered Load Measurement Set and their Output Scale
Factors are applied to yield Analog Output Loads as percentages of their Full
Scale Inputs, i.e. as percentages of 500 T. To achieve this, the same Output Scale
Factor of 080, the required Analog Output Full Load (400 T) as a percentage of
individual FSI ( in this case equal to sensor capacity 500 T), was entered for both
outputs during setup.
D/A conversions are executed and the loads are output as voltage or current
signals.
6. For Analog Output A+B:
A+B is read from the filtered Load Measurement Set and the Output Scale Factor
is applied to yield the Analog Output Load as a percentage of total FSI, i.e. as a
percentage of 1000 T. To achieve this, an Output Scale Factor of 080, the
required Analog Output Full Load (800 T) as a percentage of total FSI (1000 T),
was entered during setup.
A D/A conversion is executed and the load is output as a voltage or current signal.
7. For Analog Output A-B:
A-B is read from the filtered Load Measurement Set and the Output Scale Factor
is applied to yield the Analog Output Load as a percentage of individual FSI, i.e.
as a percentage of 500 T. To achieve this, an Output Scale Factor of 020, the
required Analog Output Full Load (100 T) as a percentage of individual FSI
(Sensor Capacity 500 T), was entered during setup.
A D/A conversion is executed and the load is output as a voltage or current signal.
8. For Load Level Alarms A and B:
A and B are read from the unfiltered Load Measurement Set and compared to their
Thresholds of 350 T. To achieve this, a Threshold of 070.0, (350 T) expressed as
a percentage of individual FSI (500 T), was entered for both Alarms during setup.
An Alarm is asserted if the Threshold is exceeded.
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9. For Load Level Alarm A-B:
A-B is read from the unfiltered Load Measurement Set and compared to its
Threshold of 40 T. To achieve this, a Threshold of 008.0, the required Threshold
(40 T) expressed as a percentage of individual FSI (500 T), was entered during
setup.
The Alarm is asserted if the Threshold is exceeded.
10. For Rate-of-Change-of-Load Alarm A+B:
The change in A+B per ms is calculated and compared to its Threshold of 100 T
per ms. To achieve this, a Threshold of 010.0, the required Threshold (100 T/ms)
expressed as a percentage of total FSI (1000 T/ms), was entered during setup.
The Alarm is asserted if the Threshold is exceeded.
5.4 Signal Filtering
The DSP2 applies the following fixed filtering to each channel to ensure signal quality:
input filters 50 kHz anti-aliasing and 3db filter with bandwidth on 2.8 kHz. Analog
output smoothing filter has a bandwidth of approximately 3.2 kHz.
A further filtering option is available to the user. This filter is applied after the signal is
transferred to the digital domain of the DSP2 Signal Processor. The input signal is
sampled at a rate of 50 kHz and processed at 10 kHz. A running average filter is available
to the user. The user may select a filter coefficient in the range 1-999. This coefficient
sets the number of samples to be averaged prior to the application of offset and gain
adjustments and subsequent formulation of values to be transferred to the Load
Measurement Set.
The following diagram shows a filter response with setting of the filter coefficients from
1 to 20. For default filter value N=1 with no filtering applied; actual value should be
chosen in accordance with the needs of the application.
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Analog output [V]
Rollmax DSP2: FILTER RESPONSE
10
1 2 3 4 5 6 7 8 9
0
0 0.25 0.5 0.75 1 1.25 1.5 1.75 2 2.25 2.5
Filter response [msec]
For the users guide a signal rise with the filter is presented by following formula:
Trise98% = 0.00032 + 9.75e - 5 & Filter
Settling time to within 1% of full scale is presented by following formula:
Tsettle1% = 0.0005 + 9.75e - 5 & Filter
This formula is valid for filter settings in the range of 6-999. For filter settings from 1-5 a
time of approximately 1 ms is required for filter to settle within 1% of full scale.
Note. The programmable logic outputs use a signal processed at 10kHz and is not
affected by the filter setting.
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5.5 Wrap Angle Compensation
The Calibration Target Loads supplied with Tensiometer Load Cell Assemblies and
Monoblocs are for fixed strip entry and exit angles, as specified on their Calibration Data
Sheets. 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 the user selects the Wrap Angle input mode from the following list:
MAN for manual input via the FPI, UAP or SCI

Fbs for input over the Fieldbus connection
AIN for input via the Auxiliary Analog Input Card
OFF for no input
Fbs or AIN are used when the wrap angle is continuously changing during the process.
MAN would be used when changes are infrequent and can be processed by operator
intervention.
The lookup tables are generated by KELK, based on the rolling geometry (from which the
relationship between wrap angle and wrap angle sensor output or Wrap Angle Value may
be determined) specified by the user. Each table comprises 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.
The WAC Look-up Tables are supplied using Form 858, refer to Appendix F. KELK
uses the Application Wizard in the User Access Program, see Appendix C, to generate
these forms. In the event of changes to the system geopmetry, the user can generate their
own tables using this method.
Two Auxiliary Analog Inputs are provided. Input 1 is normally used for the strip entry
angle, and Input 2 for the exit angle. These can be reversed; however, it is essential that
the lookup tables and inputs always correspond.
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5.6 Pre Power-up Check
Before turning on the DSP2 check that:
The sensors and wiring are properly installed and connected to the correct Sensor
Ports.
If used, the wrap angle sensors and wiring are properly installed and connected to
the correct Auxiliary Analog Inputs.
All Analog Outputs, Logic I/O, J-7 Com 1 and Fieldbus cables are correctly
installed.
Any equipment that responds automatically to the outputs is not active.
Lockout is disabled. See Section 6.11.
Caution
Prior to and during setup and configuration, 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
5.7 Setup and Configuration - User Access Program
Connect the PC or laptop serial port to DSP2 rear panel port J7 COM 1 and run the User
Access Program.
Set DSP2 and PC communications as instructed in Appendix E.
Follow the instructions on the screen.
5.8 Setup and Configuration - Front Panel Interface
Select Setup to enter the setup menu (Figures 3.5 and 3.7).
5.8.1 Input Channels
Select InpChSet to enter the Input Channels Setup Menu, Figure 3.8. Set the variable
parameters.
Application - select AppForce for force measuring systems, App Tens for tension
measuring systems, App Press for pressure measuring systems.
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Shunt Resistor - select the value corresponding to that on the sensor Calibration
Cards or Calibration Data Sheet, e.g. Shnt150K. This selection is utilized during
Configuration and must be correctly chosen to ensure correct measurement data.
Calibration Target Loads - set to the values on the sensor Calibration Cards or
tensiometer Calibration Data Sheets, as applicable, corrected for the resistance of the
interconnecting cables, e.g. AT081.32 for Sensor A Calibration Target Load of
81.32% and BT082.08 for Sensor B Calibration Target Load of 82.08%. See
Section 5.2 for additional information. The value must be in the range 20 to 150%.
This value is utilized during Configuration and must be correctly chosen to ensure
correct measurement data.
Filter - set filter in the range 1 to 999, e.g. Filtr020. See Section 5.4 for additional
information.
Source - select Inp A&B for Sensor A to be connected to Channel A and Sensor B
to Channel B, Inp 2xA for Sensor A to be connected to both Channels or Inp 2xB for
Sensor B to be connected to both Channels. Inp A&B is normally selected, the other
options invoke Single Sensor Operation and are intended for use if a sensor, or input
channel, has failed and a load signal is required on both channels.
5.8.2 Analog Outputs
Each of the installed Analog Outputs (maximum 6) can be setup to output A, B, A+B or
A-B from the Load Measurement Set in ± 10 V, 4 to 20 mA or 0 to 20 mA mode.
Select AnaChSet to enter the Analog Output Setup Menu, Figure 3.9. Set the variable
parameters. Output 1 is described. The other Outputs are setup in the same way.
Source - set Out1 A for A, Out1 B for B, Out1 A+B for A+B, Out1 A-B for A-B
or Out1 OFF to disable the output.
Mode - set the output mode - O1 V 10 for ± 10 V, O1mA4-20 for 4 to 20 mA or O1

mA0-20 for 0 to 20 mA. For A, B, and A+B the zero point is at 0 V in the voltage
mode, 4 mA in the 4 to 20 mA mode and 0 mA in the 0 to 20 mA mode. For A-B,
the zero point is at 0 V in the voltage mode, 12 mA in the 4 to 20 mA mode and 10
mA in the 0 to 20 mA mode. The analog output connections are different for voltage
and current modes (Section 4.3.4). Ensure that the mode selection is appropriate for
the connection; if it is not, the analog output will be incorrect.
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Output Scale Factor - set the Output Scale Factor, i.e. the load to be represented by
full scale (10 V or 20 mA) Analog Output, expressed as a percentage of:
Individual Full Scale Input for A, B and A-B,
Total Full Scale Input for A+B,
in the range 1 to 999 %. e.g. O1Scl100 for 100%. See Section 5.3 for additional
information.
5.8.3 Load Alarms
Each of the four Load Alarms can be setup to indicate when a load level or
rate-of-change-of-load exceeds a threshold.
Select RelaySet to enter the Load Alarm Setup Menu, Figure 3.10. Set the variable
parameters. Load Alarm 1 is described. Load Alarms 2 to 4 are setup in the same way.
Source - Select the load from the Load Measurement Set. Set Rel1 A for A, Rel1 B
for B, Rel1 A+B for A+B, Rel1 A-B for A-B or Rel1 OFF to disable the alarm.
Mode - select R1md Ld for load level, R1md Rt+ for positive
rate-of-change-of-load or R1md Rt- for negative rate-of-change-of-load.
The parameters for Threshold and Time are different depending on the selection
of Load or Rate of change of load.
Threshold - set in the range 1.0 to 150.0 e.g. R1T010.0 for a load level to be
asserted at 10% or a rate-of-change-of-load to be asserted at 10%/ms. See Section
5.3 for additional information.
Load Threshold
Typically set in the range 1.0 to 150.0, e.g. R1T080.0 for a load level to be
asserted at 80%.
Rate of Change of Load Threshold

Typically set in range 1.0 to 10.0, e.g. where the parameter represents the
percent load per millisecond.
e.g. R1T070.0 for a rate of change of load alarm to be asserted at a rate
70%/ms.
Time - set the response time in the range 1 to 999 ms, e.g. R1Tim025 for 25 ms.
See Section 5.3 for additional information.
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Time parameter for Load alarm is the time for which the load must exceed the
threshold before the alarm is asserted and conversely, the time after the load has
fallen below the threshold, before the alarm is de-asserted.
- set the response time in the range 1 to 999 ms. e.g. R1Tim025 for 25 ms.
Time parameter for the Rate of Change Alarm is the duration of the alarm
condition after the rate of change of load threshold has been exceeded
- set the response time in the range 1 to 999 ms, e.g. R1Tim050 for 50 ms.
Refer to Table 5.1 and Figure 5.1 for examples of relay assertion and timing.
# Ch. %FS Type msec. Indication

Lower operating threshold (Load
1 A 50.0 [ % ] Ld 50
Switch)
Upper operating threshold (Load
2 A 75.0 [ % ] Ld 100
Switch)
3 A 5.0 [% / ms] Rt+ 999 Rate Switch
4 A 2.0 [% / ms] Rt- 100 Rate Switch
Table 5.1 Example of Relay Output Parameters
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RELAY CONTACT: Low = Open Hi = Closed

100 msec
Relay 4
999 msec
Relay 3
100 msec 100 msec
Relay 2
50 msec 50 msec
Relay 1
100
75
Ch. 'A' % Load
50
25
0
0 1 2 3 4 5
Time [sec]
Figure 5.1 Example of Logic I/O Timing versus Mill Stand Load
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5.8.4 Wrap Angle Compensation
Each of the Wrap Angle Compensation (WAC) Inputs can be setup to provide
compensation in varying wrap angle tension measuring applications. See Section 5.5 for
additional information. See Form 858 in Part A of the System manual for Look up table
entry information.
Select WAC to enter the WAC Setup Menu, Figure 3.11. Set the variable parameters.
WAC Input 1 as described. WAC Input 2 is setup in the same way.
Source - set the data source. If Wrap Angle Compensation is not required, select
W1Sc OFF and ignore the remaining parameters for the input. If Wrap Angle Values
are to be input through the UAP, FPI or SCI, select W1Sc Man. If Wrap Angle data
are to be input via the Auxiliary Analog Input select W1Sc Ain. Select W1Sc Fbs
for input Wrap Angle Values via the Fieldbus Interface.
Table Entries - a series of table entry points will be presented in the form
1NNTXXXX, where leading number 1 or 2 indicates WAC Input 1 or WAC Input 2,
NN is the point number and XXXX is the value for that point. Enter the table
supplied by KELK, e.g., to enter a value of 6731 for point 17, 117T6731.
W1 in XXXX is used to enter Wrap Angle Values manually in off-line wrap angle
input mode, see section 6.8.
5.8.5 Communications
Select ComunSet to enter the Communications Setup Menu, Figure 3.12. Set the
variable parameters.
Serial Interface:
Mode - select the mode - ComRS232 or ComRS485.
Address - set the DSP2 address in the range 1 to 254, e.g. Addr 005.
For RS232 mode use address 254.
For RS485 select value from 1 to 254.
Baud Rate - select 9600, 19K, 38K or 57K baud, e.g. Baud 57K.
Fieldbus Interface:
Address - See appropriate Appendix.
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5.8.6 FPI Display
This part of the setup procedure allows the user to:
Scale the absolute loads in the FPI Display.

