DDM-3020 Diameter Gauge

Newlead trade Suzhou Co.
,Ltd
Suzhou Newlead Augmented Intelligence Equipment Co.Ltd
DDM-3020 Diameter Gauge for

Measurement and Control
No2401,Jingchang Tech park, Suzhou city,JiangSu province,China

008618913191585 jerrypro@qq.com www.newleadgroup.com
Operating Instructions
1 General
Type DDM-3020 is the third generation dynamic diameter gauge for measurement and control developed
by Shanghai Online. Employing the measuring principle of high speed pulsed IR ray combined with high
precision CCD sensor and aided by high speed digital image process technique, this generation gauge
features high measurement accuracy, high stability, easy application and maintenance and extra-long
service life. A complete set of the Gauge includes a DDM-3020 diameter measuring head, measuring head
support and a separate DSP-3A Monitor.
DDM-3020 Dynamic Diameter Gauge is used mainly for online diameter measurement and control for
electric wire and cable, optic fiber cable, tubes and wires. Compared with the previous generation products,
the third generation gauge is characterized by
☆ All digital image process technique and dedicated ultra-large scale integrated circuit, which ensure high
stability, compact size and low power consumption.
☆ Hardware acceleration, which provides high measuring speed up to 1800 measurements/s and makes it
possible to use the Gauge as a lump & neck detector.
☆ RS-485 communication interface，which makes the Gauge to be connected easily to an industry
computer, PLC and touch panel.
☆ Advanced feedback control system, which improves the control effect.
1.1 Service conditions and packing size

Power: 100～240VAC, 50～60Hz;
Operating temperatures: 0～45
Atmospheric humidity: ≤ 90%（free of condense water）
Ambient requirement: The surrounding air shall free of corrosive gas, oil, steam and
heavy dust
Packing size: 615 mm×330 mm×280 mm（L×W×H）
Weight of the complete machine: 11 kg
1.2 Principal technical data

Nominal measuring range: 20 mm
Recommended measuring range: 0.2～20 mm
Measuring accuracy: ±（0.002 + 0.02% gauge readout）
Measuring speed: 1800 measurements/s
Power consumption: < 10W
Communication interface: RS-485
Centre height（including support）: 850～1100 mm
Dimensions（excluding support）: 100 mm×100 mm×410 mm
1.3 Complete set of machine 1

Each package of standard configuration of DDM-3020 Diameter Gauge includes the following items：
DDM-3020 Diameter Gauge: 1
Column of the measuring head support: 1 set
Footing of the measuring head support: 1
Cushioning spring of the support: 1
2.5m power cord: 1
4-pin aircraft plug at the communication interface: 1
DSP-3A Monitor: 1
Output amplitude adjusting potentiometer
of the feedback control system: 1
Operating manual: 1
───────Diameter measuring head
─────────── Set screws of the measuring head
──────────── Support column inner tube
─────────── Set screws of the support column inner tube
──────────── Support column outer tube
─────────── Set screws of the support column outer tube

─────── Footing of the measuring head support
Figure 1-1 Mounting of the diameter measuring head and support
2
│ │
│ │
│ │
Power socket Comm interface
Figure1-2 Diameter gauge panel Figure1-3 Power socket and comm interface
2 Mounting
2.1 Mounting position
DDM-3020 Diameter Gauge may be mounted either before or after the cooling trough when it is used with
the wire and cable production line. When the Gauge is mounted before the cooling trough, optimal control
can be achieved due to in-time feedback resulting from short distance from the Gauge to the extruder. But
the measurement at this position is usually somewhat larger than the actual diameter because the plastic
melt has not been solidified and the measurement is the diameter of the hot-state wire or cable; for this
reason, the set nominal shall be increased appropriately. When the Gauge is mounted after the cooling
trough, the measurement will be more accurate because it reflects the actual diameter. But the control effect
becomes worse due to large control lag. Besides, the tested wire or cable shall be wiped dry otherwise the
water film on the surface of the wire or cable will affect adversely the measuring accuracy. In actual
operation, the set nominal shall be increased appropriately according to the water content of the tested
object.
2.2 Mounting procedures

