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DGT 2000
DIGITAL CONTROLLER
Users Manual

1705 Valley Road
Wanamassa, NJ 07712
Phone : (800) 713-6170
Fax : (732) 493-2949
Email : info@andantex.com
Web : www.andantex.com

User Manual

DGT 2000 Merobel

TABLE OF CONTENTS
1 – Introduction
2 – Regulation Modes
2-1 Applications
2-2 System hardware
2-3 Main functions
2-3-1 Open loop control
2-3-2 Closed loop control

2-4 Other functions
2-4-1 Inertia compensation
2-4-2 P.I.D. with variable parameters
2-4-3 Open loop and closed loop regulation
2-4-4 Taper
2-4-5 No-Stop (splice) function
2-4-6 Alarm

3 – General description
3-1 DGT 2000 cabinet
3-1-1 Dimensions / Mounting
3-1-2 Display
3-1-3 Keyboard

3-2 Programming interface
3-3 PC software

4 – Wiring
4-1 Introduction
4-1-1 Power supply
4-1-2 Wiring guidelines

4-2 Open loop with diameter measurement
4-2-1 Standard regulation wiring
4-2-2 Inertia compensation wiring

4-3 Open loop with diameter calculation
4-3-1 Standard regulation wiring
4-3-2 Inertia compensation wiring

4-4 Dancer
4-4-1 Standard regulation wiring

4-5 Force Control (load cells)
4-5-1 Standard regulation wiring
4-5-2 Inertia compensation wiring

5 – Programming
5-1 General programming description
5-1-1 Program structure
5-1-2 Programming with the keyboard
5-1-3 Programming with the PC

5-2 P.I.D. Programming
5-2-1 Proportional (P)
5-2-2 Integral (I)
5-2-3 Derivative (D)

5-3 Advanced functions
5-3-1 P.I.D. with variable parameters
5-3-2 Open loop + closed loop regulation

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6 – Input / Output calibration
6-1 Process integration
6-1-1 Logical inputs configuration
6-1-2 External set point control

6-2 Open loop with diameter measurement
6-2-1 Standard regulation
6-2-2 Inertia compensation

6-3 Open loop with diameter calculation
6-3-1 Standard regulation and inertia compensation

6-4 Dancer
6-4-1 Standard regulation
6-4-2 Inertia compensation

6-5 Force control (load cells)
6-5-1 Standard regulation
6-5-2 Inertia compensation

6-6 Logical outputs

7 – User quick reference guide
8 – Technical features
8-1 Hardware
8-2 Inputs
8-3 Outputs
8-3 CE – CEM electromagnetic compatibility

9 – Appendix
9-1 User quick reference guide
9-2 DGT 2000 software structure
9-3 Usual P.I.D. values
9-4 Mechanical dimensions / mounting
9-5 Block diagram
9-6 Wiring guidelines
9-7 DGT soft installation and troubleshooting
9-8 Software parameters description
9-9 Technical support

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1 – Introduction
Congratulations on choosing Merobel’s DGT 2000 digital controller !
You are using the most user friendly and powerful digital controller of its category.
This user manual was designed to give you an overview of the DGT 2000 features and also to easily identify the
parameters settings for your application.

2 – Regulation modes
2-1 Application range
The DGT 2000 digital controller has been designed to provide a solution to all of the web and wire tension
control problems.
In addition to advanced control features the Merobel DGT 2000 includes dedicated functions for unwinding or
rewinding enabling a quick commissioning of the product.
Its versatility allows a total compatibility with torque, force and position sensors used in the industry.
Besides, the regulation output can control any type of Merobel brake or clutch as well as any friction brake or
motor.

2-2 Hardware
The Merobel DGT 2000 digital controller is a multi input / output system plus a P.I.D. calculator.
The DGT 2000 is built around a 32 bit micro-controller.
Analog inputs are connected to 12 bits A/D converters to guarantee a 5 mV accuracy on a -10/+10V range.
The refresh rate is 100 Hz = 10 ms cycle time.
The DGT 2000 includes a load cells amplifier with a fully digital gain setting function that allows calibration
without any manual intervention (zero switch, zero potentiometer).
An EEPROM memory allows to save 5 complete sets of parameters when the power is off.
The large backlit display with 2 x 16 characters and the plain text messages (in English, French, German or
Italian) guarantee a very simple operation.
The PC connection (RS232) can be used with a Windows compatible software for easy system parametrization.
The block diagram of the system is shown in appendix 9-5.
2-3 Main functions
2-3-1 Open loop tension control
- Reel diameter measure (ultrasonic sensor or following arm).
- Reel diameter calculation (revolution speed over line speed ratio).
2-3-2 Closed loop tension control
- Dancer position control (web tension given by the dancer weight)
- Force control (control loop with load cells)

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2-4 Other functions
2-4-1 Inertia compensation
The reel inertia (mass and speed) are computed in order to improve control during acceleration and
deceleration phases.
2-4-2 P.I.D. with variable parameters
The parameters P (proportional gain), I (integral) and D (derivate) can be changed independently related to
the reel diameter or any other signal.
This P.I.D. adaptation gives the possibility to take into account for instance important inertia change for
demanding applications.
2-4-3 Open loop + closed loop control
The Merobel DGT 2000 allows open loop (diameter measured or computed) plus force or position control
(dancer or load cell).
This function is used for solving difficult control problems..
2-4-4 Taper
Set point automatic decrease related to diameter.
Usually used for rewinding.
2-4-5 Non Stop function
Simultaneous control of 2 axis (1 output for regulation – 1 output for holding) used for automatic reel change.
2-4-6 Alarms
2 alarms switches are available for machine errors management.
- Set point range (upper and lower limit around the set point).
If the measured value is beyond the set point range an alarm will warn the operator.
- Diameter threshold (percentage of max – diameter).
This alarm warns the operator when the bobine comes close to its minimum diameter.

