Carotron DIV280-000 User manual

Divider
Module
Instruction Manual
DIV280-000

2
Table of Contents
1. General Description....................................................................................................... 3
2. Specifications ................................................................................................................ 4
2.1 Electrical ........................................................................................................... 4
2.2 Physical ............................................................................................................ 4
3. Installation ..................................................................................................................... 5
3.1 Wiring Guidelines ............................................................................................. 5
3.2 Signal Connections........................................................................................... 5
4. Description of Features & Adjustments ......................................................................... 6
5. Adjustment Procedure ................................................................................................... 7
5.1 Velocity Mode Winder....................................................................................... 8
5.2 Torque Mode Takeup/Letoff ........................................................................... 11
6. Prints ........................................................................................................................... 14
C13814 DIV280-000 Block Diagram..................................................................... 14
C13813 DIV280-000 Assembly ............................................................................15
C13815 DIV280-000 General Connections .......................................................... 16
7. Standard Terms & Conditions of Sale ......................................................................... 17
List of Figures
Figure 1: Winder Speed vs Winder Diameter (10:1 Build Ratio) ....................................... 3
Figure 2: Physical Dimensions .......................................................................................... 4
Figure 3: General Connections.......................................................................................... 5
Figure 4: Diameter Signal Examples ................................................................................. 6
Figure 5: Velocity Mode Winder Example 1 ...................................................................... 8
Figure 6: Velocity Mode Winder Example 2 ...................................................................... 8
Figure 7: Torque Mode Drive Example............................................................................11
Figure 8: Torque Mode Brake Example........................................................................... 11

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General Description
A problem encountered in center driven takeup and letoff velocity mode applications is
the nonlinear relationship between the diameter of a roll and the motor speed required to
maintain constant surface speed of the roll during diameter increase or decrease. A plot
of this relationship shows a hyperbolic curve.
Figure 1: Winder Speed vs Winder Diameter (10:1 Build Ratio)
When the line speed and roll diameter values are known, the required roll speed can be
calculated (i.e. Roll Speed = Line Speed/Roll Diameter). The material surface speed on a
takeup or letoff would be held constant during roll diameter changes.
Furthermore, in torque applications, the torque required to maintain constant tension is
proportional to roll diameter. When the line speed and roll rotational speed values are
known, the required torque can be calculated (i.e. Roll Diameter = Line Speed/Roll
Speed). The tension applied to the material on a takeup or letoff would be held constant
during roll diameter changes.
Model DIV280-000 is designed for the above industrial applications where the division of
DC voltage signals is required to produce the non-linear plot. The module has two
voltage inputs (X & Y). Each voltage input has an associated Teach terminal that can be
used to calibrate the minimum and maximum input levels. The output is based on the
following formula:
BuildRatioInputY
InputX
Output × =
Multiturn GAIN, BIAS, BUILD RATIO, and Y TRIM RANGE potentiometers are used to
calibrate the DIV280-000 module. An internal jumper allows selection of a voltage or
current output. Onboard EEPROM is used to backup and retain the calibration values
during a power loss.
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Specifications
2.1 Electrical
D.C. Power Input
•24 VDC ±10%, 60mA max,
internally fused
+10VDC Reference Output
•10mA max
X & Y Inputs
•Range: 0-10VDC
•Input Impedance: 10
12
Ω
Potentiometers
•Turns: 15
Temperature Range
•0-55º C
Signal Output
•Voltage Output
Selected by position V on J2. This
circuit allows the output to source a
voltage level of up to +10 VDC into a
minimum resistance of 600 Ohms. If
resistance is too low, output linearity
may be affected.
•Current Output
Selected by position I on J2. This
circuit allows the output to source a
regulated current up to 20mA into a
maximum resistance of 500 Ohms.
Using the BIAS pot, the output can
source a 4 to 20mA signal.
2.2 Physical
Figure 2: Physical Dimensions
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Installation
3.1 Wiring Guidelines
To prevent electrical interference and to minimize start-up problems, adhere to the
following guidelines:
Use fully insulated and shielded cable for all signal wiring. The shield should be
connected to circuit common at one end only. The other end of the shield should be
clipped and insulated to prevent the possibility of accidental grounding.