Select the parameters for the Default Display menu. The FPI display automatically
reverts to this menu after a period of no user activity at the interface, unless a
specific load has been selected in the FPI Load Display menu.
Select User Int to enter the FPI Display Setup Menu, Figure 3.13. Set the variable
parameters:
Scale Factor - enter the Scale Factor, in the range 1 to 9999, to set the absolute load
values in the FPI display:
A and B absolute full scale loads equal the Scale Factor, e.g., for a Scale Factor of
600, A# 0600 and B# 0600 correspond to A%100.00 and B%100.00,
respectively.
Σ#XXXX =
A#XXXX+B#XXXX, the sum of the individual loads, for roll force
measuring systems
(A#XXXX+B#XXXX)/2, the average of the individual loads, for pressure
and tension measuring systems,
∆#XXXX = A#XXXX - B#XXXX, the difference between the individual loads.
e.g. enter SF#200.0 for a Scale Factor of 200.0.
Timeout - set the time, in the range 15 to 1800 seconds, the default display is to
remain inactive following user activity, e.g. DMT0300 for 300 s.
Display Time - set the time, in the range 2 to 25 seconds, each selected parameter is
to be displayed before being replaced by the next , e.g. DCT 10.0 for 10 s.
Default Menu - select the parameters (maximum 8) to be displayed from:
Bar graphs A and B: A/B====== (default selection)

Bar Graphs A+B and A-B: Σ/∆
∆======
Load A %: A%XXX.X (default selection)
Load B %: B%XXX.X (default selection)
(A+B) %: Σ%XXX.X
(A-B) %: ∆%XXX.X
Load A #: A#XXXX
Load B #: B#XXXX
(A+B )#: Σ#XXXX
(A-B) #: ∆#XXXX
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5.8.7 Configuration
After all necessary parameters have been entered in the Setup procedure, the
'Configuration' command must be invoked to apply the Calibration data and to zero each
channel before the DSP2 is placed on-line.
The procedure must also be invoked whenever changes are made to the Shunt Resistor
Value or the Calibration Target Load or a connected sensor has been replaced. It is also
recommended that, if the user applies a Self Test, Configuration is also invoked to fully
check the sensor calibration.
Caution
If Configuration is not performed after parameter entry, the

measuring system is not calibrated. The Digital and Analog
Outputs and the Load Alarms are unpredictable and use of
the system for mill control purposes may cause the
Press MENU. Select Config N (Figure 3.5). Set to Config Y. Press ENTER. Display
will show WAIT!!! while Configuration is in progress and revert automatically to Config
N on completion.
It is recommended that the setup be checked by running Simulation, Section 7.7, before
using the system on-line.
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KELK Operation
PART 6 OPERATION
6.1 Introduction
The Rollmax Digital Signal Processor, Model DSP2, provides the user with several
capabilities for system monitoring and control:
Load Displays.
Load Level and Rate-of-Change Alarms.
Single Sensor Operation.
Auto Zero.
Auto Calibration.
Self Test.
Reset.
Load Simulation.
Lockout.
6.2 Load Display
Measured loads are displayed in the UAP Operations screen and the FPI alpha-numeric
display.
The FPI display normally cycles through the user selected Default Menu. A load can be
selected for continuous display - Press MENU, select LoadDisp, select load (Figure 3.6).
During normal operation (i.e. both Sensors A and B operational), the sum (Σ) and
difference (∆) loads in the FPI display are:
Σ% = (A% + B%)/2
∆% = A% - B%
Σ# = A# + B # for roll force measuring applications
= (A# + B#)/2 for pressure and tension measuring applications
∆# = A# - B #
During Single Sensor Operation (i.e. 2 x Sensor A or 2 x Sensor B), the sum (Σ) and
difference (∆) loads in the FPI display are:
Σ% = A% (or B%)
∆% = 0
Σ# = 2A# (or 2B#) for roll force measuring applications
= A# (or B#) for pressure and tension measuring applications
∆# = 0
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KELK Operation
6.3 Load Alarms
Load alarm conditions (i.e. when a user set load levels, or rates-of-change are exceeded)
are annunciated:
by Logic Output relays (Section 2.7.8)

by Logic Output indicators on the DSP2 front panel and in the UAP Operations
screen
by alarm messages at the Serial Communications and Fieldbus Interfaces
(Appendices A, B and C).
6.4 System Status
The DSP2 continuously monitors the signal processing electronics, the sensor excitation
currents and signals, the Auxiliary Analog Inputs, the Fieldbus Interface and the internal
temperature. System status is annunciated:
by Electronics Healthy, System Fault, Channel A Fault, Channel B Fault and

Single Sensor Operation indicators on the DSP2 front panel and in the UAP
Operation screen.
by status messages at the Serial Communications and Fieldbus Interfaces
(Appendices A, B and C).
by System Fault, Channel A Fault, Channel B Fault and Single Sensor Operation
Logic Output relays (Section 2.7.7).
If a fault is indicated, see Part 7, Troubleshooting.
6.5 Single Sensor Operation
Single Sensor Operation, otherwise known as load doubling, connects both Channel A
and B registers in the Load Measurement Set to the same sensor channel.
Single Sensor Operation can be invoked:
Through the FPI - Press MENU, select Setup, InpChSet, Inp 2xA or Inp 2xB
(Figure 3.8).
Through the UAP - Operations screen.
Through the SCI.
Through the Fieldbus Interface.
By contact closure at the Single Sensor A or the Single Sensor B Operation Logic
Input. Single Sensor Operation latches on, it is not revoked when the external
contacts are opened.
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KELK Operation
Note
Single Sensor Operation is not automatically invoked if

a fault is detected, user intervention is required.
When invoked:
The sum load (A+B) is twice the selected sensor load and the difference load
(A-B) is zero.
The front panel Single Sensor Indicator is illuminated.
The Single Sensor Operation Logic Output relay closes.
Single Sensor Operation can be revoked only:
Through the FPI - Press MENU, select Setup, InpChSet, Inp A&B (Figure 3.8).
Through the SCI.
6.6 Auto Zero
Auto Zero adjusts the fine offset of both channels to set their outputs to zero. It is
normally used to compensate for small changes in tare weight.
Configuration establishes a zero reference at the input stage. The Auto Zero command
will successfully zero the outputs provided the total offset detected at the input stage does
not exceed ±20% of the Full Scale Input also established during Configuration. This
limit serves to advise the user of the accumulation of small offsets successively corrected
and/or to alert the user to a single large change in offset.
It is recommended that in the event of a zero out of range error message that the cause be
investigated prior to further operation. To determine the actual magnitude of the offset
consult Section 7.6.1. To continue operation invoke Configuration to establish a new
zero reference.
Auto Zero can be initiated:
By pressing the front panel ZERO key.

Through the Serial Communications Interface.
By contact closure at the Auto Zero Logic Input.
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KELK Operation
Caution
During Auto Zero, 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
If the new zero offset exceeds the allowable limit, a fault condition will be indicated. See
Section 7.1 for assistance with troubleshooting.
6.7 Auto Calibration
Auto Calibration allows the user to ensure that the measuring system 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.
Caution
During Auto Calibration, the Digital and Analog Outputs

and the Load Alarms are temporarily frozen. Ensure that
Auto Calibration is intended for routine system

checking and fine tuning. It will not recalibrate the
system following sensor replacement. If a sensor is
replaced, sensor data entered during setup must be
updated and Configuration must be run.
Auto Calibration can be initiated:
By pressing the front panel CAL key.

Through the Serial Communications Interface.
By contact closure at the Auto Calibration Logic Input.
If a new fine gain and/or zero offset exceeds the allowable limit of 2%, a fault condition
will be indicated. See Section 7.1 for assistance with troubleshooting.
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KELK Operation
6.8 Wrap Angle Compensation
If W1Sc Man was selected during setup, the Wrap Angle Value can be updated:
Through the FPI - Press MENU, select Setup, WAC - WAC 1, W1inXXXX
and/or WAC 2, W2inXXXX. Enter the Wrap Angle Value in the range 0 to 1000,
e.g., to enter a value of 0543 for W1, W1in0543.
Through the UAP - select the Operations screen and set the new values for W1in
and/or W2in.
Through the Serial Communications Interface, see Appendix A.
If W1Sc Fbs was selected during setup, the Wrap Angle Value must be updated through
the Fieldbus Interface, see Appendix B or C.
6.9 Self Test
The Self Test checks:
For the presence of excitation current. If no current is detected, an attempt is made

to initiate current flow.
That the excitation current is within a specified range.
That changing the coarse gain has a proportional effect on the analog input signal.
That changing the coarse zero offset has a proportional effect on the analog input signal.
Self Test can be initiated:
Through the FPI - Press MENU, select Self T N. Set to Self T Y. Press ENTER.
Display will show WAIT!!! while Self Test is in progress and revert
automatically to Self T N on completion (Figure 3.5).
By contact closure at the Self Test Logic Input.
Caution
During Self Test, the Digital and Analog Load Outputs

and the Load Alarms are temporarily frozen. Ensure that
If a fault condition is indicated, see Section 7.1 for assistance with troubleshooting.
To fully check the system the user is advised to invoke Configuration to check zero and
calibration are also within limits.
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KELK Operation
6.10 Reset
Reset has the same effect as turning on the system. The system is initialized and normal
operation commenced.
Reset can be initiated:
Through the FPI - Press MENU, select Reset N. Set to Reset Y. Press ENTER.
Display will show WAIT!!! while Reset is in progress and revert automatically to
Reset N on completion. (Figure 3.5)
Caution
During Reset, the Digital and Analog Outputs and the

Load Alarms are frozen. Ensure that they are not used
for mill control as this may cause the production of
off-specification product or mill damage.
6.11 Lockout
When enabled, Lockout prevents:
any change being made to a setup parameter.

initiation of Configuration.
initiation of Reset and Simulation.
The Lockout condition is controlled primarily by a logic input at terminals J8-15 and
J8-33. When these terminals are open Lockout is asserted. When closed the user has full
access through all interfaces. Lockout can be overridden over the SCI, through the User
Access Program. This override will remain in effect until:
revoked through the SCI directly or through the User Access program,
automatically revoked by the DSP2 after no setup parameter has been changed or
Configuration, Self Test, Reset or Simulation has been activated, for a period of
1 hour.
Note that Lockout cannot be accessed over Fieldbus.
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KELK Troubleshooting
PART 7 TROUBLESHOOTING
7.1 Introduction
Fault conditions are categorized as follows:
Electronics Fault
A fault has been detected in the hardware or by the hardware. See Table 7.1
Measurement Channel Faults

Channel 'A' Fault and Channel 'B' Fault.
An error has been detected that may influence the quality and accuracy of
the measurement data. See Table 7.2
System Fault
This is a composite fault indication that includes both measurement channel and
electronic faults.
Fault conditions are indicated by:

LEDs on the FPI
At the Logic Outputs
Status codes over the SCI (can be observed in the UAP)
Status codes over the Fieldbus interface
Faults are identified:
in the UAP Diagnostics Status screen.

in the FPI as Hex sums of individual faults (Tables 7.1 and 7.2) - Press MENU, select
Diagnose, Status - FltAXXXX, FltBXXXX and FltEl XX (Figure 3.14).
in the Serial Communications Interface (Appendix A) and Fieldbus Interface
(Appendices B and C) by bitmapped messages (Tables 7.1 and 7.2).
Fault History Recording
All DSP2 fault condition indications are volatile, that is, the fault indication is cancelled
as soon as the problem is corrected. To assist the user in the event that intermittent or
transient process or measurement system fault conditions occur the User Access Program
contains features for logging and reporting fault conditions, see section 7.8 for details.
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Electronics Fault Error Codes
A continuous routine monitors the status of the DSP2 hardware and signal processing. In
the event that a fault is detected, the ‘Electronics Healthy’ LED on the FPI goes out
indicating a fault condition. The user can access the error codes associated with the fault
through the FPI , the UAP over the SCI or via the Fieldbus option.
The following table, Table 7.1, lists the error codes displayed over the FPI or transmitted
over the SCI and Fieldbus in the event that a fault is detected in the hardware or the DSP2
signal processing. The table also includes a possible cause for the fault for the user to
investigate. For the case when multiple faults are detected the error code displayed or
transmitted will be the sum of the individual fault codes. An explanation of how to
determine the individual components of a combined error code together with an example
is given at the end of this section 7.1.
FPI Hex Fieldbus Fault Possible Cause See

Number SCI Section
01 Bit 0 Signal Processing error Signal Processor Board fault 7.2
02 Bit 1 Not assigned 7.2
10 Bit 4 Spurious Reset External influences 7.2
40 Bit 6 Not assigned 7.2
80 Bit 7 Excessive internal temperature Overheating 7.2
Table 7.1 Status Messages - Electronics
Measurement Channel Fault Error Codes
Measurement Channel Faults may be detected either by the continuously running

diagnostic routine or by user initiated routines as follows: Configuration, Self Test, Zero
and Calibration. Some faults are identified using terms such as ‘Coarse Offset’ and
‘Coarse Gain’. These terms refer to adjustments attempted automatically by the DSP2
during the user initiated routines. The DSP2 monitors the outcomes of these routines and
posts a warning in the event that a problem is detected.
In the event that a fault occurs the appropriate Channel Fault LED on the FPI will be
illuminated and the corresponding logic output will be asserted. The user can access the
error codes associated with the fault through the FPI , the UAP over the SCI or via the
Fieldbus option.
The following table, Table 7.2, lists the error codes displayed over the FPI or transmitted
over the SCI and Fieldbus in the event that a fault is detected in either signal processing
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channel. The table also includes a possible cause for the fault for the user to investigate.
For the case when multiple faults are detected the error code displayed or transmitted will
be the sum of the individual fault codes. An explanation of how to determine the
individual components of a combined error code together with an example is given at the
end of this section 7.1.
To decipher the FPI status messages:
Subtract the largest fault number as identified by the FPI Hex Number in the tables
above, equal to or less than the displayed number, from the displayed number. That
fault is present.
Repeat the above, subtracting from the remainder, until the remainder is reduced to zero.
Note that the fault identifier is a number in hexadecimal format.
Examples:
For Electronics Status Message FltEl81
81 - 80 (Excessive internal temperature) = 01
01 - 01 (Signal processing error) = 0
Errors detected are 80 and 01 in Table 7.1
For Channel A Status Message FltA08C0:

08C0 - 0800 (fine gain out of margin) = 00C0
00C0 - 0080 (signal in range but no response with coarse offset
adjustment) = 0040
0040 - 0040 (no response with coarse offset adjustment) = 0000
Errors detected are 0800, 0080 and 0040 in Table 7.2.
For status messages transmitted over the SCI or the Fieldbus faults are
directly identified by bit position as indicated in the tables:
1 = fault detected, 0 = fault not detected
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FPI Hex SCI Activated by: Fault Possible Cause See

Number Fieldbus Section
0001 Bit 0 Continuous Excitation current OFF. Sensor connection fault. 7.3
monitoring Sensor fault. Excitation
supply failure or shutdown
(short detected).
0002 Bit 1 Continuous Excitation current low Sensor connection fault. 7.3
monitoring Sensor fault. Sensor has been
changed. Excitation supply
failure
0004 Bit 2 Continuous Input Saturation Mill condition. Sensor 7.3
monitoring connection fault. Sensor
fault. Calibration Target
Load or Shunt Resistor entry
error.
0008 Bit 3 Configuration Excitation current out of Sensor connection fault. 7.3
or Self Test range. Sensor fault. Excitation
supply failure.
0010 Bit 4 Configuration No response to shunt resistor. Strain Gage Interface Board 7.3
or Signal Processor Board
failure
0020 Bit 5 Configuration Coarse Offset correction Sensor connection fault. 7.3
failure Sensor output too high.
0040 Bit 6 Configuration Coarse Offset; no response. Sensor connection fault. 7.3
Strain Gage Interface Board
failure.
0080 Bit 7 Configuration No valid Input. Sensor connection fault 7.3
Strain Gage Interface Board
failure.
0100 Bit 8 Configuration Shunt resistor input too low. Incorrect Shunt resistor or 7.3
or Self Test CTL.
0200 Bit 9 Configuration Coarse Gain fault Strain Gage Interface Board 7.3
failure.
0400 Bit 10 Self Test, Fine Zero offset out of Mill condition. Sensor 7.3
Zero or Cal margin. connection fault. Sensor
fatigue.
0800 Bit 11 Self Test, Fine Gain out of margin. Sensor connection fault. 7.3
Zero or Cal Sensor changed. Shunt
Resistor or CTL changed.
1000 Bit 12 Invalid parameter value. Invalid parameter. 7.3, 7.5
2000 Bit 13 User initiated Load Simulation active This is a user selected 7.4,7.7
condition.
4000 Bit 14 User initiated .Internal routines active. This is user initiated 7.4
conditions.
8000 Bit 15 User initiated Signal off (other channel This is a user selected 7.4 ,7.7
doubled). condition.
Table 7.2 Status Messages - Channels A and B.
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7.2 Electronics Faults
Refer to Table 7.1
01 (Bit 0) Signal Processing Error

A fault has been detected in the Signal Processing Board. The DSP2 should be returned
to KELK for evaluation and repair. The Signal Processor Board is not user replaceable.
10 (Bit 4) Spurious Reset

Spurious Resets are Resets not initiated by the user but are caused by external influences
such as EMI or AC line noise. To reduce the effect of spurious resets the DSP2 has a
check that determines if a Reset was correctly initiated. If not correctly initiated, the reset
is categorized as ‘spurious’ and the full Reset algorithm is not exercised. The DSP2 is
reset to normal operation with the minimum disruption. When such a reset occurs the
error code 10 is displayed. This is simply for recording purposes, no action is required by
the user.
20 (Bit 5) Strain Gage Interface Board Fault

One of the strain gage interface boards has failed or a Signal Processor Board fault has
been detected during DSP2 boot up or during a Reset. Identify and Replace the Strain
Gage Interface Board, Section 8.3. If this does not correct the problem, the fault is on the
Signal Processor Board. The Signal Processor Board is not user replaceable, the DSP2
should be returned to KELK for evaluation and repair.
80 (Bit 7) Excessive Internal Temperature

Excessive internal temperature has been detected. This alarm is triggered when the
internal temperature of the DSP2 enclosure exceeds 70°C (158 °F). This alarm ususally
indicates that the ambient temperature around the DSP2 is too high. Check that the
temperature immediately adjacent to the unit (if installed in a cabinet, the temperature
inside the cabinet) does not exceed 40°C (104°F). Check that air flow around the unit is
not restricted. Check the status message one hour after taking corrective action to ensure
that it was effective.
Other
In the case of a suspected Auxiliary Analog Input Board or Fieldbus Card fault, replace
the board, Section 8.3. Note that faults in these boards are not indicated by the DSP2
diagnostics.
Note. Printed circuit boards are not user serviceable. Defective boards should be
returned to KELK for evaluation and repair.
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7.3 Channel Faults
Refer to Table 7.2
0001 (Bit 0) Excitation Current Off

Continuous monitoring has detected a fault condition in the excitation supply for one
channel.
A low or zero excitation current can be caused by a poor sensor connection, a sensor
failure or an excitation supply failure. Note that the excitation circuit is short circuit
protected; it will automatically shut down when a short is detected. The DSP2 will
attempt an automatic restart if Configuration, Self Test or Reset is invoked. Test the
system, Section 7.6.1. Check for presence of excitation voltage, 10VDC. Follow with
the interconnecting cable (Section 7.6.2) and sensor (Section 7.6.3) tests, as required.
0002 (Bit 1) Excitation Current low

Similar to fault 0001 above. The excitation current is below the expected level. Check
for presence of excitation voltage, 10VDC. Check the sensor type and connections. The
DSP2 automatically clear this fault when the problem is corrected.
0004 (Bit 2) Input Saturation

The input to one or both channels is high causing saturation.
Saturation not caused by a mill operating condition indicates:

Incorrect measurement channel setup such that the Full Scale Input is too low for the
normal mill operating condition. This can be the result of incorrect Shunt Resistor
value or Calibration Target Loads entered during Configuration, see Section 7.5.
Interconnecting cable or sensor fault. Test the system, Section 7.6.1. Follow with the
interconnecting cable (Section 7.6.2) and sensor (Section 7.6.3) tests, as required.
Fault indication is automatically cleared out when the input falls within the operational
range.
0008 (Bit 3) Excitation current out of range

See 0001 above. This fault is detected by Self Test or Configuration and indicates that a
significant change in the level of excitation current has been detected. This fault is cause
by poor sensor connections or a change in the actual sensor since the last test. Check the
sensor thoroughly as indicated in 0001 above. Test the system, Section 7.6.1. Follow
with the interconnecting cable (Section 7.6.2) and sensor (Section 7.6.3) tests, as
required.
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0010 (Bit 4) No Response to Shunt Resistor

This fault is detected during Configuration. It indicates a fault in the Strain Gage
Interface Board, the Signal Processor Board or the sensor connections. Check the sensor
thoroughly as indicated in 0001 above. Test the system, Section 7.6.1. Follow with the
interconnecting cable (Section 7.6.2) and sensor (Section 7.6.3) tests, as required. If no
sensor related fault is found replace the Strain Gage Interface Board, Section 8.3. If this
does not correct the problem, the fault is on the Signal Processor Board. The Signal
Processor Board is not user replaceable, the DSP2 should be returned to KELK for
evaluation and repair.
0020 (Bit 5) Coarse Offset Correction Failed

This fault is detected during Configuration. The input cannot be reduced to a close to
zero value by the input circuitry. DSP2 has circuitry that automatically adjusts to reduce
the input due to tare loads (referred to here as the Coarse Offset) to a value within the
range of the Fine Zero adjustment. The input is either open or the input signal is too large.
Check the sensor connections for an open. Check that the input is below 5.0 mV/V.
0040 (Bit 6) Coarse Offset; No Response

This fault is detected during Configuration. The cause could be either a shorted input, no
excitation or failed Strain Gage Interface Board. Check the sensor thoroughly as indicated
in 0001 above. Test the system, Section 7.6.1. Follow with the interconnecting cable
(Section 7.6.2) and sensor (Section 7.6.3) tests, as required. If no sensor related fault is
found replace the Strain Gage Interface Board, Section 8.3.
0080 (Bit 7) No Valid Input

This fault is detected during Configuration and indicates that there is no valid input. It is
very similar to 0040 above. The cause could be either a shorted or open input, failed
Strain Gage Interface Board. Check the sensor thoroughly as indicated in 0001 above.
Test the system, Section 7.6.1. Follow with the interconnecting cable (Section 7.6.2) and
sensor (Section 7.6.3) tests, as required. If no sensor related fault is found replace the
Strain Gage Interface Board, Section 8.3.
0100 (Bit 8) Shunt Resistor Input Too Low

This fault is detected by Configuration. Input with shunt resistor applied is too small,
yielding an FSI <0.1mV/V. The reason is an incorrect Shunt Resistor value selection or
an incorrect Calibration Target Load. Check the value of both parameters entered.
0200 (Bit 9) Coarse Gain Fault

This fault is detected by Configuration. It indicates a fault in the Strain Gage Interface
Board. Replace the Strain Gage Interface Board, Section 8.3.
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0400 (Bit 10) Fine Zero Offset Out of Margin

This fault is detected by a Auto Calibration or Auto Zero operation.
The accumulated fine zero margin is ±20 % of full scale. Fine zero is set close to zero
during Configuration, so first review mill conditions to determine if there has been a
significant change in the tare load since the system was last configured. If Auto Zero was
run with more than the tare load applied, correct the loading and run Auto Zero again to
establish the correct offset and clear the fault message. If the tare load has been changed
by approximately 20% or more, run Configuration to reset the offset to zero and clear the
fault message. If the offset cannot be explained by either of the foregoing, check the
measuring system.
Tare offset and Fine Zero offset data are accessible via the FPI or the UAP.
The FPI - Press MENU, select Diagnose - TareLoad (Figure 3.14).

Select Channel A which returns a reading, for example:
Atar+055 which represents an offset from internal zero equal to +55% of FSI.
Select Channel B which returns a reading, for example:
Btar-003 which represents an offset from internal zero equal to -3% of FSI.
Configuration applies Coarse Offset adjustment to correct for this offset.
Next select Cal Disp (Figure 3.15)

Select Channel A which returns a reading, for example:
Az-01530 which represents an offset equal to -15.30% of FSI.
Select Channel B which returns a reading for example:
Bz+00123 which represents an offset equal to +1.23% of FSI.
The above values are relative to the value determined by Coarse Offset adjustment
during Configuration.
The total value of tare is the sum of Atar and Az or Btar and Bz.
For the above example:
For Channel A Total Tare = 55 - 15.3 = 39.7 % of FSI.
For Channel B Total Tare = -3 + 1.23 = - 1.77 % of FSI.
Tare offset information is available in the ±175% range. Tare applied outside that
range will saturate at ±175%.
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The same information is available via the UAP - DIAGNOSTIC - Input Channel
Configuration Diagnostics, Calibration screen.
This data is valuable for tracking zero shifts that may occur.
A stable zero offset in the direction of the applied load, not caused by a tare load
or other mill operating condition, indicates that the sensor has been overloaded. If
the offset exceeds the available adjustment range, the sensor should be replaced.
A slow zero drift, not caused by a tare load or other mill operating condition,
indicates sensor fatigue. Fatigue manifests itself when a sensor reaches the end of
its life, which is typically after more than 10 million load cycles under proper
loading conditions. It will occur prematurely if a sensor is continuously locally
overloaded due to poor loading conditions. The drift is normally in a direction
opposite to the load direction. It progresses sufficiently slowly that Configuration
and Auto Zero will provide sufficient compensation to permit sensor replacement
to be planned and implemented on a relatively convenient schedule. If fatigue
occurs prematurely, thoroughly inspect the sensor installation for indications of
uneven loading and correct any problem before replacing it.
An unstable zero offset indicates an interconnecting cable or sensor problem.