（1）Open the package, inspect the Gauge and accessories according to the packing list.
（2）In reference of Figure1-1, mount the Gauge and support.
（3）Place the Gauge in an appropriate location of the line. Move the Gauge support so that the tested wire
or cable is at the centre of the measuring window. Fix the Gauge by fixing the anchor bolts.
（4）Adjust the height of the Gauge support so that the tested wire or cable is at the centre of the measuring
range. Tighten the related set screws.
（5）Plug the power cord into the power socket on the base of the Gauge（see Figure 1-3）. Switch on the
power. The Gauge is ready to operate at this time.
3 Panel display and operation

3.1 Panel make-up
As shown in Figure1-2，DDM-3020 Diameter Gauge panel consists of the following components：
（ 1） 5-digit LED display, used to displaymeasured diameter, lump & neck alarm count, gauge
abnormality and set parameter. 3
（2）20-segment LEB (light-emitting bar) display, used to display diameter deviation, feedback control
output , location of the tested object in the measuring range and abnormal alarm.
（3）8 status indicators, used to display the Gauge operating mode or display modes and parameters.
（4）5 keys, i.e., parameter key, shift key, increase key, decrease key and lump & neck key. They have
different functions in different operating modes.
3.2 Gauge operating mode

DDM-3020 Diameter Gauge has three main operating modes as follows:
（1）Normal operation：In this operating mode, the diameter of the tested object is measured continuously
at the speed of 1800 measurements/s. The results are displayed in digitals on the panel. At the same
time, the diameter is inspected to see if it exceeds the tolerance limits and if the tested object has
surface lump & neck based on the set working parameters. Besides, automatic feedback control
quantity for the diameter is calculated and sent out. The communication task is performed.
（2）Abnormal alarm: The abnormal alarm mode is entered whenever abnormal operation is detected. In
this operating mode, the abnormal or fault message is displayed on the panel and alarm is given.
（3）Parameter setting：This operating mode can be further divided into two sub-states, i.e., parameter
display and parameter setting, used respectively for viewing and setting the individual working
parameters. Press 【 Parameter key 】 in the normal operation mode to enter the parameter
display/setting mode. For details, see chapter 4.
3.3 Status indicator

DDM-3020 Diameter Gauge has 8 status indicators on the panel. Their significance is as follows：
Indicator flashes, indicating that the difference between the measured diameter and nominal exceeds
the negative tolerance (i.e., the wire is too thin).
Indicator flashes, indicating that the difference between the measured diameter and nominal exceeds
the positive tolerance (i.e., the wire is too thick).
Indicator is bright, indicating that the current operating mode is nominal display/setting
Indicator is bright, indicating that the current operating mode is tolerance display/setting
Indicator is bright, indicating the feedback control is on in the normal operation mode and feedback
control parameter display/setting in the parameter setting mode.
Indicator flashes, indicating the feedback control is frozen in the normal operating mode and
feedback control parameter error in the abnormal alarm mode.
Indicator is bright, indicating that the digital display is used for lump & neck alarm count in the
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normal operating mode and lump & neck parameter display/setting in the parameter setting mode.
Indicator flashes, indicating presence of non-reset lump & neck alarm output.
Indicator is bright, indicating that the current operating mode is parameter display/setting
Indicator is bright, indicating that the LEB displays the location of the tested object in the
measuring range.
3.4 Function of the individual keys

【Parameter key】（1）Press this key in the normal operation mode to enter the parameter display
mode.（2）Press this key in the parameter display mode to return to the normal operation mode.（3）
Press this key in the parameter setting mode to confirm and save the current setting and return to the
parameter display mode.
【Shift key】（1）Press this key in the normal operation mode to make the LEB display the location
of the tested object in the measuring range for ca. 20s. Press this key once more to return to the
original indication.（2）Press this key in the parameter display mode to enter the parameter setting
mode.（3）Press this key in the parameter setting mode to make the cursor (i.e., the flashing number)
move one digit to the right.
【Increase key】（1）Press this key in the normal operation mode to turn on the feedback control
(provided the control mode is manual and feedback control work mode is not disabled).（2）Press
this key in the parameter display mode to diaplay the previous parameter in the parameter menu.（3）
Press this key in the parameter setting mode to increase the number indicated by the cursor by 1.
【Decrease key】（1）Press this key in the normal operation mode to turn off the feedback
control (provided the control mode is manual and feedback control is turned on).（2）Press this
key in the parameter display mode to display the next parameter in the parameter menu.（3）Press
this key in the parameter setting mode to decrease the number indicated the cursor by 1.
【Lump & neck key】 This key functions only in the normal operation mode and when lump &
neck detection is enabled. Press this key when the measured diameter is displayed on the digital
display to display the lump & neck alarm count and reset the lump & neck alarm (if any). Press this
key once more to clear the lump & neck alarm count and return to the measured diameter display
mode. If the key is not pressed, the system returns automatically to the measured diameter
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display mode in 20s but the lump & neck alarm count will not be cleared.
3.5 Normal operation