3 – General description
3-1 DGT 2000 housing
3-1-1 Dimensions / Mounting
Merobel DGT 2000 housing design allows 3 types of mounting :
- Rear mounting
- Front panel mounting
- DIN rail mounting
Dimensions are available in appendix 9-4
3-1-2 Display
A large backlit display with 2 x 16 characters lines, gives access to the system status.
By programming you can choose the information displayed on each line among the following list :
- Set Point
- Measure
- Diameter
- Output 1
- Output 2
- Status output 1
- Status output 2
3-1-3 Keyboard
4 large keys are usually used for manual operation, they also give full access to the parametrization when the
PC software cannot be used.
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3-1-3-1 « Operator » functions
The operator has access to the following menus :
Main menus
- Set point adjustment
- Freewheel mode
- Hold mode (adjustable value)
- Memorized set of parameters loading
Other functions
- Web width selection
- Taper adjustment
- Output polarity change (2 ways machines).
3-1-3-2 Parametrization
Parametrization is password protected (see 5-1-2), all the parameters are available through the 4 keys.
The program structure is given in appendix 9-2.

3-2 PC programming
A RS232 connector is available on the lower side of the DGT 2000 housing.
A PC cable supplied with the DGT 2000 allows connection to the serial port of a PC.

3-3 PC software
Merobel DGT software is supplied with the DGT 2000.
This user friendly software gives easy access to all the DGT 2000 parameters during start-up and
commissioning.
It allows saving and storing of parameters files without any limit.
An online help is available.
To install the DGT software, go to appendix 9-7 or read the file “ readme.doc “ on the CD-Rom.

4 – Wiring
4-1 Introduction
4-1-1 Power supply
Power supply : 24 V AC or DC, 10 W.
Connection to pin L+(40) and M (39) – (0V pin for DC supply).

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4-1-2 Wiring guidelines
See appendix 9-6

4-2 Open loop regulation with diameter measure
4-2-1 Standard wiring

US

Drive

24Vdc/ac

Fig –1-

4-2-2 Wiring with inertia compensation

Fig –2-

Speed

4-3 Open loop with diameter calculation
4-3-1 standard regulation wiring

drive

Fig –3-

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Line
speed

Rotation
speed

24Vdc/ac
Contact

init

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4-3-2 Inertia compensation wiring

4-4 Dancer (position control)
4-4-1 Standard regulation wiring

Pot R

drive

Strap

Strap

24Vdc/ac

Fig –4-

4-5 Force control (load cells)
4-5-1 standard regulation wiring

Cell 2

Cell 1

Fig –5-

Cmde

Strap

24Vdc/ac

In case of half bridge load cells (e.g. : CI, CI-PF, CZ of Merobel range)
If you are using 2 load cells, the full bridge can be recreated by wiring as shown:

Bl

Y

Br

CELL CIPF

Bl

Y

Br

Bl : blue
Y : yellow
Br : brown

CELL CIPF

Caution : in this case, during calibration you need to declare 1 load cell since only 1 input is used.

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If you are using only 1 load cell, the full bridge can be recreated with the 2 stage special connector supplied with the DGT
2000 :

Bl Y Br
CELL CIPF
4-5-2 Inertia compensation wiring

US
tachy

Fig –6-

5 – Programming
5-1 Introduction
5-1-1 General structure
All the DGT parameters can be set from a PC with the DGT Software or from the keyboard.

See software menus appendix 9-2
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5-1-2 Programming from the keyboard
Access to programming mode is password protected :
Password :
Esc - Ent - Esc - Ent - Esc
(to be done in less than 3 s.)

- Navigation rules
In a column : use the arrows to go up or down.
To change column: “ Ent “ = to go to the right
“ Esc “ = to go to the left
- List selection
When the first choice in a list is displayed you can have access to the list by pressing simultaneously on both
arrows.
The choice is done with the arrows to go up or down, then validate with “ enter “ key.
- Value selection
When you select a digital parameter, the actual value appears on line 2 and a cursor appears under the last
digit to show that it can be modified.
• To move / validate each digit : “ Ent “
• To change the value: arrow up or down.
The parameter validation is done only when each digit has been validated (from right to left).
The cursor disappears to indicate that the new value has been taken into account.
-

Saving the new values (after power off)

Caution: the new parameters must be saved in one of the 5 memories, if not it won’t be possible to recall
these values after turning off the power.
5-1-3 Programming with a PC

Software installation, see 9-7.

5-2 Regulator parametrization
5-2-1 P: proportional factor
P is the multiplying factor of the difference between the set point and the measure.
It is critical for system response time, but a too high value will lead to low stability.
P optimal value is a compromise between stability and response time.
Typical values are given in appendix 9-3.
5-2-2 I: integral factor
The integral factor is the sum of the set point – measure difference.
It is used to cancel the static error.
The system response time is related to the integral factor, a low I value improves accuracy but decreases the
response time.
The I value is a compromise between long term accuracy and systems reactivity.
Typical values are given in appendix 9-3.

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5-2-3 D: derivative factor
This parameter is used to compensate for measures delays (inertia effect), for instance in Dancer
configurations.
This parameter makes the system very sensitive to disturbances (mechanical or electrical)
The D value chosen is a compromise between delays compensation and system stability.
Typical D values are given in appendix 9-3.
5-2-4 Filtering
Filtering is available individually on each of the analog input.
Filtering decreases the effect of disturbances but it generates a delay.
Typical filtering values are given in appendix 9-3.
More information is given in chapter B of appendix 9-8.

5-3 Advanced functions
5-3-1 P.I.D. with variable parameters
5-3-2 Open loop + closed loop regulation

6 – Input / Output calibration
6-1 Process integration
6-1-1 Logical input configuration
See appendix 9-8/G.
6-1-2 Control with external set point
The DGT 2000 can be used with a remote set point (potentiometer or PLC), in case of a 0-10V signal,
choose “external 0-10V” in the menu “set point”, if the signal is 4-20 mA, choose “external 4-20 mA”.