Signal level wiring such as listed above should be routed separately from high level
power wiring (such as the A.C. line, motor, operator control, and relay control wiring).
When these two types of wire must cross, they should cross at right angles to each
other.
Any relay, contactor, starter, solenoid or other electro-mechanical device located in close
proximity to or on the same line supply as the DIV280-000 should have a transient
suppression device such as an MOV or R-C snubber connected in parallel with its coil.
The suppressor should have short leads and be connected as close to the coil as
possible.
3.2 Signal Connections
Figure 3: General Connections
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Description of Features & Adjustments
JUMPER J2
Selects the Output Mode between Voltage or Current. Position V on J2 selects the
Voltage Mode and the output is sourced from terminals 7 & 8. Position I on J2 selects
the Current Mode and the output is sourced on terminals 7 & 9.
BUILD RATIO Potentiometer
The BUILD RATIO is the ratio of maximum diameter to minimum diameter. The BUILD
RATIO potentiometer has a range of 1 to 20. Clockwise rotation increases the ratio.
INPUT Y TRIM RANGE Potentiometer
In the velocity mode application (where Roll Speed is calculated by dividing Line Speed
by Roll Diameter), a signal proportional to roll diameter (or radius) is required. When the
minimum and maximum signal levels are taught (see the Teach function), the DIV280-
000 module assumes the Zero Diameter and Max Diameter levels are used (points A
and C). Note that point A is the ‘zero’ diameter level which would correspond to the
center axis of the roll. With this type of signal, the normal operating range of signal
would be between points B and C (since the diameter should never fall below core).
During the teach process, the Zero Diameter point (center axis of roll) must be measured
or simulated. Often, it is easier to calibrate the diameter signal by teaching the Core and
Max Diameter levels. (points B to C). However, this introduces an error because the
module assumes the Zero Diameter point has been taught. The Y TRIM RANGE
potentiometer can be used to re-scale the signal so that the minimum input is treated as
the Core level instead of the Zero level.
Figure 4: Diameter Signal Examples
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GAIN Potentiometer
Sets the maximum output level at terminal 7.
BIAS Potentiometer
Sets the minimum output level at terminal 7.
TEACH INPUTS
The INPUT X and INPUT Y terminals can accept a nominal 0 to 10VDC input signal.
Each input has an associated TEACH terminal that can be used to calibrate that input to
the actual minimum and maximum signal levels. Thus, an input signal with a range less
than 10V (1V to 9V for example) can be calibrated to reflect a 0 to 100% input. In
addition, the order in which the voltage levels are taught can be used to invert the slope
of the input. Thus the 1-9V input can reflect a 0-100% or a 100-0% signal.
Apply the signal level to the input terminal that corresponds to 0%. Teach this level by
connecting the associated Teach input to circuit common (terminal 11). Next, apply to
the input terminal the signal level that corresponds to 100%. Teach this level by
disconnecting the Teach input from circuit common. If an error is made during the teach
process, simply repeat the procedure.
Adjustment Procedure
WARNING! DURING CALIBRATION, THE DIV280-000 MODULE WILL
PRODUCE AN OUTPUT. PLEASE DISCONNECT ANY EQUIPMENT
FROM THE MODULE THAT COULD BE DAMAGED OR CAUSE INJURY
DURING THIS PROCESS.
Proceed to Section 5.1 for velocity mode takeups and to Section 5.2 for torque mode
takeups or letoffs.
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5.1 Velocity Mode Winder
The DIV280-000 can be used as a velocity mode winder control. In this application, the
winder controls/sets the material speed. As the diameter increases, the center driven
winder speed must be reduced in order to maintain a constant material speed. The
DIV280-000 module calculates the winder speed signal by dividing the line speed by
diameter. The diameter can be measured by using electronic sensors (such as a sonic
or a laser, Figure 5) or by a simple rider arm and potentiometer (Figure 6).
Figure 5: Velocity Mode Winder Example 1
Figure 6: Velocity Mode Winder Example 2

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Step 1: Select Output Type
1. Select the type of output desired using Jumper J2. If a Voltage output is desired,
select V on J2 and use output terminals 7 (OUTPUT) and 8 (VOLTAGE
RETURN). If a Current output is desired, select I on J2 and use output terminals 7
(OUTPUT) and 9 (CURRENT RETURN).