Test the system, Section 7.6.1. Follow with the interconnecting cable (Section
7.6.2) and sensor (Section 7.6.3) tests, as required.
0800 (Bit 11) Fine Gain Out of Margin

This error may be detected when the Auto Calibration function is invoked indicating
that the calibration point exceeds ±5% of the value set by the last Configuration. The
most likely cause is that the sensor or its calibration data parameters have been changed
without applying Configuration. Check all calibration data entries.
1000 (Bit 12) Invalid Parameter Value

This will rarely occur. It represents an incorrect parameter entered during factory
calibration and test. Check all entries and apply Configuration.
7.4 User Initiated Error Conditions
2000 (Bit 13) Load Simulation active

This is a warning given in response to a user initiated action. It will be cancelled when
the Load Simulation is terminated.
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4000 (Bit 14) Internal Routines Active

This is a warning given in response to a user initiated action such as Configuration,
Self Test and Auto Calibration. It will be cancelled when the function is finished.
8000 (Bit 15) Signal OFF (other channel doubled)

This is a warning given in response to a user initiated action. A fault has been detected
on one channel and Load Doubling has been invoked. It will be cancelled when the
function is terminated.
7.5 Unexpected Load Measurements and Alarms
If load measurements or alarm levels deviate significantly from expected values and
cannot be attributed to a tare load or other mill operating condition, run Simulation
(Section 7.7) in Shunt mode:
First ensure that the system is off-line, apply Auto Zero to bring each channel to zero.
For roll force, pressure and load measuring systems, the DSP2 load displays should
correspond with the Sensor Calibration Target Loads (including interconnecting cable
corrections).
For fixed wrap angle tension measuring systems, the DSP2 load displays should
correspond with the Tensiometer Calibration Target Loads (including interconnecting
cable corrections).
For varying wrap angle tension measuring applications, the DSP2 load displays
should correspond with the Tensiometer Calibration Target Loads (including
interconnecting cable corrections) x the WAC Scale Factor. The Scale Factor is
accessible in the UAP Operations screen (Figure 3.1) and the FPI - Press MENU,
select Diagnose, WAC, Wf XXXX (Figure 3.14). If the displayed loads are correct,
erroneous wrap angle compensation may be causing the problem. Ensure that the
WAC lookup tables have been entered 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 and apply Configuration. Any error
will affect the Digital and Analog Outputs, the Load Displays and the Load Alarms.
If the displayed loads are correct and an Analog Output is erroneous, check that the
correct Output Scale Factor has been entered. Any error will affect only the associated
Analog Output.
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If the displayed loads are correct and a load level alarm is not asserted at the expected
level, run Simulation (Section 7.7) to determine the assertion point. If this differs from
the expected level, correct the Threshold setting. Any error will affect only the associated
Alarm.
If the problem cannot be attributed to any of the above causes, run Self Test, Section 6.9.
If an electronics fault is reported, see Section 7.2.
Several parameters in a new DSP2 are factory set at values outside of their acceptable
ranges so as to create an error message if the DSP2 is used before valid values have been
entered and Configuration has been run. If an invalid parameter message is displayed,
review the setup, ensuring that all required parameters have been entered, and run
Configuration.
7.6 Tests
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-specification
product or mill damage.
7.6.1 System Test

Note
This test assumes that the interconnecting cable and

sensor wires are the same colour. If different coloured
interconnecting wires are used, ensure that the test
connections correspond to the sensor wire colours.
1. Ensure the suspect channel is either not loaded or only tare loaded.
2. Switch off the DSP2. Disconnect the red and white interconnecting cable wires.
Switch on the DSP2.
3. With a DVM, measure the excitation voltage between the green (+) and black (-)
wires. This should be 10 VDC, ±0.5 VDC. A low reading indicates current leakage
in the cable or sensor, or an excitation supply problem.
4. With the DVM set to millivolts, measure between the red (+) and white (-) wires.
The reading will normally be less than 3 mV. Values above 15 mV are unusual. If
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the value is high, it may be beyond the range of the zero control. A reading of ±5V
indicates sensor failure.
5. Switch off the DSP2, disconnect the green (+) and black (-) wires (this completely
disconnects the cable from the DSP2) and conduct the following tests in order:
(a) Input resistance: Using an Ohmmeter with a resolution of 0.1 Ohm, measure
between the green and black wires. The reading should be within 1 Ohm of the
resistance specified on the Calibration Card plus the resistance of the
interconnecting cable.
(b) Output resistance: Repeat (a) between the red and white wires.
High or low readings for tests (a) - (b) indicate cable problems or a damaged
sensor.
(c) Using a DVM set to millivolts, measure between any wire and ground. The
reading should be less than 5 mVDC.
(d) Repeat (c) between any wire and the internal cable shield.
(e) Repeat (c) between the internal cable shield and ground.
Any reading above 5 mVDC for tests (c) - (e) indicates moisture in the sensor or
cable which will result in unstable readings and, more noticeably, zero drift.
(f) Using a DVM or megometer with a test voltage of less than 50V, measure
bridge to ground resistance, i.e. any sensor wire to ground.
Caution
Do not use an insulation tester with test voltages in

excess of 50V. Higher voltages may damage the sensor.
(g) Measure bridge to shield resistance by repeating (f) for any sensor wire to the
cable shield.
If all readings were normal for tests 4 and 5, the excitation supply is faulty. Replace the
Strain Gage Interface Board, Section 8.3.
If any readings were abnormal for tests 4 and 5, the problem is caused by the
interconnecting cable or the sensor.
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7.6.2 Interconnecting Cable Test
1. Disconnect the cable at the junction box.
2. Test all conductors for continuity.
3. Measure the resistance to ground of all conductors.
4. Measure the resistance to shield of all conductors.
5. Measure shield to ground resistance.
6. When reconnecting the cable:

Replace all dirty and corroded terminal blocks and lugs. Ensure that there are no
frayed wires to cause momentary shorts to ground.
Ensure that the box and all internal components are dry. If moisture is seen or
suspected, dry with alcohol.
Ensure that the cable shield is electrically isolated from the box ground.
Ensure, when closing, that the box is properly sealed, checking the cover and all
cable entry points.
A reading of 20 MΩ or less for tests 3 - 5 indicates cable damage or moisture in the cable.
If values below 20 MΩ are measured or if any conductor is found not to be continuous,
the cable must be replaced.
7.6.3 Sensor Test
1. Disconnect the sensor cable from the junction box.
2. Repeat tests in Step 5 of the System Test, Section 7.6.1.
3. If a problem is encountered it could be in either the sensor cable or the sensor itself.
Remove the sensor for a complete inspection, see the measuring system User’s
Manual.
4. Inspect the full length of the cable for damage, including crushing or kinking. If
damaged near its point of entry into the sensor, the sensor should be replaced. If
damaged at some point along its length, it can be repaired using KELK Splicing Kit
Part Number 20311. All necessary instructions are included in the kit. This is the
only recommended method.
5. If the cable is not damaged, the problem is probably in the sensor itself. Return the
sensor to KELK for evaluation and repair.
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7.7 Load Simulation
Load Simulation is provided to facilitate checking the DSP2 setup and the load output
(analog or digital) to mill control system interface.
There are two Load Simulation modes:

Shunt - shunt resistors are applied to both channels. 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 user selected 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 using the FPI menu:
Select Press MENU, select Diagnose, Load Sim (Figure 3.14). Press ENTER.
For application of the Shunt Resistors to the inputs - Select Sim SHNT, Press
ENTER, or
For Load Simulation at user selected levels - Select Sim USER. Press ENTER. The
levels of the data outputs will correspond to the levels set in SimA XXX and SimB
XXX. To change a level - select SimA XXX or SimB XXX, as required. Press
ENTER, set the required value. Press ENTER.
To return to normal operation, select Sim SHNT or Sim USER, as applicable. Press
ENTER. Select Sim OFF. Press ENTER.
To simulate a load using the UAP, press Simulation/Test in the Operations Screen to
expose the Simulation pop-up panel.
WARNING: Do not attempt to initiate Auto Calibration, Auto Zero, Self Test or Reset
when Load Simulation is active.
Load Simulation is automatically disabled if Auto Calibration, Auto Zero, Self Test or
Reset is initiated.
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7.8 Fault History Recording via the User Access Program
All DSP2 fault condition indications are volatile, that is the fault indication is cancelled
as soon as the problem is corrected. The User Access Program has features to assist the
user in the event that intermittent or transient process or measurement system fault
conditions occur.
7.8.1 System Status Logger
When a successful connection is made to an operational DSP2 using the User Access
Program, a Fault logging file is automatically created using the same ‘Name’ as the
backup configuration file, for example, Test.log for a DSP2 backup configuration file
named Test.cfg. The Name.log file is in the same directory as the backup configuration
file, see Figure 7.1. System Status logging is intiated whenever the UAP connection is
made to the DSP2.
Figure 7.1 Typical Directory Path to DSP2 Status Logging File
Important Note. If there are multiple DSP2s then each DSP2 must have its own Backup
Configuration file identified by ‘name’. An existing backup configuration file can be
used as a source for configuration data for any DSP2. Data can be read from file by the
UAP and applied to any DSP2 using the ‘Apply to DSP2’ button on the SETUP panel.
The user must assign a NAME to the DSP2, also via the SETUP panel before saving
using ‘Save to File’. The Save to File action will cause the ‘Name’.log file to be created
for that DSP2.
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The following data, see Figure 7.2, is logged to the System Status logging file; reading
left to right
Date
Time
Fault code for input channel A
Fault code for input channel B
Comment.
Figure 7.2 Extract from a DSP2 Status Logging File
7.8.2 Start-Up Codes and Start-Up Counter
The Start -Up Code and Counter windows are illustrated in Figure 7.3.
These Start-Up Code and Start-Up Counter features work in conjunction with each other.
There are two modes by which the DSP2 can be started.
1. External power ON/Off via the unit switch or external power supply failure or from a
user initiated Reset, code 0x080.
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2. Internal software reset in response to an abnormal condition detected by the DSP2

internal diagnostic routines, resulting in one of the following codes: 0x01.0x04, 0x10
or 0x20. These codes indicate an internal problem not directly associated with the
user. In the event of such codes being displayed consult KELK.
If either of these error conditions occurs then the appropriate error code is posted on the
UAP Diagnostics panel and the Start-Up counter incremented.
The Start-Up counter keeps count of the number of start-up occurences while
communication with the UAP is maintained. If the UAP connection is broken then the
counter returns to zero.
Figure 7.3 Extract from Diagnostic Screen
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KELK Maintenance
PART 8 MAINTENANCE
8.1 Introduction
The Rollmax Digital Signal Processor, Model DSP2, requires no routine maintenance,
other than occasional cleaning, if necessary, Section 8.4. Service is required only if a
failure occurs.
8.2 Fuse Replacement
Both the line and the neutral are fused. To replace a fuse:
1. Disconnect the power supply and unplug the power cord from the rear of the DSP2,
see Figure 4.1.
2. Insert a screwdriver in the small notch in the fuse holder at the entrance to the power
socket and gently pry the fuse holder free.
3. Replace the fuse, see Section 9.9 for rating.
4. Replace the fuser holder and power cord. Reconnect to the power supply.
8.3 Printed Circuit Board Replacement
The Strain Gage Interface Boards, Auxiliary Analog Input Board, Analog Output Boards,
and Fieldbus Card, may be replaced, or added, by the user.
Caution
Electrostatic discharge (ESD) can damage static

sensitive components used in the DSP2. To prevent
ESD, follow the guidelines given below when handling,
removing and installing printed circuit boards.
To minimize the probability of electrostatic damage when handling printed circuit boards:
Handle boards as little as possible.
Store and transport boards only in static shielding bags or containers.
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Wear a grounded wrist strap when handling boards not in protective packaging
Do not place boards on any surface other than a properly grounded static
dissipative mat.
Before installing or removing any board, ensure that the equipment is properly
grounded and ground the wrist strap to the equipment chassis.
Figure 8.1 Printed Circuit Board Locations
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KELK Maintenance
Figure 8.2 Connector Mount
To replace or add a board (Figures 8.1 and 8.2):
1. Disconnect the DSP2 from the power supply.
Warning
If the cover is removed with the DSP2 connected to the

power source, connections at line voltage are exposed.
Contact with these connections may cause injury or death.
2. Unplug the external cable of the board to be replaced.
3. Remove the enclosure cover.
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4. If replacing a board, remove the two jack posts and the two screws holding the
connector plate, see Figure 7.2. Remove the connector plate. Using the tab at the
top rear corner of the board, carefully remove the board by pulling upwards until
it is just free of its socket, then sliding backwards.
If adding a new board, remove the two screws holding the cover plate. Remove
the cover plate.
5. Install the new board - center the connector in the rear panel opening and press
downwards to engage the socket on the Signal Processor Board. Install the
connector plate, screws and jack posts.
6. Replace and secure the enclosure cover.
7. If replacing a board, reconnect the cable removed in step 2. If adding a board,

wire the external connection, see Section 4.3.
8. Reconnect the DSP2 to the power supply.
9. If a new board is being added, setup the new feature. See Part 5.
10. If a Strain Gage Interface Board is replaced, run Configuration.
Caution
If Configuration is not performed the measuring system

may not be calibrated. The Digital and Analog Outputs
and the Load Alarms are unpredictable and use of the
system for mill control purposes may cause the
11. Check that any fault indication has been cleared.
8.4 Cleaning
The DSP2 enclosure and front panel may be cleaned using a soft cloth dampened with
water and a mild detergent. Do not use harsh chemicals. Before cleaning, turn the power
off. Do not allow moisture to enter the DSP2.
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KELK Specifications
PART 9 SPECIFICATIONS
Full Scale corresponds to the input or output level with the sensor loaded to rated capacity.
9.1 Performance
Calibration Accuracy ±0.01% of Full Scale
Linearity 0.05% of Full Scale
Gain Drift ±0.01% of Full Scale per 0C
Zero Drift ±0.01% of Full Scale per 0C
Sensor Input Bandwidth 2.2 kHz
Sensor Sampling Rate 50,000 per second
Zero Compensation Range ±50% of Full Scale
Analog Output
Update Rate 10,000 per second
Resolution 0.002% of full scale
Ripple and Noise
Voltage 5 mV peak-to-peak at 10 kHz
Current 5 µA peak-to-peak at 10 kHz
Digital Output (Fieldbus)
Update Rate 500 per second
Resolution 0.01% of Full Scale
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9.2 Sensor Inputs
ROLLMAX DSP2 is for use with sensors with the following specifications:
Sensitivity 0.25 to 2.5 mV/V Full Scale
Bridge Resistance 80 to 2,000 Ohms
Excitation 10 VDC. DSP2 supply is short circuit protected,

regulated and isolated from earth or system ground
9.3 Auxiliary Analog Inputs
Range ±10 VDC or 0-10VDC
Input Impedance 200 kOhm
Isolation Group isolated.
Sampling Rate 100 per second
9.4 Analog Outputs
Mode
Voltage ±10 VDC into a resistive load of 2000 Ohms

minimum with 10 % over range capability
Current 4 to 20 mA, or 0 to 20 mA, into a resistive load of
500 Ohms maximum, with 5% over range capability
Isolation Group isolated by Analog Output Board pair
9.5 Logic Inputs
Type
External Contact Closure Rating 20 mA, maximum voltage drop 3 VDC