6-2 Open loop with diameter measurement
6-2-1 standard regulation
To calibrate an analog ultrasonic sensor or a follower arm, use 2 points between max and min diameter and
define (menu / units) if you are using mm or inches.
6-2-2 Inertia compensation
For inertia correction, 2 pieces of information are needed: diameter and line speed.
The line speed usually comes from a tachymeter, this signal must be 10Vmax at max line speed.

6-3 Open loop with diameter calculation
6-3-1 Standard regulation and inertia compensation
In menu “Diameter”, validate the calculation function.
For more details refer to appendix 9-8/F.

6-4 Dancer
6-4-1 Standard regulation
In menu “Inputs / Measure”, specify the voltage used (10V) and the number of sensors (1 in this case), then
calibrate with 2 points (usually 1 point = max range = 100%, 1 point = min range = 0%).

6-5 Force control (load cells)
6-5-1 standard regulation
Load cell calibration is carried out in menu “Inputs / measure”.
Specify the load cells power supply voltage (5 or 10V) and the number of load cells (1 or 2).
Then choose standard or special calibration (CX and TRS Merobel load cells).
For more information refer to appendix 9-8/B.
6-5-2 Inertia compensation
Speed calibration. See 6-2-2.

6-6 Logical outputs
See appendix 9-8/F
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Appendix 9-1

User quick reference guide

1 – SET POINT Setting

2 – Variables Setting
Hold for increase

Ent

Push on both for entering in
•
Data field (visible underscore)

Hold for decrease

Push for increase / decrease
•
each digit

Escape from
Setting mode

Esc

Push to valid each digit
•
Last digit validation send the
•
complete value to the system
(underscore disapears)

4 – System General Settings
Initial readout

Ent

-------------------------------

RECALL MEMORY

Ent

M1

Ent

MEMORY READ

Esc

M2 ... / ... M3 , M4, M5

HOLD
000,0

HOLD
000,0
_

Variable setting

Esc

WIDTH COEFF
100

WIDTH COEFF
100

Variable setting

Esc

TAPER COEFF
000

TAPER COEFF
000

Variable setting

Esc

Ent

MOTOR DIRECTION
- -> + / + -> -

TAPER DIAM.
00,000

MOTOR DIRECTION
- -> +

Variable
setting

TAPER DIAM.
00,000

Variable setting

Esc

3 – Additional functions

Releasing Mode

Ent

Push on both for releasing the system (Output = 0)

Esc

Escape from releasing
Hold Mode

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Ent

Push on both for blocking the system (Output = Max)
This value may be adjusted (see « SET POINT
settings »)

Esc

Escape from Hold

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Appendix 9-2

DGT2000 internal software structure
display
language
French
English
Italian
Deutsch
units
Measure
N
kg
lb
Nm
PLI
Ftlb
%
Diameter
m
in
Display config.
1st line

Output ao1
Output ao2
Set point
Diameter
Measure
ao1 config
ao2 config

2nd line

Output ao1
Output ao2
Set point
Diameter
Measure
ao1 config
ao2 config

inputs
measure
Cells number
1
2
Cells supply
5v
10v
Standard calib.
Upper level val.

-->
-->

0000,00 à 9999,00
20 à 100

-->

Full scale %

0000,00 à 9999,00

-->

0 à 20

validate
Bottom level val.
validate
Special calib.
Cell type
CY
TRS 05
Other TRS
Tuning coeff.

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Full scale value

-->

0000,00 à 9999,00

-->

0 à 9999

-->
-->

0 à max capteur
0 à 9999 (x 10 ms)

-->

0 à 9999

-->

0,010 à 99,000 (unit)

-->

0,010 à 99,000 (unit)

-->
-->
-->
-->
-->

1,00 à 999,00
1,00 à 999,00
0,010 à 99,000 (unit)
0,010 à 99,000 (unit)
0,010 à 99,000 (unit)
0 à 9999

-->

0 à 9999

-->
-->
-->

001,00 à 999,00
000,0 à 100,0
000 à 100

-->
-->
-->

0000 à 9999
0000 à 9999
0000 à 9999

-->
-->
-->
-->

000 à 100
000 à 100
000,0 à 100,0
000 à 100

P
I
D

-->
-->
-->

0000 à 9999
0000 à 9999
0000 à 9999

P
I
D

-->
-->
-->

0000 à 9999
0000 à 9999
0000 à 9999

OL coeff
CL coeff
Inertia gain

-->
-->
-->
-->

000 à 100
000 à 100
000,0 à 100,0
000 à 100

-->

001 à 999 (x 10 ms)

Validate
Filtering
Set point
Set point option
Internal
Set point value
Slope duration
External 0-10V
External 4-20mA
Filtering
diameter
Sensor option
Analog sensor
Dmax value
Validate
Dmin value
Validate
Pulses sensor
nb pulse/unit
nb pulse/rotation
Max diameter
Min diameter
Initial diameter
Filtering
tachymeter
Filtering
Regulation
type
Open loop
Max. effort
Inertia gain
Web width coeff
Basic PID
P
I
D
Loop coeff
OL coeff
CL coeff
Inertia gain
Web width coeff
Variable PID
Max diam. coeff

Min diam. coeff

Loop coeff

Web width coeff
functions
Time delay start
Duration

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Time delay stop
Duration

-->

001 à 9999 (x 10 ms)

Fixed
Proportional

-->
-->

000 à 100 (%)
100 à 500 (%)

value

-->

000,0 à 100,0

value
duration

-->
-->

-10 à +10 (V)
1 à 99 (x 10 ms)

-->
-->

000 à 100 (%)
00,000 à 99,000 (unit)

-->
-->

-10,00 à +10,00 (V)
-10,00 à +10,00 (V)

E-stop option

No-stop
Disable
Enable
hold
Demagnetization

Taper
percentage
Diameter taper
outputs
Thresholds
Upper limit
Bottom limit
AO3 reading
Set point
Measure
Diameter
Logical outputs
AL1 error range

-->

000 à 100 (%)

AL2 diam limit

-->

000 à 100 (%)

memories
Save
M1
M2
M3
M4
M5
Call
M1
M2
M3
M4
M5

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Appendix 9-3

Usual P.I.D.values.