Step 2: Connections
1. Make connections per drawing C13815 on page 16. Initially, there should be no
connection on the Teach inputs on terminals 10 & 12.
Step 3: Initial Settings
1. Initially set the potentiometers as follows:
GAIN........................ fully counter-clockwise (CCW)
BIAS ........................ fully counter-clockwise (CCW)
BUILD RATIO .......... fully counter-clockwise (CCW)
Y TRIM RANGE....... fully counter-clockwise (CCW)
2. Remove all material from the winder and load the smallest empty core that will be
used.
3. Apply power to the module.
Step 4: Teach Inputs
1. Turn the Line Speed potentiometer fully counter-clockwise to apply the 0% Line
Speed signal level to Input X on terminal 4. Connect the Teach X input (terminal
10) to circuit common (terminal 11). Turn the Line Speed potentiometer fully
clockwise to apply the 100% Line Speed signal level to Input X. Disconnect the
Teach X input from circuit common.
2. Apply either the Zero Diameter or Core Diameter signal level to Input Y on
terminal 5. Connect the Teach Y input (terminal 12) to circuit common (terminal
11). Apply the Max Diameter signal level to Input Y. Disconnect the Teach Y
input from circuit common.
Step 5: Set Minimum and Maximum Output
1. With GAIN fully CCW, adjust the BIAS potentiometer for minimum output on
terminal 7. For a voltage output, the minimum output is typically 0V. For a current
output, the minimum output is typically either 0mA or 4mA. (Note that the X & Y
input levels have no affect on the output at this time since the GAIN is fully CCW.)
2. Load an empty core. Set external line speed potentiometer to maximum, and start
the winder drive. With the BUILD RATIO fully CCW, adjust the GAIN
potentiometer for the maximum desired output on terminal 7. Typical output levels
are 10V or 20mA. A hand tachometer can be used to measure the surface speed
of the winder (i.e. Ft/min[fpm], Ft/sec[fps], m/min[mpm], etc…). Adjust the GAIN
potentiometer and/or the drive’s speed scaling settings to obtain the maximum
desired surface speed of the empty core. Note the surface speed as this level will
be required later.
3. Ensure the external line speed potentiometer has control of the speed. Verify
speeds with the external line speed potentiometer at minimum, mid-position, and
maximum positions. Stop the drive when complete. If speeds are not correct, re-
teach the Line Speed signal.

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Step 6: Adjust Build Ratio
1. Determine the BUILD RATIO by dividing the maximum roll diameter by the
minimum roll (empty core) diameter. If multiple sizes are used, calculate with the
smallest core and the largest maximum diameter. For example, a maximum
diameter of 32” and a core diameter of 4” will yield a Build Ratio of 8.
2. Determine the Max Diameter Core Speed by dividing the surface speed measured
in 5.2 above by the BUILD RATIO. For example, with a maximum speed of
100fpm and a BUILD RATIO of 8, the Max Diameter Core Speed would be
12.5fpm (100fpm/8=12.5fpm)
3. Load a maximum diameter roll so that it can be rotated without feeding material.
Rotate the BUILD RATIO potentiometer fully clockwise (approx 20 turns) and the
external speed potentiometer to minimum. Start the winder drive and slowly rotate
the external line speed potentiometer to maximum. Slowly adjust the BUILD
RATIO potentiometer counter clockwise until the surface speed of the material
matches the maximum surface speed measured in 5.2. Alternatively, if a portion
of the core is not obstructed by the material, its surface speed should be equal the
Max Diameter Core Speed value calculated in 6.2. Stop the machine once
complete.
Step 7: Adjust Y TRIM RANGE
1. If the diameter signal on Input Y was calibrated using the Zero Diameter and Max
Diameter levels, then no adjustment is required on the Y TRIM RANGE
potentiometer (leave fully CCW). Calibration is now complete. Otherwise,
continue below. (Note: The majority of users will need to continue with the
following step.)