Voltage Input 10 VDC to 24 VDC at 10mA max.
Minimum On Time 100 mS
Sampling Rate 100 per second

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9.6 Logic Outputs
System Status
Update Rate 10 per second

Relay Ratings
System Fault Form C. Energized for no fault condition.
30VDC/VAC, 1 A
Channel A Fault, Form A. Normally Open. 30 VDC/VAC, 80 mA
Channel B Fault and
Single sensor operation
Load alarms
Update Rate 1,000 per second

Relay Rating Form A. Normally Open. 30 VDC/VAC, 80 mA
9.7 Serial Communications Interface
Type RS232/RS485 user selectable
Baud Rate 9600, 19k, 38k, 57k user selectable.
9.8 Fieldbus Communications
Type Ethernet (Modbus/TCP), Profibus.
9.9 Power
120 VAC 90 - 135 V, 47 - 63 Hz, 50 VA
240 VAC 175 - 264 V, 47 - 63 Hz, 75 VA
Installation Overvoltage Category II. Ref. IEC 61010-1
Fuse Quantity 2, 1.25 A, Time Lag, 5 mm x 20 mm
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9.10 Physical
Operating Environment
Location Fixed, indoors

Temperature -10°C to 40°C (14°F to 104°F)
Humidity 10 to 90%, non condensing
Altitude 4000 m (13120 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)
Enclosure
Style 19 inch rack mounting

Width 483 mm (19 inch)
Height 133.4 mm (5.25 inch)
Depth 225 mm (8.87 inch)
Cabinet Depth The depth of any cabinet in which the DSP2 is

installed must be 285 mm (11.25 inch) minimum to
provide clearance for cabling
Weight 6 kilograms (13 pounds)
9.11 User Access Program
Minimum Computer Requirement 90 MHz Pentium

32 MB RAM
8 MB hard drive space
CD ROM drive
800 x 600 video adapter
Windows environment
Format CD
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APPENDIX A SERIAL COMMUNICATION INTERFACE
A.1 Introduction
The Serial Communications Interface (SCI) can be used to monitor and control the
Rollmax Digital Signal Processor, model DSP2.
Caution
Load measurement data accessed through the Serial

Communications Interface are intended for data logging
and monitoring purposes only. For mill control, the
higher data rate of the Fieldbus Interface is required.
A.2 Setup and Configuration
Connect the DSP2 to the mill computer, Section 4.3.6. All DSP2’s employed in a mill
can be connected in parallel, in RS485 mode, to the computer.
Configure the DSP2 at the Front Panel Interface, Section 5.8.5. Set:
Mode (RS232 or RS485).

Address (1 to 254)
Bit Rate (9600, 19K, 38K or 57K baud)
Parity is fixed to none, there is one stop bit.
Any attempt to modify any of these parameters via the SCI will be ignored.
A.3 Processing
The Modbus communications protocol (PI-MBUS-300 Rev.J, Modicon Modbus Protocol

Reference Guide, Modicon Inc., June 1996) is used for data exchange on the SCI. This
section describes its implementation; many of the terms used are drawn from the Modbus
specification.
The SCI interface functions as a Modbus slave device. Once the SCI is configured, it
waits for a query (message) from a Modbus master. The DSP2 processes the request and,
if required, returns an appropriate response. While processing a query, the DSP2 ignores
any new query.
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If RS485 mode has been selected, the DSP2 normally configures the port hardware for
receive, switching to the transmission configuration only when sending a response.
The DSP2 supports the remote terminal unit (RTU) serial transmission mode of the
Modbus protocol only.
The DSP2 always requires a “silent time” of at least 3.5 character times as an indication
of the end of a query. Characters received with less than this time separating them will be
deemed part of a single query.
Only queries containing 255 characters or less are supported. Any query longer than this
is ignored.
Characters that have a framing error are ignored. This will typically cause any associated
query to be rejected (as missing characters will normally cause the CRC validation check
to fail).
The table of Modbus registers is given in Section A.4.2.
The following function codes are supported:
Value Name Notes

(Hex)
3 Read Holding Registers Used to read an arbitrary number of (contiguous) registers.
Equivalent to the “Read Input Registers” function code.
4 Read Input Registers Used to read an arbitrary number of (contiguous) registers.
Equivalent to the “Read Holding Registers” function code.
6 Preset Single Register Used to write a single register. The value written becomes
effective immediately.
10 Preset Multiple Registers Used to write multiple (contiguous) registers. The value(s)
written become effective immediately.
Write errors generally result in the return of an exception response. Since write errors are
tested per-register as a query is processed, some registers may be written even if an
exception response is returned.
Caution
Reads of undocumented registers will return

indeterminate values. Writing to undocumented registers
may cause the Digital and Analog Outputs and the Load
Alarms to be unpredictable and use of the system for mill
control purposes may cause the production of
off-specification product or mill damage
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The following table summarizes the exception codes:
Value Name Sent When:

(Hex)
1 Illegal Function An unrecognized function code is received
A query requests a response that would contain more than 255
characters
2 Illegal Data Address An attempt is made to write to an unimplemented register
3 Illegal Data Value An attempt is made to write to a read-only register
An attempt is made to write an out-of-range value to a register
An attempt is made to write to a register during a critical function
such as Configuration, Auto Calibration, or Self Test (see Note
below)
Note
During certain critical functions all writes to Modbus

registers are blocked. If an attempt is made to write to
the DSP2 when it is in this state, an error will result.
The following is an example of the use of the “read holding registers” function to read
Load and/or Load Alarm. Note that these parameters have been grouped in the memory
map (Section A.4.2) so that data for both sensors may be obtained with a single command.
Query (from Master)
Value Field Name Notes

(Hex)
0A Slave Address
03 Function Code Using the “Read Input Registers” function code would yield
identical results
00 Starting Address Hi Starting address = 0000 Hex
00 Starting Address Lo
00 Number of Points Hi Number of points = 0002 Hex
02 Number of Points Lo
C5 CRC Lo
70 CRC Hi
Response (from DSP2)

(Hex)
0A Slave Address Echo of query
03 Function Code Echo of query
04 Byte Count Number of (data) bytes that follow
27 Data Hi (Register 0000) Load (Percentage) = 2710 (Hex) = 10000 = 100.00%
10 Data Lo (Register 0000)
27 Data Hi (Register 0001) Load (Percentage) = 2710 (Hex) = 10000 = 100.00%
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10 Data Lo (Register 0001)

51 CRC Lo
BE CRC Hi
The following is an example of the use of the “preset multiple registers” function to write
both Wrap Angle Value inputs.
Query (from Master)

(Hex)
0A Slave Address
10 Function Code Preset Multiple Registers
10 Starting Address Hi Starting register address = 1000 Hex
00 Number of Registers Hi Number of registers to write = 2
02 Number of Registers Lo
04 Byte Count Number of bytes of data that follow = 4
09 Data Hi WAC Input W1 = 929 (Hex) = 2345 = 23.45%
29 Data Lo
15 Data Hi WAC Input W1 = 1538 (Hex) = 5432 = 54.32%
38 Data Lo
C6 CRC Lo
5D CRC Hi
Response (from DSP2)

(Hex)
0A Slave Address Echo of query
03 Function Code Echo of query
10 Starting Address Hi Echo of query
00 Number of Registers Hi Echo of query
02 Number of Registers Lo
C1 CRC Lo
B0 CRC Hi
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A.4 Communications
A.4.1 Data Formats
The following table defines the formats of data that have been reconstructed after transmission.
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, unless stated otherwise.
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 the 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. 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.
Name Description Details

Signed Integer Types
16I0 16 bit, signed integer, no decimal digits Example: -12345 stored as -12345
16I2 16 bit, signed integer, two decimal digits Example: -123.45 stored as -12345
Unsigned Integer Types

16U0 16 bit, unsigned integer, no decimal digits Example: 12345 stored as 12345
16U1 16 bit, unsigned integer, one decimal digit Example: 1234.5 stored as 12345
16U2 16 bit, unsigned integer, two decimal digits Example: 123.45 stored as 12345
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16U4 16 bit, unsigned integer, four decimal digits Example: 1.2345 stored as 12345
Enumerated Types
16E9 Source 0-A&B
1-2xA
2-2xB
16E12 No/Yes 0 - No
1 - Yes
16E13 Disable/Enable 0 - Disable
1 - Enable
16E14 Simulation 0 - Disable
1 - Simulate
2 - Shunt
Bitmapped Types
16B0 Logic Outputs (System Status Indicators and Bit 0 - System Fault
Load Alarms) Bit 1 - Channel A Fault
Bit 2 - Channel B Fault
Bit 3 - Single Sensor Operation
Bit 4 - Load Alarm 1
16B1 Electronics Status Bit 0 - Signal Processing
Bit 1 - Not assigned
Bit 3 - Not used
Bit 4 - Not used
Bit 5 - Strain Gage Interface Board failed
Bit 6 - Not assiged
Bit 7 - Excessive internal temperature
16B2 Channel Status Bit 0 - Excitation current OFF
Bit 1 - Excitation undercurrent low
Bit 2 - Input Saturation ±
Bit 3 - Excitation current out of range
Bit 4 - No response to shunt resistor
Bit 5 - Coarse offset failure
Bit 6 - Coarse offset; no response
Bit 7 - No valid input
Bit 8 - Shunt resistor input too low
Bit 9 - Coarse gain fault
Bit 10 - Fine zero offset out of margin
Bit 11 - Fine gain out of margin
Bit 12 - Invalid parameter value
Bit 13 - Load Simulation active
Bit 14 - Internal routines active
Bit 15 - Signal Off (other channel doubled)
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A.4.2 Memory Map
The following table lists the Modbus registers that may be accessed. Each register
contains a 16-bit value (i.e., consistent with the definition of a Modbus register).
Address Name Format Units Min Max Default Notes

(Hex) Value Value Value
Loads and Load Alarms (Read-Only, Volatile)
0000 Load A 16I2 % -327.67 327.67 -
0001 Load B 16I2 % -327.67 327.67 -
0002 Logic Outputs (Relays) 16B0 - - - -
0003 Sum (A+B) Load 16I2 % -327.67 327.67 -
0004 Difference (A-B) Load 16I2 % -327.67 327.67 -
System Status Data (Read-Only, Volatile)

000C Electronics Status 16B1 - - - 0
000D Channel A Status 16B2 - - - 0
000E Channel B Status 16B2 - - - 0
Operational Parameters (Read-Write, Volatile)

1000 Wrap Angle Compensation 16U1 % 0.0 100.0 0 1
(WAC) Input 1
1001 Wrap Angle Compensation 16U1 % 0.0 100.0 0 1
(WAC) Input 2
1002 Auto Calibration 16E12 - - - 0 2
1003 Auto Zero 16E12 - - - 0 2
2001 Source 16E9 - - - 0 3
2180 Lockout 16E13 - - - 1 4
Notes:
1. These registers are used to input Wrap Angle Values off-line wrap angle input mode,
see Sections 5.5 and 6.8 for additional information. The SCI should not be used to
input wrap angle sensor signals in on-line wrap angle input mode, the higher data rate
of the Fieldbus Interface is required.
2. The Auto Calibration (ref. Section 6.7) and Auto Zero (ref. Section 6.6) registers are
normally in the “No” state. A “Yes” instruction is required to initiate a function.
When the function is complete, the register is automatically reset to “No” by the DSP2.
3. If this register is set for Single Sensor Operation (1 for 2xA or 2 for 2xB), it can only
be changed to 0 for normal operation (A+B). See Section 6.5 for additional
information.
4. The effect of an instruction to the Lockout register is dependent on the status of the
Lockout Logic Input, see Section 6.11.
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The SCI registers relate to the Status Indicators and Logic Outputs as shown in the
following table.
Status Indicator/Logic Output SCI Register

Electronics Healthy (Indicator only) Electronics Status (000C) = 0
System Fault Electronics Status (000C) ≠ 0,
Channel A Status (000D) ≠ 0, and/or
Channel B Status (000E) ≠ 0
Channel A Fault Channel A Status (000D) ≠ 0, and/or
Source (2001) = 2
Channel B Fault Channel B Status (000D) ≠ 0, and/or
Source (2001) = 1
Single Sensor Operation Source (2001) ≠ 0
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APPENDIX B FIELDBUS - ETHERNET (MODBUS/TCP) PROTOCOL
B.1 Introduction
The 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 appendix describes the Ethernet (Modbus/TCP) version
B.2 Setup and Configuration
Note: the switches on the rear of the unit are not used.
B.2.1 Connections
Connect the DSP2 to the fieldbus at connector J9 as indicated below.
Connector Signal Description

pin
1 TD+ Positive Transmit Data
2 TD- Negative Transmit Data
3 RD+ Positive Receive Data
4 NC No connection
5 NC No connection
6 RD- Negative Receive Data
7 NC No connection
8 NC No connection
Casing PE Protective earth
B.2.2 Terminations
This module is for use with twisted pair cables; no external terminator is required.
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B.2.3 Node Address
Configure the DSP2 either at the Front Panel Interface, Section 5.8.5, or via the User
Access Program. Set:
• Address (1-254)
Note: the IP address default is 10.0.0.254; it is the last field that is set via the FGI or the
UAP.
B.2.4 Indicators
This module is equipped with four bi-color status and indication LED’s at the front of the
unit. They indicate as follows:
Number Color Frequency Indication
1 Green Steady Connection Status
2 Green Steady Module Status
3 Green Flashes Network Status
4 Green Flashes Transmission Activity
B.3 Processing
Because the DSP2 Fieldbus interface is implemented as two sections of dual port RAM,
one Read and the other Write, 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 has been updated by the host 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, used to identify changes, is set to 0. If the host
tries to write a zero to a DSP2 variable, no action will be taken and the DSP2
variable will remain at its default power-on value.
If the host tries to write the same value twice to a DSP2 variable, no action will be
taken and the DSP2 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 Auto Calibrate and Auto 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:
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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 1 from the mirrored read register.
When the function is completed, the host will read 0 from the mirrored read register.
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 as is the case on the SCI bus. If the host sends
invalid (out of range) data it is ignored by the DSP2.
B.4 Communications
B.4.1 Data Formats

I - Signed Integer
E - Enumerated
B - Bitmapped
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Etc.