Dmax / Dmin
high
low
X
X

Inertia
high
low

X
X

"D"

Filtering

X
X

X

X

"I"

200
250
100
100

10
10
10
10

200
250
100
50

0
10
0
0

(1)
-(1)
--

X
X

200
250
200
150

50
50
100
100

0
0
0
0

100
200
100
100

(2)
(2)
(1)
--

X
X

X

X

"P"

X
X

(1) The control quality can be bettered by using additional function : variable PID.
(2) The control quality can be bettered by using additional function : Inertia compensation.
Elastic products : gradually increase the filtering value to stabilise the system .

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Appendix 9-4

Mechanical dimensions / mounting

178

89
268
41

11

84

(cotation in mm)

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Appendix 9-5

Block diagram

Logical inputs
REG - INIT
Time delay start and
stop with REG

MEASURE

Cell 1

A
/
N

Logical inputs
A-B
Function no-stop

10
11
00
01

Filtering
scaling
absolute value

00
01
11
10

Calcul PID
Calcul PID
PID locked
Init PID

Hold
Regulation
E-stop
Demagnetization

+

Cell 2

P

Set point
0-10V / 4-20mA

A
/
N

Filtering
scaling
Taper function

I

-

D

CL Coeff

PID variable
DIAMETER

Diameter
0-10V

A
/
N

Filtering
scaling

multiplication

+
OL Coeff

+
Line speed

Rotatio
n speed

Counters
Diameter
calculation

logical input
INIT

Inertia
compensation
calcul

Gain
Inertia

O
U
T
P
U
T
S
C
O
N
F
I
G

Set point
Measure
Diamètre

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A
/
N

AL1 : error range
Filtering

AL2 : diameter limit

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N
/
A

A 01

N
/
A

AO2

N
/
A

AO3

ALARMS

Web
width
Tachymeter
0-10V

OUTPUT

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System Architecture
Esc

Programming

Ent
Fn

DGT 2000

1 x Load Cell (Classic 350 Ohms / full bridge)

Power supply 2A - Merobel PWR 2A

1 x Load Cell (semiconductor half bridge)

Power supply 5A - Merobel PWR5A
Power supply +/- 5A - Merobel PWR 5A INV

2 x Load Cells (Classic 350 Ohm / full bridge)
2 x Load Cell (Semiconductor half bridge)

EtoP (for Pneumatic Brake control)

Potentiometer ( > 4.5 kOhms)

Drive (For Motor control)

0 - 10 V or 4 - 20 mA set point remote control

- 10 / + 10 V auxilliary output

Ultrasonic sensor
or Potentiometer

Outputs

Tachometer (0 - 10 V)

2 x Hall effect sensors
2 x Encoders

Inputs

Logic Input A

Alarm 1

Logic Input B

Alarm 2

Logic Input Init
Logic Input Reg

Process

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Appendix 9-6

Wiring Guidelines
Généralities
The DGT 2000 Merobel fulfil the standarts concerning electromagnetic compatibility (EMC).
However, it is necessary to follow the next points to ensure the right using of the DGT2000 :
-

use a power supply or a transformer with 0V to earth.

-

Use shield wires. (imperatif on analogical inputs).

Mounting the glands
- strip the sheath of the shielded cable on 15cm.
- place

glands on the cable as indicated on the figure opposite

- Place the gland on the trap door as describe on the
pictures.

- tighten the glands and check the electrical contact
between earth , internal part of the trap door and
shielding with a ohmeter.
Cut the external shielding (1 cm).

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0V A01 0V A02 A03

0V LS 24V 0V RS 24V

AL- AL1 AL2

Analog outputs

Counters

Alarms

09 10 11 12 13 14 15 16

17 18 19 20 21

22 23 24 25 26 27

28 29 30

OV

OV

Logic
inputs

M

L+

Regul.
Block - Reg

Supply

31 32 33 34 35 36 37 38

39 40

Init

+
24 V AC / DC

Reg.

Init

Logic input B

Logic input A

Logic output 1

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Logic output 2

Logic output reference

+24 V

Supply

24V A 24V B 24V INIT 24V REG

24 V

OV
Rotation speed counter

Linear speed counter

Output 3 (-10 / +10 V)

Output 2 (-10 / +10 V)

Output 1 (-10 / +10 V)

Tacho input (0 - 10 V)

+24 V

+24 V

OV

OV
Diameter (0 - 10 V)

+10 V

Set point (0 - 10 V or 4-20 mA)

+10 V / + 5 V

Signal 2 +

+10 V / + 5 V

Signal 2 -

Signal 1 +

Signal 1 -

OV

OV

01 02 03 04 05 06 07 08

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Set point / ø / Analog

Logical inputs

_

0V SP 10V 0V DM 24V 0V TC

Load Cell 2

Alarms

24 V

S1- 0V S1+ V+ S2- 0V S2+ V+

Load Cell 1

Counters

24 V

Analog outputs

24 V

Set point / Diameter / Tacho

OV

Measurements

OV

Electrical wirings

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DGT 2000 Merobel

Appendix 9-7

DGTSoft installation and troubleshooting
The CD-Rom delivered with your box contains a software PC of the DGT called DGTsoft.
Launch the Setup to install automatically the DGTsoft on your PC in C:\ProgramFiles. A short cut is also
created in your PC desktop.
A double clicking on the DGTsoft icon launch the application. The password is 1234.
To open an application, two possibilities are offered:
- click on the thumb index in ‘parameter’ then ‘new’ and choose the application type which is appropriate to
you.
- click on ‘File’ then ‘open parameters files…’and under C:\ProgramFiles\DGTsoft, open the file .prm
correspondent with your application.
- For a direct access to the help, click right on the buttons.
If you meet problems when installing the DGTsoft on your computer, ensure the following points:
- the operating system is windows95/98/2000 or NT.
- In the event of defect of COM during the launching of the application, make sure that the cable is well
connected on the COM1 of the PC. If COM1 is not available, configure the application to work on port
COM2 according to following instructions :
. create a short cut on the desk towards the DGTsoft.exe application.
. click in the properties of the short cut (right click on the short cut icon).
. in the thumb index short cut, write in the target after the access path - com2
(example : xxx.exe - com2).
in other cases, call the Merobel engineering department.