2. Load an empty core and set external line speed potentiometer to minimum.
Rotate the Y TRIM RANGE potentiometer fully clockwise (approx 20 turns). Start
the winder and slowly increase the external line speed potentiometer to maximum.
Rotate the Y TRIM RANGE potentiometer counter-clockwise until the winder
surface speed equals the maximum surface speed level measured in Step 5.2
above.
Step 8: Final Settings
1. The external Line Speed potentiometer can be used to set the desired material
speed. As the diameter builds, the DIV280-000 will decrease the velocity signal to
the winder to maintain a constant material speed.

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5.2 Torque mode Takeup/Letoff
Another common application for the DIV280-000 module is the basic torque mode
takeup (winder) or letoff (unwinder). The module takes a line speed signal and divides it
by a roll speed signal to calculate a diameter (or torque) signal. The diameter signal can
then be trimmed by an external Tension potentiometer to provide a torque reference for a
motor or a brake. Note that this application provides only diameter compensating torque.
Some applications may require additional torque compensation. Please contact
Carotron for assistance in these advanced applications.
Figure 7: Torque Mode Drive Example
Figure 8: Torque Mode Brake Example

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Step 1: Select Output Type
1. Select the type of output desired using Jumper J2. If a Voltage output is desired,
select V on J2 and use output terminals 7 (OUTPUT) and 8 (VOLTAGE
RETURN). If a Current output is desired, select I on J2 and use output terminals 7
(OUTPUT) and 9 (CURRENT RETURN).
Step 2: Connections
1. Make connections per drawing C13815 on page 16. Initially, there should be no
connection on the Teach inputs on terminals 10 & 12.
Step 3: Initial Settings
1. Initially set the potentiometers as follows:
GAIN ........................fully counter-clockwise (CCW)
BIAS.........................fully counter-clockwise (CCW)
BUILD RATIO ..........fully counter-clockwise (CCW)
Y TRIM RANGE .......fully counter-clockwise (CCW)
2. Remove all material from the winder and load the smallest empty core that will be
used.
3. Apply power to the module.
Step 4: Teach X Input
1. Apply the minimum Line Speed signal level to Input X on terminal 4. Connect the
Teach X input (terminal 10) to circuit common (terminal 11). Apply the maximum
Line Speed signal level to Input X. Disconnect the Teach X input from circuit
common. Use a hand tachometer to measure the actual surface speed of the line
(i.e. Ft/min[fpm], Ft/sec[fps], m/min [mpm], etc…). Note this level as it will be
needed later.
Step 5: Teach Y Input
1. The minimum and maximum signal levels for Input Y are taught in a similar
fashion to Input X. Follow the steps below based on the type of toruqe producing
device being used:
Drive: In the normal operating mode, the drive will be in the torque mode.
However, in order to calibrate the speed signals, the drive must be temporarily
converted to a velocity (or speed) mode. With the takeup/letoff roll stopped,
connect the Teach Y input (terminal 12) to circuit common (terminal 11). Run
the empty core and increase its speed until it matches the surface speed
measured on the line in Step 4.1 above. Disconnect the Teach Y input from
circuit common.
Brake: Using a brake on a letoff complicates the process in that a brake
cannot be used to rotate the unwind roll at a given speed needed for
calibration. In most cases, a calculation will have to be performed to
determine the roll speed signal level. A potentiometer can then be temporarily
connected to Input Y (terminal 5) and adjusted to simulate the roll speed
signal. Once calibration is completed, the potentiometer is dis-connected and
the actual roll speed signal is re-connected. If needed, please contact
Carotron for assistance in performing this calculation. Rotate the
potentiometer to minimum. Connect the Teach Y input (terminal 12) to circuit

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common (terminal 11). Rotate the potentiometer until the calculated voltage
level is obtained on Input Y (terminal 5). Disconnect the Teach Y input from
circuit common.
Step 6: Set Minimum and Maximum Output
1. With GAIN fully CCW, adjust the BIAS potentiometer for minimum output on
terminal 7. For a voltage output, the minimum output is typically 0V. For a current
output, the minimum output is typically either 0mA or 4mA.
2. With the maximum levels applied to both inputs and BUILD RATIO fully CCW,
adjust the GAIN potentiometer for the maximum desired output on terminal 7.