Enumerated Types
16E9 Source 0-A&B
1-2xA
2-2xB
16E12 No/Yes 0 - No
1 - Yes
1 - Enable
Bitmapped Types
16B1 Electronics Status Bit 0 - Signal Processing error
Bit 3 - Not used
Bit 4 - Not used
Bit 5 - Coarse offset correction failure
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B.4.2 Memory Map
The following table defines the data that may be accessed via the Fieldbus interface. The
grouping of the data reflects the manner in which it is treated by the DSP2. Process
variables are updated from the DSP2 to the Fieldbus memory at 500Hz, other variables
are updated at approximately 45Hz.
Modbus TCP Memory Map
Host Read Host Write Name Format Units Min Max Default Notes
Address Address Value Value Value
(Hex) (Hex)
Process Variables (Read-Only, Volatile)
0000 Input A Load 16I2 % -327.68 327.67 - 1
0001 Input B Load 16I2 % -327.68 327.67 - 1
0002 Relay Outputs 16B0 - - - - 1
0003 Input Sum A+B 16I2 % -327.67 327.67 - 1
0004 Input Difference A-B 16I2 % -327.67 327.67 - 1
000C Electronics Status 16B1 - - - 0 2
000D Channel A Status 16B2 - - - 0 2
000E Channel B Status 16B2 - - - 0 2
000F Electronics Temperature 16U1 °C -55.0 125.0 - 2
0020 0420 WAC Input W1 16U0 - 0 1000 0 2
0021 0421 WAC Input W2 16U0 - 0 1000 0 2
0022 0422 AutoCalibrate 16E12 - - - 0 2,3
0023 0423 AutoZero 16E12 - - - 0 2,3
Configuration Parameters (Read-Write, Non-Volatile)
0041 0441 Sensor Input Configuration 16E9 - - - 0 2,4
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Notes:
1. These variables are updated by the DSP2 at 500Hz.
2. These variables are updated by the DSP2 one at a time sequentially every 2ms.
(about 45Hz).
3. Refer to B.3 above for operation of this function request register.
4. Sensor Input Configuration is for invoking 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 SCI bus can clear it.
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KELK Profibus
APPENDIX C FIELDBUS - PROFIBUS PROTOCOL
C.1 Introduction
The 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 appendix describes the Profibus DP protocol version.
C.2 Setup and Configuration
Figure C1. Rear view of card
C.2.1 Connections
Connect the DSP2 to the fieldbus at connector J9 as indicated below.

Pin Name Function
Housing Shield Connected to PE
1 Not Connected -
2 Not Connected -
3 B-Line Positive RxD/TxD according to RS485 specification
4 RTS Request to Send *
5 GND BUS Isolated GND from RS 485 side *
6 +5V BUS Isolated +5V from RS 485 side *
7 Not Connected -
8 A-Line Negative RxD/TxD according to RS 485 specification
9 Not Connected -
* +5V BUS and GND BUS are used for bus termination. Some devices, like optical transceivers
(RS485 to fibre optics) might require external power supply from these pins. RTS is used in
some equipment to determine the direction of transmission. In normal applications only A-Line,
B-Line and Shield are used.
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C.2.2 Termination
The end nodes in a Profibus-DP network has to be terminated to avoid reflections on the
bus line. The AnyBus-S Profibus-DP module is equipped with a termination switch to
accomplish this in an easy way. If the module is used as the first or last module in a
network the termination switch has to be in ON position. Otherwise, the switch has to be
in OFF position.
PLEASE NOTE: If an external termination connector is used the switch must be in OFF
position.
Termination switch ON Bus termination enabled
If the module is the last or first module, the

bus termination has to be set on, or an
external termination connector has to be
used
Termination switch OFF Bus termination disabled
C.2.3 Node Address
On the rear of the Fieldbus card are two rotary switches. These are for the purpose of
manually setting the address. The switch setting is not used by DSP2 and, therefore, both
switches must be set to zero
Configure the DSP2 either at the Front Panel Interface, Section 5.8.5 or via the User
Access Program. Set:
Address (1-125) DSP2 accepts values up to 254, the card, however, is limited to a
maximum of 125.
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C.2.4 Indications
The module is equipped with four LED's mounted at the front panel and one LED on the
board, used for debugging purposes. The front LED's can be mounted in two ways, either
top mounted or angle mounted. The function of the LED's are described in the table and
figure below.
1. Not used
2. On-Line
3. Off-Line
4. Fieldbus diagnostics
There is also one additional Bicolour Watchdog LED on the AnyBus-S module. The
functionality of this LED is the same for all AnyBus-S modules, and is specified in the
AnyBus-S Design Guide.
Name Colour Function
Fieldbus Diagnostics Red Indicates certain faults on the Fieldbus side.
Flashing Red 1 Hz - Error in configuration: IN

and/or OUT length set during initialization of the
module is not equal to the length set during
configuration of the network.
Flashing Red 2 Hz - Error in User Parameter data:
The length/contents of the User Parameter data set
during initialization of the module is not equal to
the length/contents set during configuration of the
network.
Flashing Red 4 Hz - Error in initialization of the
Profibus Communication ASIC.
Turned OFF - NO diagnostics present
On-Line Green Indicates that the module is On-Line on the
fieldbus.
Green - Module is On-Line and data exchange is
possible.
Turned Off - Module is not On-Line.
Off-Line Red Indicates that the module is Off-Line on the
fieldbus.
Red - Module is Off-Line and no data exchange is
possible.
Turned Off - Module is not Off-Line
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KELK Profibus
C.3 Processing
Because the DSP2 Fieldbus interface is implemented as two sections of dual port RAM,
one Read and the other Write, 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 has been updated by the host 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, used to identify changes, is set to 0. If the host
tries to write a zero to a DSP2 variable, no action will be taken and the DSP2
variable will remain at its default power-on value.
If the host tries to write the same value twice to a DSP2 variable, no action will be
taken and the DSP2 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 Auto Calibrate and Auto 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 1 from the mirrored read
register.
When the function is completed, the host will read 0 from the mirrored read
register.
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 as is the case on the SCI bus. If the host sends
invalid (out of range) data it is ignored by the DSP2.
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KELK Profibus
C.4 Communications
C.4.1 Data Formats

I - Signed Integer
E - Enumerated
B - Bitmapped
Etc.
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KELK Profibus

Enumerated Types
16E9 Source 0-A&B
1-2xA
2-2xB
16E12 No/Yes 0 - No
1 - Yes
1 - Enable
Bitmapped Types
16B1 Electronics Status Bit 0 - Signal Processing error
Bit 3 - Not used
Bit 4 - Not used
Bit 5 - Coarse offset correction failure
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KELK Profibus
C.4.2 Memory Map
The following table defines the data that may be accessed via the Fieldbus interface. The
grouping of the data reflects the manner in which it is treated by the DSP2. Process
variables are updated from the DSP2 to the Fieldbus memory at 500Hz, other variables
are updated at approximately 45Hz.
Byte based addressing is used.
Each DSP2 variable occupies two bytes (MSB:LSB)
Profibus DP Memory Map
Host Read Host Write Name Format Units Min Max Default Notes
Address Address Value Value Value
(Hex) (Hex)
Process Variables (Read-Only, Volatile)
0000:1 Input A Load 16I2 % -327.68 327.67 - 1
0002:3 Input B Load 16I2 % -327.68 327.67 - 1
0004:5 Relay Outputs 16B0 - - - - 1
0006:7 Input Sum A+B 16I2 % -327.67 327.67 - 1
0008:9 Input Difference A-B 16I2 % -327.67 327.67 - 1
0010:11 Electronics Status 16B1 - - - 0 2
0012:13 Channel A Status 16B2 - - - 0 2
0014:15 Channel B Status 16B2 - - - 0 2
0016:17 Electronics Temperature 16U1 °C -55.0 125.0 - 2
0020:21 0000:1 WAC Input W1 16U0 - 0 1000 0 2
0022:23 0002:3 WAC Input W2 16U0 - 0 1000 0 2
0024:25 0004:5 AutoCalibrate 16E12 - - - 0 2,3
0026:27 0006:7 AutoZero 16E12 - - - 0 2,3
Configuration Parameters (Read-Write, Non-Volatile)
0030:31 0010:11 Sensor Input Configuration 16E9 - - - 0 2,4
Notes:
1. These variables are updated by the DSP2 at 500Hz.
2. These variables are updated by the DSP2 one at a time sequentially every 2ms.
(about 45Hz).
3. Refer to the paragraph C.3 above for operation of this function request register.
4. Sensor Input Configuration is for invoking 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 SCI bus can clear it.
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KELK Spares
APPENDIX D RECOMMENDED SPARES
Below are lists of DSP2 options and spares. They may be used with any Rollmax DSP2
electronics system. Refer to KELK drawing 41990, provided at the end of this appendix, for the
DSP2 product structure and the availability of spares.
Description Part Number
Fuses (Spare) *07054 (1.25 Amp Slow Blow Fuse)

DSP2 - Main Frame Assembly (Spare) PL043046
Includes,
DSP2 enclosure,
Front Panel Interface,
Power Supply,
Signal Processor board.
Strain Gage Interface Board (Spare) 063310
Analog Output Board Option PL042978
Auxiliary Analog Input Board Option PL042977
Fieldbus Interface Card Option
Profibus PL042858
Ethernet (Modbus/TCP) PL042857
Note: If the user intends to expand an existing system by including an above analog input or
output option, the corresponding cable assembly for that option must be ordered
separately, see Individual Input/Output Cable Assemblies section below.
Basic DSP2 Wiring Harness
Harnesses are manufactured to a fixed length with 1.2 metres of connecting cable between the
DSP2 frame and the start of the terminal block assembly, as required for installation in KELK
cabinets. An optional, extended harness length of 2.0 metres is available.
Each harness configuration can be defined by a discrete part number:
PL044673-YYZL.L
The extension YYZ is added to denote included options in the same way as the DSP2 unit. The
extension L.L provides the harness length. A further explanation is as follows:
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KELK Spares
YY represents: No. of Analog Output Boards -1A, -2A, or -3A. (the number of
actual boards, with “A” denoting
“Analog”
Z represents: Auxiliary Analog Input Board -X (left blank if option not selected)
L.L represents: Harness length -1.2 standard or 2.0 metre extended

option
Individual Input/Output Cable Assemblies
The following individual cable assemblies can be ordered apart from the Basic DSP2 harness. As
described above, if an optional analog input or output board is purchased for an existing system,
the respective cable assembly must also be ordered from the list below.
The Twin Strain Gage Input and Logic I/O cable assemblies (that are used in the Basic DSP2
Wiring Harness) can be ordered as spares. As can be seen below, the part numbers for these
assemblies have only a length extension. The first number is the standard length, while the value
in parentheses is the optional, longer length.
NOTE: Length of each cable assembly specified below is the full length, measured from the exit
point of the DSP2 to the respective terminal block.
Twin Strain Gage Input Cable Assembly PL042971-2.3M(3.05M) (services two

Strain Gage Inputs--i.e only one cable
assembly required per DSP2)
Logic I/O Cable Assembly PL042973-2.05M(2.8M)
Analog Output Cable Assembly PL042972-1.80M(2.55M)
Auxiliary Analog Input Cable Assembly PL042980-1.80M(2.55M)
Note that Profibus, Ethernet and Serial connections are provided directly on the DSP2 unit and
do not require a separate cable assembly.
Power Cord
IEC Power Cord *05901
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KELK USER ACCESS PROGRAM
APPENDIX E USER ACCESS PROGRAM
E.1 Introduction
The DSP2 is designed to function with a large range of strain gage sensor types and in a
range of applications. The DSP2 offers many features and options and can operate in a
number of distinct modes depending on the specific application. It is necessary, therefore,
that before the unit is placed into operation the user must define and set various parameters
and optional features. A menu driven Front Panel Interface is provided for this purpose.
The Front Panel Interface is limited in that it can only display one parameter at a time. The
User Access Program has been developed to provide the user with a more friendly and
more comprehensive tools by which to setup and monitor the DSP2.
The User Access Program (UAP) is supplied on CD together with a copy of the DSP2
Manual in pdf format. The program is designed for use with any PC operating in a
Windows environment; connection to the DSP2 is through the serial port. Connection is
made at J7-COM1 on the back of the DSP2.
E.2 Features
The UAP completely replicates the Front Panel Interface (FPI) for the setup of:
a) Input Channels
b) Wrap angle Compensation
c) Output Channels
d) Relays and Load Alarms
e) Communications
f) Front Panel Display
A full screen to monitor the load outputs from each channel and to determine the
status of the system.
A full diagnostics screen to provide the user with instant readout of the system status
plus an indication of any faults detected.
The program uses standard conventions and menu structure for its operation. Each
screen is self explanatory. Areas on any screen not available to the user are shown in
gray.
The UAP, when connected to the DSP2, automatically assesses the hardware
configuration of the DSP2.
An existing operation configuration can be read back from a DSP2.
A new or revised operation configuration can be downloaded to the DSP2.
Password protection can be applied to any file.
The UAP provides additional user access to the DSP2 not provided by the FPI.
a) Calculation of Cable Correction factors for installations with very long cable runs.
b) Calculation of wrap angle from known Tension system geometries.
c) Calculation of Look Up Table entries for Wrap Angle Compensation.
d) Internal configuration data.
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e) Component board identification.

f) Factory calibration information.
g) DSP2 System Status Logger, see Section 7.8.
E.3 Installation
For use with Windows 98, ME, 2000, or XP. Refer to Section 9.11 for minimum
computer requirements.
Insert the CD in the drive and follow 'NEXT' prompts to complete installation of the
program.
If the CD does not automatically start the installation process, open the CD icon and
double click on SETUP.EXE.
If there is already an earlier version of the program installed on the PC, the install
program will prompt you before uninstalling it. When the uninstall is complete,
remove and re-insert the CD to start the install process.
Once the program is installed, navigate through: Start\Programs\DSP2UAP and click

on DSP2UAP to launch the program.
From Windows Explorer or the My Computer folder:

Right clicking on the CD icon will display a menu of additional choices:
Read Me - Display this file
View Manual - Displays DSP2 User Manual (Requires Acrobat Reader)
Install UAP - Same actions as AutoRun
Install FLASH Loader - Use only under direction of KELK application specialist.
E.4 DSP2 Communication Setup
1. Turn on the DSP2.