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Appendix 9-8

Software parameters description
A- Parameters setting
Begin a new parameter setting
Choose the type of parameter setting
Before beginning a new parameter setting, you must select the application type :
click in menu Parameter, and in the thumb index New, choose your application.
-

Open loop
Tension control Application by measurement of the diameter.
Inertia compensation with analogical line speed information
Closed loop
Tension control Application by measurement of the tension or the torque.
Dancer Application (control of the dancer roll position)
Inertia compensation
Tension control application when inertia becomes dominating in the transitional phases.

Each of these application types proposes a different interface of parameter setting, choose the category
corresponding to your use of the DGT2000.

Modify the parameters
The parameters are divided into three or four categories (according to the application type). Click on the
button of one of these categories to modify the contents of it.
In bottom on the left of the interface, you can find a list of special functions. By notching a special
function, it automatically modifies the associated parameters available in the interface. Once the
parameter setting finished, you can save it or send to the regulator.
Caution! If you do not save, the set of parameters will be lost when you close the interface.

Communicate parameters to the regulator
Save or load a set of parameters on the PC
To save a set of parameters, click in the thumb index ‘file’ then choose ‘save as…’ for recording in a
new file (file..PRM.), or ‘recording’ to record the set of parameters in the file in progress.
To open a set of parameters, click in menu ‘file’, then choose ‘open…’. The set of parameters will be
automatically loaded in the right interface.

The banks of memories of the regulator
There are two ways to memorize a set of parameters in the regulator:
- send in RAM (not safeguarded when the regulator is extinct).
- send in one of the 5 banks of memory.
The set of parameters in RAM is the one which is in progress. When switching on the regulator, it
automatically loads the last bank of memory used

Read the parameters of the regulator
PC software can also reach these 5 banks memory by clicking in the thumb index ‘regulator’ then ‘read
from regulator’ and select the memory
For reading the parameters in RAM of the regulator, you must read the bank memory in progress.

Send the parameters to the regulator
To send a set of parameters, you have two possibilities:
- you can use the button ‘send in RAM’ if you wish to change the current parameter setting of the
regulator without saving it which can be useful to test a set of parameters.
- you can use the menu ‘Regulator’, then ‘send to regulator’.Select then the bank memory in
which you want to record the parameters.

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It is strongly recommended to use the recording of the parameters in the memories M1 to M5 because
the parameters charged in RAM are not safeguarded.
note: the reading of the value is not always updated at the reception of the parameters. In this case, you just
have to click in another window and return to the one you want to read for getting the parameters updated.

B – Inputs Menu
Measure
This menu appears when choosing closed loop or Inertia correction.
It allows to choose and to calibrate measure.

Measure definition
Number of load cells: 1 or 2 load cells on connector measurement.
Power supply: 5 or 10 V sensor supply on input pin V+.

Measure calibration
2 types of calibration are available depending on the type of load cells used :
-

Special calibration : this automatic calibration is used with Merobel sensors (sensors with known
characteristics).
In this mode there is no need for weights (e.g ; for test bench applications).
Sensor type : CY, TRS05 or other TRS.
Calibration factor : value engraved on the sensor.
Full scale value : sensor full scale value.
Calibrate : after having typed in the information and sent them to the DGT 2000 RAM, click on the
button “calibrate”. Sensor calibration is done automatically.

-

Standard calibration : used for any type of measure from a few mV to 10V.
% full scale :type in the percentage of full scale corresponding to the upper point used during
calibration (this percentage must be more than 20%).
Valid high level : type in the value for the upper point.
Valid low level : type in the value for the lower point.

Procedure : type in the first 3 parameters and then click « send to RAM », then simulate physically the
upper point and click « valid high level », wait 5 seconds, simulate physically the lower point and click
« valid low level », wait 5 seconds. Calibration is done !

Set Point Menu
3 Types of set points are available.
Internal set point : type in the chosen value, it can be modified by the operator with the arrows on the
keyboard
A ramp can be used for soft start. The ramp is activated when the switch Regul is turned on.
External 0-10V set point : potentiometer or PLC connected to « set point « pin.
External 4-20mA : 0-20mA PLC signal connected to »set point » pin.
The set point unit is given in menu General / Units / Measure.

Open loop case:
In this case the parameter Max Effort must be given. It corresponds to the max product tension.
This parameter is used to calibrate the system since there is no measure.
Example: Merobel brake FAT 350
Nominal torque = 35 Nm at 1 A.
Bobine max diameter = 1 m.
Max current in brake = 0.5 A.
1/ from the FAT 350 torque vs current, we obtain 0.5A = 22.5Nm.
2/ Max Effort = 22.5Nm / 0.5m = 45N.
Max Effort = 45N (or 4.5kg).

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Diameter Input
Diameter measure
2 possibilities:
analog sensor (e.g. ultrasonic), 0-10V signal on the DM pin of the connector.
Calculation from line speed over rpm ratio, click on the check box “pulse sensor for diameter” and refer to “special
functions” for more details.

Diameter calibration
With an analog diameter measure, the signal must be calibrated from physical values (upper point = max diameter,
lower point = min diameter).
Valid max diameter: type in the max diameter value.
Valid min diameter: type in the min diameter value.
The diameter unit is chosen in the General / Units / Diameter menu.
Procedure: type in the values and click on the button “send to RAM”, then simulate physically the max diameter and
click on the button “valid max diameter”, wait 5 seconds and do the same with min diameter and the button “valid min
diameter”.