Typical output levels would be 10V or 20mA.
Step 7: Adjust Build Ratio
1. Determine the BUILD RATIO by dividing the maximum roll diameter by the
minimum roll (empty core) diameter. If multiple sizes are used, calculate with the
smallest core and the largest maximum diameter. For example, a maximum
diameter of 32” and a core diameter of 4” will yield a Build Ratio of 8.
2. Using the minimum and maximum output values set in Step 6 above, calculate the
nominal output level for core diameter.
MinOutput
BuildRatio
MinOutputMaxOutput
erLevelCoreDiamet +
−
=)(
For example, a nominal 0 to 10V output with a Build Ratio of 8 would yield:
VV
VV
erLevelCoreDiamet 25.10
8
)010( =+
−
=
or a nominal 4 to 20mA output with a Build Ratio of 4 would yield:
mAmA
mAmA
erLevelCoreDiamet 84
4
)420( =+
−
=
3. With maximum signal applied to Inputs X and Y, adjust the BUILD RATIO
potentiometer clockwise until the output on terminal 7 equals the value calculated
above.
Step 8: Final Settings
1. Convert the velocity mode drive back to torque mode or disconnect the temporary
roll speed potentiometer and re-connect the actual roll speed feedback signal.
2. If a minimum torque level is desired when stopped, a torque bias level must be set
in the drive or the brake controller. The DIV280-000 will then add to this level
once motion starts and the diameter/torque level calculation begins.
3. The external Tension potentiometer can be used to set the desired tension level.

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1.
Prints
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Standard Terms &
Conditions of Sale
1. General
The Standard Terms and Conditions of Sale of Carotron, Inc. (hereinafter
called “Company”) are set forth as follows in order to give the Company
and the Purchaser a clear understanding thereof. No additional or different
terms and conditions of sale by the Company shall be binding upon the
Company unless they are expressly consented to by the Company in
writing. The acceptance by the Company of any order of the Purchaser is
expressly conditioned upon the Purchaser’s agreement to said Standard
Terms and Conditions. The acceptance or acknowledgement, written, oral,
by conduct or otherwise, by the Company of the Purchaser’s order shall
not constitute written consent by the Company to addition to or change in
said Standard Terms and Conditions.
2. Prices
Prices, discounts, allowances, services and commissions are subject to
change without notice. Prices shown on any Company published price list
and other published literature issued by the Company are not offers to sell
and are subject to express confirmation by written quotation and
acknowledgement. All orders of the Purchaser are subject to acceptance,
which shall not be effective unless made in writing by an authorized
Company representative at its office in Heath Springs, S.C. The Company
may refuse to accept any order for any reason whatsoever without
incurring any liability to the Purchaser. The Company reserves the right to
correct clerical and stenographic errors at any time.
3. Shipping dates
Quotation of a shipping date by the Company is based on conditions at
the date upon which the quotation is made. Any such shipping date is
subject to change occasioned by agreements entered into previous to the
Company’s acceptance of the Purchaser’s order, governmental priorities,
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reasonable control of the Company. In no event shall the Company be
liable for consequential damages for failure to meet any shipping date
resulting from any of the above causes or any other cause.
In the event of any delay in the Purchaser’s accepting shipment of
products or parts in accordance with scheduled shipping dates, which
delay has been requested by the Purchaser, or any such delay which has
been caused by lack of shipping instructions, the Company shall store all
products and parts involved at the Purchaser’s risk and expense and shall
invoice the Purchaser for the full contract price of such products and parts
on the date scheduled for shipment or on the date on which the same is
ready for delivery, whichever occurs later.
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The Company warrants to the Purchaser that products manufactured or
parts repaired by the Company, will be free, under normal use and
maintenance, from defects in material and workmanship for a period of
one (1) year after the shipment date from the Company’s factory to the
Purchaser. The Company makes no warranty concerning products
manufactured by other parties.