2. At the Front Panel Interface select ‘ComunSet’, see Figure 3.7. Refer to section 5.8.5
of this manual.
3. Select ‘Serial’ then ‘ComRS232’ or ‘ComRS485’.
4. Assign an address to the DSP2 ‘Addrxxx’ in the range 001-254.
5. Select Baud rate 9600 / 19K / 38K or 57K.
E.4.1 Connection to DSP2
Connect the computer to the DSP2 via the serial link at connection J7-COM1 at the rear
of the DSP2.
Refer to Section 4.3.6.
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E.4.2 UAP Communications Setup
Start UAP
Under ‘File’ there is a menu item ‘Communications Setup’.
Selection of this item yields a panel that displays the Communication Setting List of
previously and currently connected DSP2 and a window for the entry of a new
Communications Setup. An active setting in the Communication Setting List will be
indicated by a ‘check’ in the second column; inactive settings are indicated by a red ‘X’.
Selection of any Setting on the list causes the details of that setting to be displayed in the
Communications Setup window. This display can be partially cleared by selecting ‘Add’
permitting the user to define a new setting. In this window:
The ‘COM port’ is the host computer COM port.
The Protocol and Address entries must match the target DSP2 protocol and address.
The DSP2 Name is user definable.
When the required setup has been defined click ‘Connect’ to add it to the Communications
Setting List. If a unit is detected to which this setup can be applied, a succesful connection
will be indicated, otherwise, the new entry will be marked with a red ‘X’.
E.4.3 Connect to DSP2
To connect to a DSP2 go to File and select ‘Communications Setup’ and select a

Communications Setting from the display or define a new Setup and click ‘Connect’.
To disconnect from the DSP2 go to File and select ‘Release’.
E.5. Using the UAP
E.5.1 Not connected to a DSP2
The UAP program can be accessed without connection to a DSP2. This mode allows the
user to view or edit backup configuration files and familiarize themselves with the
program and its navigation.
Upon start up the UAP will search for a connected DSP2 and attempt to establish
communication.
If no unit is found then the user is prompted to

a) Open a Configuration File. The program has a Default file ‘Default.cfg.’ available to the
user or the user may select from their own previously saved backup configuration files.
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b) Search for an ‘Attached device’

Select ‘Open a Configuration File’ and ‘Continue’
The program has a Default file ‘Default.cfg.’ available or the user may select from their
own previously saved files.
Selection of the default or a backup file will result in the display of the ‘Rollmax DSP2
Navigation Panel’.
E.5.2 Connected to a DSP2
Ensure that the computer is connected to the DSP2 and that the DSP2 communications
parameters have been defined as in E.4. above.
Upon start up the UAP will search for a DSP2 specified by Communication Setting List
and attempt to establish communication. If no unit is found then the user is prompted to
a) Open a Configuration File. The program has a Default file ‘Default.cfg.’ available to
the user or, the user may select from their own previously saved backup configuration
files or,
b) Search for an Attached device. This option presents the user with a Communications
Setup panel from which an existing connection can be accessed or a new connection
defined.
When a DSP2 is successfully detected, its configuration is automatically read back into
the UAP and the operating condition of that DSP2 is displayed.
The user has the option to go to the DSP2 Setup to select

a) Read from the DSP2 or
b) Read from a backup configuration file (default or customer file)
Selection of any read option will result in the display of the ‘Rollmax DSP2 Operation
Panel’ for either the file or the connected DSP2.
E.5.3 Data Entry
Data entry into any data field in any panel will result in the background of that field
changing colour to yellow to indicate that the field has been edited. The field background
will remain yellow until the data is applied to the DSP2 using the Apply command on the
DSP2 Setup panel or cancelled by selecting ‘Cancel Changes’. Data entered via the Input
Channel panel (see below) can only be applied to the DSP2 using the Configuration
command on the DSP2 Setup Panel.
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E.5.4 Applying Data to the DSP2
Data as entered into the UAP fields is applied to the DSP2 by the ‘Apply to DSP2’
command on the DSP2 Setup Panel. Data can be applied at anytime the UAP is in use.
See also ‘Configuration via the UAP’.
E.5.5 Configuration via the UAP
Data directly related to the sensor and to the sensor /DSP2 system setup (refer to section
5.2) can only be applied to DSP2 using the ‘Configuration’ command on the DSP2 Setup
Panel. When this command is invoked DSP2 verifies that the parameter values applied
(in E.5.3 and E.5.4 above, for example) are valid and then configures the internal gain
settings to provide the required system gain.
The user is advised to double check this data prior to invoking the ‘Apply to DSP2’ and
‘Configuration’ commands.
E.5.6 Printing Data From the UAP
A feature is available from the ‘File’ menu for the purpose of printing the following:
• a copy of the screen currently displayed

• and a summary of the Setup and Configuration applied to a given DSP2. An example
is given at the end of this Appendix.
E.5.7 Save File
‘Save File’ and ‘Save as’ buttons are provided on the DSP2 Setup Panel. Customer can
define the directory and save as ‘Name’.cfg.
E.6 UAP Displays
E.6.1 DSP2 Main Screen
This Screen is divided into two panels. The left panel is the Navigation Panel; this contains
menu systems for both connected DSP2 and any selected DSP2 configuration files. The
right hand panel is user selected from the menus listed on the Navigation Panel.
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E.6.2 Navigation Panel
The Navigation panel displays DSP2 file menus represented in three main sections
DSP2; ‘Name’ displays the current Operational status of a connected DSP2.
SETUP
DIAGNOSTICS
SETUP and DIAGNOSTICS contain sub-menus of related panels that can be selected and
accessed by the user.
The right hand panels that can be accessed via the Navigation panel are briefly described below.
E.6.3 DSP2 (name); Operations Panel
Selection of either ‘DSP2 (name)’ or ‘Operations’ will display the DSP2 Operations
panel, Figure E1.
‘Name’ is user applied for a connected DSP2, otherwise the FILE ‘name’ field indicates
that backup ‘name’ file is accessed.
Figure E1. DSP2 Operations Panel

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The DPS2 Operations panel displays the following operational details:

a) the current channel output levels on a bar graph in ‘% of F.S.’ or in customer
specified ‘Load Units[#]’
b) the load alarm condition
c) the system status
A series of buttons is available for the user to access any one of seven operations.
Activation of any button changes the dialogue box to reference the chosen operation and
displays another button for the user to invoke the chosen operation.
Operations:
1) Status
2) Single Sensor Operation; see Section 6.5
3) Calibration; see section 6.7
4) Zero; see section 6.6
5) Self-Test; see section 6.9
6) Reset; see section 6.10
7) WAC Input; see section 6.8
E.6.4 DSP2 Setup Panel
This panel, Figure E2, shows the current status of each parameter module. Any changes
made over the UAP will cause the appropriate box to change colour to yellow. This
indicates that changes have been made to the UAP file but have not yet been applied to a
DSP2 or saved to file.
Any parameter module can be selected from the SETUP sub-menu at the left of the panel.
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Figure E2. DSP2 Setup Panel
E.6.5 Setup Sub-Menu Panels
Input Channels Panel

The areas highlighted on this panel must be completed.
For Application, see section 5.8.1.
For Channel Calibration Data, see section 5.2.
For Filter, see section 5.4.
Gray areas are optional and can be accessed by selecting ‘Extended entry’.
Extended entry provides:
Entry of sensor data from the sensor Calibration Card.
A Cable Calculator feature for compensation for long interconnecting cables see
Section 5.2 of the manual.
An Application Wizard for Tension applications see section 5.5
An Apply Corrections button.
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Wrap Angle Compensation Panel
This panel shows the Wrap Angle Compensation Tables and allows the user to select the
mode of WAC input to the DSP2. Table data can be entered manually or by using the
Application Wizard. The data for entry is fully described in the panel notes. See also
section 5.5 of the manual.
Application Wizard
The Application Wizard may be accessed through the Input Channels Panel and Wrap
Angle Compensation Panel. The Application Wizard provides the means for the user to
select the type of tensiometer system in place, strip configurations, mounting
configurations, fixed or variable angles and to specify the system geometry. The
Wizard calculates wrap angles, system formulae, maximum loads and Utilization
factors for each defined system. Using the ‘Show Section View’ button, the user can
visually verify that the data input does correctly define the basic system configuration.
In the case of variable angle systems the Wrap Angle Coefficients are calculated and
can be applied directly to the DSP2. These coefficients can be further verified using the
‘View’ and ‘Check’ buttons on the Wrap Angle Compensation panel.
Analog Outputs Panel
For the configuration of the Analog Outputs, refer to Section 5.8.2.
Load Alarms Panel
For the configuration of the Load Alarms, refer to Section 5.8.3.
Communication Panel
This panel is for the setting of the Fieldbus communication parameters. See section 5.8.5.
Note the Serial communication parameters can only be changed or set at the DSP2 FPI.
FPI Display Panel
To set the mode and format of the front panel load display, refer to section 5.8.6.
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E.6.6 Diagnostics
Diagnostics Status Panel
This panel, Figure E3, illustrates the current status of the DSP2.
The DSP2 Internal temperature, Start Up Code and Start Up Counter are also displayed
on this panel.
See Part 7 Troubleshooting for a full explanation of all displayed fault conditions and
Start Up Codes and Counter.
Figure E3. Diagnostics DSP2 Status Panel
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Diagnostics Sub-Menu Panels
Configuration Data Panel
This panel displays the internal settings of the DSP2 for each input channel. The user has
no access to these settings; they are for information only.
Identification Panel
This panel displays DSP2 serial number and identification details for all boards installed
in the subject DSP2. This is for information only.
Factory Calibration Panel
This panel displays factory set calibration parameters for Auxiliary Analog Input and
Analog Output boards installed in the subject DSP2.
The user has no access to these parameters; they are for information only.
Simulation and Output Test Panel
This panel allows the user to simulate loads on each input channel either to some selected
level or by applying a shunt resistor directly to the sensor. The simulation is indicated at
the analog outputs and, if applicable, at the Relays. Refer to Section 7.7.
E.7 Example of DSP2 Setup and Configuration Summary Printout (see following pages)
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DSP2 Setup and Configuration Summary
Pg. 1 of 3
DSP2 Name: Test Sample Date: 2006-09-13 11:14:20
IDENTIFICATION
Rollmax DSP2
Serial Number: 133 Firmware Version: 01.12
Signal Processor Board

Serial Number: 19 Hardware Version: C2
Strain Gage Interface Boards (SGIB)

Channel 'A' Serial Number: 14 Hardware Version: D1
Channel 'B' Serial Number: 51751 Hardware Version: E
Analog Outputs Boards (AOUT):

AUOT '1' Serial Number: 27 Hardware Version: C1
AUOT '2' Serial Number: 19 Hardware Version: C1
AUOT '3' N/A
Auxiliary Analog Input Board

N/A
Fieldbus Card
N/A
SETUP
Input Channels
Load Cell Calibration Card Information Channel 'A' Channel 'B'
Model No. D1335 D1335
Serial No. 11 12
Capacity (C) [N] 2500.00 2500.0
Sensitivity (S) [mV/N] 1.6567 1.6541
Shunt Resistor at Calibration [✗✡] 250 250
Output with Calibration Shunt Resistor [Oc] [%] 42.29 42.39
Output Briidge Resistance ✡ 700.00 700.00
Interconnection Cable
Measured Single lead resistance: 1.70 [ohm]
Calibration Target Load Correction
Cable Correction Factor (Cf) 1.0097 1.0097
Utilization Factor (Uf) 1.2120 1.2120
Application Data and DSP2 Setting
Load Cell Sensitivity at Rated Load (Sr) [mV/V] — —
Application Shunt Resistor [✗✡] 100
Output with Application Shunt Resistor (Os) [%] 105.7 105.97
Calibration Target Load [%] A:86.25 B:100.20
DSP2 Inputs
Application Tension
Filter Length 999 Corner Frequency 5 [Hz]
Sensor Input Configuration Normal(A&B)
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Pg. 2 of 3
SETUP
Analog Outputs Source Operational Output Scale

Mode Factor [% F.S.]
Analog Output 1 OFF 0-10V 100.0
Analog Output 2 A 0-10V 100.0
Analog Output 3 A+B 4-20mA 100.0
Analog Output 4 A-B 4-12-20mA 10.0
Load Alarms Source Mode of Threshold Time