Filtering
All the inputs can be filtered.
Filtering makes the regulation less sensitive to electric and mechanical disturbances but generates a delay in the
system response time.

A few rules:
Measure : filtering depends on the application and product.
Converting force: from 100.
Converting force on elastic product: from 400.
Dancer: from 0.
Set point:
Diameter:

useful for external set point to filter the signal or simulate a ramp.
It is recommended to use filtering on this signal because diameter is changing slowly. 100 is a good initial
value.
Tachymeter: (speed) Try to find a compromise between noise reduction and quick response. 10 is usually a good initial
value.
The DGT 2000 uses a first order digital filter, the larger the number you give, the lower the cut off frequency (Fc) will be
and therefore the more filtering you will obtain.

Fc
nombre saisi

1
1000

2
500

3
330

4
245

5
195

6
162

7
138

8
120

9
106

10
95

12
78

15
62

Fc
nombre saisi

18
51

20
45

22
40

25
35

29
30

34
25

40
20

50
15

70
10

110
5

150
3

240
1

C – GENERAL Menu
Units / Display
The front face display allows to show some different measurement values as well as some different data used by the
Controller .
These two menus (Units / Display) have to be used to choose what will be displayed on the two available16 digits lines

Units
This menu allows to choose the units for the measurement and for the diameter values

Display
This menu allows to choose what information will be displayed on the two lines
On each line it is possible to choose between the following options :
Display AO1 (idem AO2) : Shows the analogic voltage output on AO1 output (resp. AO2).

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Set point / Diameter / Measure : Shows the actual Set point / Diameter / Measure, using the chosen unit
Shows AO1 status (idem AO2) : Shows the logic inputs configuration viewed by the Controller (according to
A / B digital inputs state), meanning HOLD mode, REGUL mode, RELEASING mode, DEMAGNETIZATION
mode

E-STOP function
Principle
The E-stop function could be used for the Emergency stop or for any other particular process .Two different options are
available : Fixed E-Stop value and Proportional E-Stop value
The last one allows to send an output voltage related to the last current output (before to switch to the HOLD mode)

How does it work
Fixed HOLD value : by entering a value between 0 - 100% , a proportional value between 0-10V will be sent on the
output.
i.e. : with 50%, 5V will be sent on AO1 output during the HOLD mode
Proportional HOLD value : input the gain value (100 - 500%) .
The last calculated output value before switching to the HOLD mode will be multiplied by the chosen gain .
i.e. : with an actual output value of 3 V (during the normal regulation), the controller will send 9 V to the ouptut
if the gain has been set to 300 %

Process
The E-stop mode is managed by the following digital inputs :
external switch A closed – external switch B closed

TIME DELAY function
Principle
When the machine process management (motor start and stop) is not synchronous with the controller logical inputs
remote control (external switchs Reg and B), some regulation troubles can appear .These synchronous problems can
be solved with the Temporization options available in the Controller functions .

How does it works
Starting time delay : Entering a Time delay value (tens of milliseconds), means that the system will wait for that
delay before the controller starts the actual calculation (after switching Reg from open to closed position)
Stopping time delay : Entering a Time delay value (tens of milliseconds), means that the system will wait for
that delay before the controller stops the actual calculation (after switching Reg from closed to open position)
The same effect will be applied on the delay to switch from Regulation mode to Hold mode

Process
It’s usually necessary to manage the switches Reg and B synchronously .

Coefficients
This menu is available for both Closed loop and Inertia compensation configurations .

Closed loop + Open loop Control function
When using a Closed loop configuration, this function allows to mix it with an Open loop control by using a specific
coefficient for each of these control modes : Open loop gain and Closed loop gain .
This function allows to add some Closed loop control around the result of an Open loop control, in order to limit the
Measure – Set point difference, to improve the system stability as well as the accuracy .
Calculation : Open loop gain CBO
DATA :
Max Force range F ( N )
Max web diameter D ( m )
Rated current for the chosen Brake IC ( A )
Max current adjusted on the power supply board IR ( A )
Rated torque for the chosen Brake CN ( N.m )
Formula :

CBO = F x D x IC x 100
2 x CN x IR

The result gives the Open loop true coefficient . This value can be modified to optimize the system stability .

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Inertia compensation function
The Inertia compensation function allows to add an Open loop control to the calculated currrent Closed loop result during
the acceleration / deceleration periods .This coefficient (Inertia gain) is related to the bobbin inertia (proportional to the
actual diameter measurement) and to the actual line speed (tachometer input) .
When the web width is not constant, it is possible to adjust the calculated Inertia term by entering the Coeff. Web width
(also always available to the operator on the controller front panel)
Calculation : Inertia gain GI :
Data :
Max bobbin weight M ( Kg )
Max bobbin diameter D ( m )
Max line speed VL ( m/s )
Decceleration duration T ( s )
Rated current for the chosen Brake IC ( A )
Max current adjusted on the power supply board IR ( A )
Rated torque for the chosen Brake CN ( N.m )
Formula :

GI = M x VL x D x IC x 100
240 x T x CN x IR

Adjustment procedure :
Proceed with the first tests with the maximum web width (Coeff. Web width = 100 %)
Temporarily disable the Open loop control (Closed loop gain = 0 %) to avoid interactions during the adjustment procedure .
Apply a high filtering coefficient on the Diameter input (slow variation input) : Diameter filtering = 500
Enter a low filtering coefficient on the Tachy measurement input to avoid fast transient troubles
Apply the calculated Inertia gain (above formula)
Start the machine and adjust the Inertia gain value to stabilize the actual measurement during acceleration / deceleration
periods .