As the Purchaser’s sole and exclusive remedy under said warranty in
regard to such products and parts, including but not limited to remedy for
consequential damages, the Company will at its option, repair or replace
without charge any product manufactured or part repaired by it, which is
found to the Company’s satisfaction to be so defective; provided, however,
that (a) the product or part involved is returned to the Company at the
location designated by the Company, transportation charges prepaid by
the Purchaser; or (b) at the Company’s option the product or part will be
repaired or replaced in the Purchaser’s plant; and also provided that Cc)
the Company is notified of the defect within one (1) year after the
shipment date from the Company’s factory of the product or part so
involved.
The Company warrants to the Purchaser that any system engineered by it
and started up under the supervision of an authorized Company
representative will, if properly installed, operated and maintained, perform
in compliance with such system’s written specifications for a period of one
(1) year from the date of shipment of such system.
As the Purchaser’s sole and exclusive remedy under said warrant in
regard to such systems, including but not limited to remedy for
consequential damages, the Company will, at its option, cause, without
charges any such system to so perform, which system is found to the
Company’s satisfaction to have failed to so perform, or refund to the
Purchaser the purchase price paid by the Purchaser to the Company in
regard thereto; provided, however, that (a) Company and its represen-
tatives are permitted to inspect and work upon the system involved during
reasonable hours, and (b) the Company is notified of the failure within one
(1) year after date of shipment of the system so involved.
The warranties hereunder of the Company specifically exclude and do not
apply to the following:
a. Products and parts damaged or abused in shipment without
fault of the Company.
b. Defects and failures due to operation, either intentional or
otherwise, (l) above or beyond rated capacities, (2) in connection
with equipment not recommended by the Company, or (3) in an
otherwise improper manner.
c. Defects and failures due to misapplication, abuse, improper
installation or abnormal conditions of temperature, humidity,
abrasives, dirt or corrosive matter.
d. Products, parts and systems which have been in any way
tampered with or altered by any party other than an authorized
Company representative.
e. Products, parts and systems designed by the Purchaser.
f. Any party other than the Purchaser.
The Company makes no other warranties or representation, expressed or
implied, of merchantability and of fitness for a particular purpose, in regard
to products manufactured, parts repaired and systems engineered by it.
5. Terms of payment
Standard terms of payment are net thirty (30) days from date of the
Company invoice. For invoice purposed, delivery shall be deemed to be
complete at the time the products, parts and systems are shipped from the
Company and shall not be conditioned upon the start up thereof. Amounts
past due are subject to a service charge of 1.5% per month or fraction
thereof.
6. Order cancellation
Any cancellation by the Purchaser of any order or contract between the
Company and the Purchaser must be made in writing and receive written
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Springs, S.C. In the event of any cancellation of an order by either party,
the Purchaser shall pay to the Company the reasonable costs, expenses,
damages and loss of profit of the Company incurred there by, including
but not limited to engineering expenses and expenses caused by
commitments to the suppliers of the Company’s subcontractors, as
determined by the Company.
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The Purchaser may, from time to time, but only with the written consent of
an authorized Company representative, make a change in specifications
to products, parts or systems covered by a purchase order accepted by
the company. In the event of any such changes, the Company shall be
entitled to revise its price and delivery schedule under such order.
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If the Purchaser desires to return any product or part, written authorization
thereof must first be obtained from the Company which will advise the
Purchaser of the credit to be allowed and restocking charges to be paid in
regard to such return. No product or part shall be returned to the Company
without a ”RETURNTAG” attached thereon which has been issued by the
Company.
9. Packing
Published prices and quotations include the Company’s standard packing
for domestic shipment. Additional expenses for special packing or
overseas shipments shall be paid by the Purchaser. If the Purchaser does
not specify packing or accepts parts unpacked, no allowance will be made
to the Purchaser in lieu of packing.
10. Standard transportation policy
Unless expressly provided in writing to the contrary, products, parts and
systems are sold f.o.b. first point of shipment. Partial shipments shall be
permitted, and the Company may invoice each shipment separately.
Claims for non-delivery of products, parts and systems, and for damages
thereto must be filed with the carrier by the Purchaser. The Company’s
responsibility therefor shall cease when the carrier signs for and accepts
the shipment.
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3204 Rocky River Road
Heath Springs, SC 29058
Phone: [phone]
Fax: [phone]
Email: [e-mail]
Web: www.carotron.com
MAN1060-00 Rev. B
Issued
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