Operation [ms]
Relay #1 A Load Level 87.5 %F.S. 10
Relay #2 A+B Load Level 75.0 %F.S. 10
Relay #3 A+B + Rate 10.0 %F.S./ms 10
Relay #4 OFF Load Level 105.0 %F.S. 10
WAC Source 1 OFF WAC Source 2 OFF

WAC Input 1 111 WAC Input 2 222
Entry# Input Coefficient Entry# Input Coefficient
Value Value
1 0 9999 1 0 9999
2 50 9999 2 50 9999
3 100 9999 3 100 9999
4 150 9999 4 150 9999
5 200 9999 5 200 9999
6 250 9999 6 250 9999
7 300 9999 7 300 9999
8 350 9999 8 350 9999
9 400 9999 9 400 9999
10 450 9999 10 450 9999
11 500 9999 11 500 9999
12 550 9999 12 550 9999
13 600 9999 13 600 9999
14 650 9999 14 650 9999
15 700 9999 15 700 9999
16 750 9999 16 750 9999
17 800 9999 17 800 9999
18 850 9999 18 850 9999
19 900 9999 19 900 9999
20 950 9999 20 950 9999
21 1000 9999 21 1000 9999
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Pg. 3 of 3
Communication
Serial: RS-232 Baud Rate: 9.6K Address: 254

FieldBus: Protocol: — Address: 10.0.0.252
FPI Display
Timeout [sec] 1800 Display Time [sec] 2.0
Full Scale Factor 2500
CALIBRATION DATA
Channel 'A' Channel 'B’
Input Channel Configuration Parameters
Hardware Settings
Zero DAC 0 -31
Gain DAC 4095 1347
Excitation DAC 4095 541
Software Settings
Fine Zero Adjustment -19550 -19445
Fine Gain Adjustment 60000 60000
Tare Load (Zero Offset)
Tare Zero Offset [ % ] -195 -194
Input Channel Settings
Zero Correction Limit [ % ] 20 20
Maximum Input [ % ] 325.00 325.00
FACTORY CALIBRATION / SETTING
Individual and Sum Full Scale Bar Graph [%] 100
Auxiliary Analog Input Board Calibration

Input 1 Input 2
0 Counts 0 0
1000 Counts 512 512
Analog Output Boards Calibration

Output Board #1 (J6) Output Board #2 (J5) (Output Board #3 (J4)
Channel 1 Channel 2 Channel 1 Channel 2 Channel 1 Channel 2
-10 Volts 3076 3046 3076 2992 0 0
0 Volts 32768 32768 32768 32768 0 0
+10 Volts 62462 62492 62460 62544 0 0
0 mA 3065 3079 3052 2985 0 0
4 mA 14926 15019 14976 14944 0 0
20 mA 62358 62768 62142 62752 0 0
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KELK Tensiometer Calibration
Information Sheets
APPENDIX F
Tensiometer Calibration Information Sheets, Forms 858 and 855
F.1 Introduction
KELK load cells can be used to measure force or tension. Each load cell is factory
calibrated to determine its full load sensitivity (output at its rated capacity). Following
this, a precision resistor of known value (calibration shunt resistor) is placed across one
arm of the load cell bridge to force a fixed and repeatable output. The forced output is
expressed as a percentage of the full scale output for force, pressure or tension, depending
on the application. This provides a precise transfer reference that allows the system to be
calibrated on-site, effectively removing the need to use dead weight or auxiliary
calibration equipment that may be difficult to apply in the actual installation.
Each KELK load cell is supplied with a calibration card giving details of the model and
serial number, its full load sensitivity and the value of transfer reference and the value of
shunt resistor applied to create it. An example of a calibration card is given in Figure F1.
Figure F1. Example of a Calibration Card
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Information Sheets
Load cell systems that require outputs in terms of force or load can be calibrated directly
using the information given on the calibration card. In the cases of systems designed to
measure tension, however, additional information is required to assist the user to calibrate
the system.
In tension measurement systems, the load cells measure load directly proportional to
tension. The constant of proportionality is related to the overall system geometry and the
wrap angles of the strip over the tensiometer roll. The accuracy of the system depends on
the precise knowledge of the system geometry and the wrap angles.
With each tension measurement system, KELK provides a ‘Tensiometer Application Data
Sheet’, Form 858 or 859, and a Tensiometer Calibration Data Sheet, Form 855.
F.2 Tensiometer Application Data Sheet
F.2.1 Fixed Wrap Angle Systems (Form 858)
Copies of this form corresponding to each application can be found in Section A of the
Tension Measurement System manual. The form is generated by KELK by inputting
application wrap angles and specific system parameters, as given on the system
installation drawing, into the DSP2 User Access Program (UAP) supplied with the
system. An example is given in Figure F2.
This feature of the UAP can be accessed by activating the ‘Application Wizard’ button in
the ‘Input Channels’ screen.
Note: the ‘Application Wizard’ button is only active if the ‘Tension’ application and
‘Extended Entry’ selections are chosen.
Refer to Appendix E for full details.
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Information Sheets
Figure F2. Form 858 Tensiometer Application Data Sheet
The wizard 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
Accurate determination of wrap angle using the selected strip to roll condition and
dimensional parameters
Determination of the maximum normal and parallel forces due to tension that are
applied to the measuring system
The maximum force on the load cell at maximum rated tension
The constant of proportionality between tension and the resulting force on the load cell
The Utilization Factor; the ratio of cell capacity to force at maximum rated tension
The above information is all displayed, and can be readily interpreted, using the
comprehensive legend.
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Information Sheets
F.2.2 Variable Wrap Angle Systems (Form 859)
Refer to Sections 5.8.4 and 6.8 for full details of Wrap Angle Compensation.
Compensation is achieved using values from look-up tables to calculate system gain
compensation factors. The UAP Application Wizard can generate the look-up tables
based on user input. Figure F3 illustrates the look-up tables for a system with one
variable angle and one fixed angle. Figure F4 illustrates the case for two variable angles.
Figure F3. Form 859 with WAC Tables for One Variable Angle Case
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Information Sheets
Figure F4. Form 859 with WAC Tables for Two Variable Angles Case
KELK generates Form 859 using the user-supplied data. In the event of system changes, the
user can utilize the UAP feature to update the system information and generate new data.
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F.3 Form 855 Tensiometer Calibration Data Sheet
This form, supplied for each application, uses the data derived using Form 858 and load
cell calibration cards to determine the Calibration Target Load to be entered into the
DSP2 to correctly calibrate each sensor channel. As a result, the DSP2 outputs a signal
directly representing 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.
1 Location Interstand 1-2 Interstand 2-3 0 0 0 0
Information
Application
2 Position OS DS OS DS 0 0 0 0 0 0 0 0
3 Rated Tension (Tr) kN 100 100 0 0 0 0
4 KELK Reference Installation dwg. xxxxx Installation dwg. xxxxx 0 0 0 0
5 Model No. Dxxxx Dxxxx 0 0 0 0

Load Cell Calibration Card
6 Serial No. 11 12 13 14 0 0 0 0 0 0 0 0
7 Capacity ( C ) kq 1400 1400 0 0 0 0

Information
8 Sensitivity (S) mV/V 1.5600 1.5499 1.5600 1.5678 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000
Shunt Resistor
9 κΩ 200 200 0 0 0 0
at Calibration
Output with Calibration
10 mV/V 0.8599 0.8450 0.8599 0.8862 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000
Shunt Resistor (Oc)
Output Bridge
11 Ω 700 700 0 0 0 0
Resistance
Corrections
Cable Correction
12 1 1 0 0 0 0
Factor (Cf)1
2
13 Utilization Factor (Uf) 2.1393 2.0890 0.0000 0.0000 0.0000 0.0000
Load Cell sensitivity

14 mV/V 0.7292 0.7245 0.7468 0.7505 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000
at Rated tension (Sr)
and DSP 2 Setting
Application Data
Application
15 κΩ 250 250 0 0 0 0
Shunt Resistor
Output with application
16 mV/V 0.6879 0.6760 0.6879 0.7090 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000
Shunt Resistor (Os)
Calibration Target Load
17
CTL=100*(Os/Sr)
% 94.34 93.31 92.12 94.47 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
18 CTL * Cf % 1 1 1 1 0 0 0 0 0 0 0 0
Customer Name
1
. To determine the Cable Correction Factor Cf, see System Manual under 'Calibration', DSP2 Manual section Mill Type
5.2 or use the DSP2 UAP.
2
. Utilization Factor Uf - the ratio of load cell capacity to force on the load cell at full rated tension; from Form 858. TENSIOMETER CALIBRATION DATA SHEET
INQUIRY: REV. DATE: DRAWN:
ZZ-YYYY 21-Feb-06
For full description of this form and its use, refer to Appendix F of DSP2 manual. JOB No.: DATE: CHK/APP:
JT-xxxx 09-Apr-08
Example for DSP2 manual.XLS

kelk
GEORGE KELK CORPORATION
FORM:
855
SHEET 1 of 1
Figure F5. Form 855 Tensiometer Calibration Data Sheet
The form also includes information to assist the user in the setup of each input channel as
follows:
Application information
Row 1. Location in mill
2. Sensor position; for example, Drive or Operator side
3. Rated tension for the application
4. KELK reference information (installation drawing number)
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Load cell Calibration Card Information

Row 5.
Load cell model number
6.
Load cell serial number for each sensor position (see Row 2 above)
7.
Load cell capacity (C)
8.
Load cell sensitivity (S) in mV/V at full rated capacity
9.
Shunt resistance used at factory calibration (note this may not be the same
value as for the application; see Row 15)
10. Output in mV/V with shunt resistor applied (OC.)
11. Sensor bridge resistance in Ohms
Correction Factors (that are applied)

Row 12. Utilization factor (Uf); the ratio of load cell capacity to force on the sensor at
full rated tension (from Form 858)
13. Cable correction factor (Cf); to compensate for additional interconnecting
cable resistance (obtained by manual calculation; see section 5.2 of this
manual, or by using the Cable Calculator feature accessed from the ‘Input
Channels’ screen of the UAP)
Application Data and DSP2 Settings

Row 14. Load cell output at full rated tension SR = S/Uf in mV/V
15. DSP2 shunt resistance to be selected for this application
16. Sensor output OS, in mV/V, with shunt resistor (row 15) applied
Where OS = OC * (Shunt Resistance at Calibration (Row 9))
(Application Shunt Resistance ( Row 15))
17. Calibration Target Load (CTL) for each sensor channel
(CTL = 100 * OS / SR)
18. Calibration Target Load corrected for cable resistance (CTL * Cf).
Important Note.
The content of Forms 855 and 858, as supplied with the manual, is derived from the information
given on the installation drawing and/or supplied by the customer. This data should be checked
against the ‘as built’ or ‘as installed’ situation at the time of system calibration. If the data on the
forms do not correspond to the ‘as installed’ situation, new forms should be created. This can
either be done by KELK or by the customer using the UAP Input Channel screen and the
Application Wizard. Software to create Form 855 is included on the UAP CD.
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ROLLMAX

DIGITAL SIGNAL PROCESSOR

MANUAL # 90348 Rev F2

© 2003 George Kelk Corporation

GEORGE KELK CORPORATION

Tel (416) 445-5850

DSP2 90348 Rev F2

Part 5 Setup and Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

DSP2 90348 Rev F2

8.3 Printed Circuit Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

DSP2 90348 Rev F2

Appendix D Recommended Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

DSP2 90348 Rev F2

Under no circumstances shall KELK be liable for consequential damages

Installation, Setup and Configuration

The DSP2 must be installed, setup and configured as specified in Part 4,

DSP2 90348 Rev F2

Warnings and Cautions

!? Caution, refer to accompanying documents.

? Caution, risk of electric shock.

Protective Conductor Terminal.

Cautions are included in this manual to advise of hazards to which equipment

Persons undertaking the installation, commissioning, operation and service of the

Electrostatic discharge (ESD) can damage static

DSP2 90348 Rev F2

PART 1 ABOUT THIS MANUAL

DSP2 90348 Rev F2

Figure 2.1 Rollmax Digital Signal Processor, Model DSP2

DSP2 90348 Rev F2

The DSP2 supports two sensors; it features:

Sensor excitation and signal conditioning

Single Sensor Operation

2.2 Hardware Configuration

The DSP2, Figure 2.2, comprises:

Plus optional boards, installed as required to suit the application:

DSP2 90348 Rev F2

Figure 2.2 DSP2 Configuration

The DSP2 is housed in a 19 inch rack mounting enclosure.

2.3 Signal Processing, Load Outputs and Alarms

DSP2 90348 Rev F2

1. Zero offsets are applied to the sensor signals.

2. Gain adjustments are applied to yield Channel A and Channel B loads.

4. For mill control purposes, load measurement data are accessible:

through the Fieldbus Interface.

DSP2 90348 Rev F2

Sensor A Shunt Resistor Sensor B

Channel B Load Normal operation

Load Measurement Set

Output Scale Threshold

DSP2 90348 Rev F2

Sensor A Shunt Resistor Sensor B

Wrap Angle Input 1 Wrap Angle Input 2

Lookup Table 1 Lookup Table 2

Wrap Angle Wrap Angle

Load Measurement Set

Output Scale Threshold

DSP2 90348 Rev F2

2.4 Auxiliary Functions

2.4.2 Auto Zero

2.4.3 Auto Calibration

2.4.4 Wrap Angle Compensation

2.4.5 Self Test

DSP2 90348 Rev F2

AnaOut 1 AnaOut 2 AnaOut 6 Relay1 Relay4 FS#200.0 DMT_1800 DCT_02.0 DispMenu