HOLD function
Principle
The Hold function can be used by the operator for the machine settings (out of regulation mode) .
It allows the operator to manage directly a constant ouptut voltage level (parameter always available on the controller front
panel)

How does it work
Hold value : entering 0-100% means 0-10V proportional output voltage

Process
Two different ways are available to manage this function :
external switch A open – external switch B open
by the front panel operator menu (priority access)

D – PID Menu
Principle
The P.I.D. is the heart of the controller calculation system when using the Closed loop mode.
P , I , and D parameters are the coefficients which give the actual output result from the Measurement – Set point
difference .
CAUTION : the PID calculation must be disabled during the machine rest periods to avoid that a static Measurement – Set
point difference increases the output value to the maximum (giving a very high overshoot for the next machine restart) .
The following process has obviously to be managed by the global machine management system ! (using the external
switches Reg and Init) .

How does it work
There are two options for the PID calculation principle :Fixed PID (coefficients) or Variable PID (coefficients) which have
to be chosen in the PID Menu (« click in the box » choice mode) .
The Variable PID option is very useful when the Fixed PID is unable to keep the same stability level for the whole range of
the Web diameter variation .
The Variable PID option offers to define a P, I and D specific value for the min. diameter, and a different one for the max.
diameter . the three P, I, and D parameters will be automatically updated in relation to a diameter measurement input
(linear variation between min. and max. for each parameter)
P parameter : This parameter is the direct gain on the Measurement – Set point difference .

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The P coefficient will directly affect the global system response time .
CAUTION : The higher the value, the higher the response time, but with a lower stability .
I parameter : This parameter is used to cancel the « static error » by the accumulation of this error from the
beginning, and by adding this error to the set point until reaching the equality .
When the Measurement – Set point difference becomes null, the Integral value is stabilised .
A high coefficient value will make the system more reactif by decreasing the time for the Measure to reach the Set
point actual value .
D parameter :This parameter is used to help the system to react for fast transients.
It is generally only used for the Dancer applications, in order to stabilize the dancer position when the web speed is
variable .
CAUTION : this parameter is used for react to transients, but it means that it could be highly sensitive to the electric
interferences on the measurement signal .Be very careful to connect the wiring shields at the best .

Process
The PID calculation is managed by the external switches Reg and Init.

Init
0
1
0
1

Reg
0
0
1
1

PID calcul mode
Stopped (blocked)
initialisation
processing
processing

CAUTION : when using the diameter calculation (counters inputs), the initialisation of diameter calculation is
managed by the same external switches (Reg = 0 , Init = 1)

E – OUTPUT Menu
THRESHOLD function
Principle
This function allows to define the two limits for the actual regulation voltage output AO1 (or AO1 and AO2 when using the
No-Stop mode) inside the global output range (-10 / + 10 V) .
Useful function when using the controller with a device which does not take care of the negative voltage .

How does it work
Min. threshold : means the minimum voltage allowed to the controller regulated output
(enter the threshold value between –10V et +10V).
Max. threshold :Means the maximum voltage allowed to the controller regulated output
(enter the threshold value between –10V et +10V - must be higher than the Min. threshold already defined).

DISPLAY output function (AO3)
This function allows to affect one of the following information as an analogic voltage to the third analogic output AO3
Set point (0 to 10V = whole measurement range as it has already been calibrated)
Measure (-10V to +10V = whole measurement range as it has already been calibrated)
Diameter (0 to 10V = 0 to the Max diameter)
NOTE : The ALARM Menu is detailed in the following « Special functions Menu »

F – SPECIAL FUNCTIONS Menu
TAPER function
Principle
TheTaper function is used to slowly decrease the tension applied to a web during the rewinding process .

How does it work
Click in the Taper special function box to enable the function in the INPUT / Set point menu

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The Taper coefficient has to be chosen between 0 and 100 % .He is defined as shown on the following sketch (D %) to
apply the requested tension decrease for the maximum calibrated diameter .
Min. Diameter and Max Diameter have to be already defined during the diameter calibration process .
Taper Diameter is the diameter value for which the Taper function will start to be applied .

DEMAGNETIZATION function
Principle
This special function may allow to send a reverse current pulse to a MEROBEL Brake (when using a PWR 5A INV special
power supply).
This function can be used to decrease the brake response time for some accurate Test Bench applications .

How does it work
Click in the Demagnetization special function box to enable the function in the GENERAL / Demagnetization menu
Two different parameters are used to define the amplitude (Voltage value) and the duration (tens of milliseconds) of the
reverse current pulse .
At the end of the pulse duration, the output remains at 0 V

Process
The Demagnetization function is managed by the external switches A = Closed – B = Open .

PULSE SENSORS FOR DIAMETER (Diameter calculation) function
Principle
Sometimes, the use of an Ultrasonic measurement is impossible to measure the web diameter (type of material, very
narrow web, machine design), and the only way is to know the Rotation speed and the Linear speed, in order to calculate
the diameter, using the following formula :
Linear speed = Rotation speed x pi x D , meaning that D = Linear speed / (pi x Rotation speed)

Set Point
(1-D%) x Set point

Min. Dia.

Taper Dia.

Max Dia.

How does it work
The input information has to be done by digital proximity sensors (Hall effect) or Encoders for both Linear and Rotation
speed (Input frequency range : 1 Hz to 10 kHz) .
Click in the « Pulse sensor for diameter » special function box to enable the function in the INPUT / Diameter menu .
Enter Nb Puls/unit and Nb Puls/ rotation to define the ratio which has to be used for the calculation .
Diameter max. and Diameter min. are used for the calibration .
Diameter init is used to keep a realistic calculation result when starting, after a bobbin change (empty to full, or full to
empty) .
NOTE : Below 1/3 Hz, as the counters inputs will not be available to work properly, the calculation result remains the last
valid one .

Process
The Demagnetization function is managed by the external switches Reg = open and Init = closed
CAUTION : when using the PID function (closed loop), the calculation initialisation is managed by the same external
switches (Reg = 0 , Init = 1)

NO-STOP function
Principle
This function is used to manage two independent outputs (one which is the calculation result output, and the second one
which is fixed – Hold value) .
This is usually very useful to manage the automatic splice turrets systems .

How does it work
Click in the « No-Stop » special function box to enable the function .
This function allows to affect the calculation result alternatively to the first or to the second Analogic outputs .

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The ouptut currently not affected to the calculation is automatically delivering the Hold or the E-stop value, depending on
the status chosen for logical inputs A and B .

Process
See the following table :

AB
00
01
10
11

AO1
Regulation
Regulation
Hold
E-Stop

AO2
Hold
E-Stop
Regulation
Regulation

0 means Open / 1 means Closed
NOTE :
When using this “No-Stop” function, the “Demagnetization” function is not available .
The Operator control panel (front face keyboard functions) remains the priority control .
That means that “Hold” or “Freewheel” modes are sent simultaneously on both AO1 and AO2 .

ALARM management function
Principle
Two digital outputs have been designed to provide two different alarm signals :
Regulation fault : when the Measurement – Set point difference is over the pre-set tolerance, it means that there
is something wrong in the process .
Min. Diameter : Diameter measurement threshold available to alert the operator before the real end of the bobbin

How does it work
Click in the « Alarm » special function box to enable the function in the OUTPUT / Alarm menu .
Error range parameter : the digital output AL1 will be closed for an actual Measurement – Set point difference
higher than the chosen percentage .
Diam Threshold parameter : the digital output AL2 will be closed for an actual Diameter measurement below the
chosen percentage of full scale diameter .

Example :
Error range :
For a 5 kg set point and 10 % Error range, the AL1 output will be closed for a measurement out of the 4.5 to 5.5
kg range ( +/- 10 % of the current set point)
Diam Threshold :
Diameter range = 0.2 to 1.0 m
Actual working range = 1.0 – 0.2 = 0.8 m
For 5 % Diam threshold, the AL2 output will be closed as soon as the actual diameter will be lower than 0.24 m
Alarm diameter = core diameter + (Actual working range x Diameter threshold)
0.2 + (0.8 x 5%) = 0.24 m

Process
The AL1 and / or AL2 digital outputs remain closed until the time that the related measurements are out of the right range .
CAUTION :

AL1 and AL2 are driven by optocoupling components . The common (0 V) point for both is ALMax output capability : Vceo = 300 V

G – DIGITAL INPUTS (process management)
Digital Inputs A and B
Principle
The digital inputs A and B are dedicated to the management of the controller global status .
It gives to the user the possibility to create an automatic relation between the machine process and the Controller status
(i.e. : to manage the E-Stop needs) .

How does it work
The following table shows the Controller main status for any different combination of A and B switches positions, as long
as the No-Stop mode is not activated (see SPECIAL FUNCTIONS Menu / No-Stop Function) .

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A
0
0
1
1

DGT 2000 Merobel
B
0
1
0
1

Output AO1
Hold
Regul
Demagnetization
E-Stop

0 means :Switch Open / 1 means : switch closed (to the 24Vdc terminal)
The Operator control panel (front face keyboard functions) remains the priority control .

Logical inputs Reg and Init
Principle
The digital inputs Reg and Init are dedicated to the management of the calculation process itself .
The calculation process mainly means of course the P.I.D. regulator, but this process has been designed as well for the
initialisation when using the diameter calculation function .

How does it work
The following table shows the calculation process status for any different combination of Reg and Init switches positions

Init
0
1
0
1

Reg
0
0
1
1

PID calculation
calculation stopped
calculation initialization
calculation in process
calculation in process

Diameter calculation
Last dia. Value initialization

0 means :Switch Open / 1 means : switch closed (to the 24Vdc terminal)

H – DATA CAPTURE Menu
Starting a Data Capture
The PC software includes a Data capture function, allowing to visualize and to record each Controller inputs / outputs
actual values / status, four times / sec.
To start a data capture, go to the REGULATOR / Start Acquisition option .
To record the data on the computer, enter a new File name (ext : .acq) . The Data Capture will start and the data will be
saved in the related File .
To have a look on the data without recording, choose Cancel .The Data Capture will be start without recording .
In both cases, press Stop to stop the Data Capture process .

How to read the acquired File
Using the recording option during the Data capture allows to store the data on the disk as a data file (ext : .acq)
The data are arranged as a text file (columns separator = Tab) which can be read by any usual spreadsheet software .
NOTE : the data are collected 4 times / sec, meaning that the time base between two lines is 250 ms (1/4 s) .

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Appendix 9-9

Technical Support
For any more information and / or any troubleshoot assistance, please contact your local reseller
which will help you to find the best solution .
Merobel direct technical support :
Fax :

(732) 493-2949

E-mail :

info@andantex.com

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Your experience and your comments will be welcomed
Thank you in advance to spend some few minutes to fill the following form, before faxing it back to :

(732) 493-2949
This answer will of course remain strictly confidential and will help us to give you some feedback, helping you to use at the
best your DGT 2000 in the future .
Your address will be necessary to be able to send you the next software updates .

A – ADDRESS
Company :
Address :
Ph :
E-mail :
Name :

Fax :
First Name :

B – APPLICATION DATA
Open loop using Ultrasonic sensor
Open loop using Diameter calculation
Dancer Closed loop system
Force closed loop (using load cells)

YES
YES
YES
YES

NO
NO
NO
NO

Using Inertia compensation option
Using the Variable PID option
Using the Open + Closed loop option

YES
YES
YES

NO
NO
NO

Torque control using :

C – SETTING UP
Setting up date :
Setting up made :

MEROBEL Brake
MEROBEL Clutch
Other Brake / Clutch
Motor / Drive

Type :
Type :
Type :
Type :

By yourself (or somebody in your company)
By a MEROBEL Technician
By a Merobel reseller Technician

D – YOUR GLOBAL OPINION ABOUT THE DGT 2000 CONTROLLER
Mechanical / Wiring setting up
++
+
0
Programming
++
+
0
Inputs / Outputs calibration
++
+
0
Regulator coefficients optimisation
++
+
0
User ‘s interface
++
+
0
User’s manual
++
+
0
Technical support
++
+
0

-

--------

Other comments :
.

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