3.5.1 Digital display
In the normal operation mode, the digital display is used to display measured diameter or lump & neck
alarm count.
（1） Usually, the measured diameter is displayed. Display format：5-digit decimal number, unit：mm，
unit of inch is also available（by system parameter setting, for details, see Chapter 4）. For example,
for a measured diameter of 4.5mm, the following will be displayd：
（2） When lump & neck detection is enabled, press【Lump & neck key】when the measured diameter is
displayed to indicate the lump & neck alarm count for ca. 20s. Display format：mark for lump & neck
alarm count“ ” followed by a 4-digit decimal number, which indicates the detected alarm count in
the range of 0000～9999. If 9999 is exceeded，the number 9999 will flash. For example, for a current
alarm count of 25, the following will be displayd：
Press 【Lump & neck key】once more when the lump & neck alarm count is displayed to clear the
lump & neck alarm count and return to the measured diameter display mode.
To sum up, the digital display is used only to display the measured diameter when lump & neck
detection is disabled. It is used to diaplay the measured diameter or lump & neck alarm count when
lump & neck detection is enabled. Conversion from one display mode to another is shown below:
Press【Lump & neck key】

When measured diameter is displayed ──────────────→ to display the lump &
neck alarm
count.
Press 【Lump & neck key】

once more or wait for 20s
When lump & neck alarm count is displayed ←────────────── to display the
measured
diameter.
3.5.2 LEB (light-emitting bar) display

In the normal operation mode, the LEB display can be used to display respectively diameter deviation,
feedback control output and location of the tested object in the measuring range.
（1）When feedback control is enabled, the LEB is used to display the output voltage of feedback control in
the range of －100%～+100%. When ±90% is6exceeded, the corresponding LEB segment will
flash，indicating that the automatic control ouput is near saturation (i.e., near the automatic control
limit ) and manual adjustment is necessary. The feedback control output is zero when the central 2
segments are bright
（2）When feedback control is disabled, the LEB is used to display the relative deviation of the diameter in
the range of －100%～+100%, which is defined as
Positive relative deviation = 100% ×（measured diameter－nominal）÷ positive tolerance
Negative relative deviation = 100% ×（measured diameter－nominal）÷ negative tolerance
（3） The LEB display can be used to view the location of the tested object in the measuring range to ease
the adjustment of the height of the Gauge support. Press 【Shift key】 in the normal operation mode
to display the location of the tested object in the measuring range with －100% as the lower limit
and +100% as the upper limit. Press 【Shift key】 once more to return to the original indication. Or
wait for 20s without pressing any key to return to the original indication.
3.6 Abnormal alarm

The diameter gauge enters the abnormal alarm mode whenever abnormal operation is detected. At this time,
all segments of the LEB display flash and the digital display indicates a fault message for the operator to
act accordingly.
（1） Fault message：
Fault cause：Lens of the Gauge is badly polluted by dust etc.

Fault removal：Remove the dust cover before the lens. Wash the lens surface with lens detergent
（or anhydrous alcohol）.
Fault cause：The tested object is at a location too high exceeding the upper limit of the measuring
range.
Fault removal：Lower the wire pulley or raise the diameter measuring head so that the tested wire
or cable is located within the measuring range of the Gauge.
Fault cause：The tested object is at a location too low exceeding the lower limit of the measuring
range.
Fault removal：Raise the wire pulley or lower the diameter measuring head so that the tested wire
or cable is located within the measuring range of the Gauge.

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Fault cause 1：The tested wire or cable has a diameter too large exceeding the measuring range of
the Gauge
Fault removal 1：Use a larger size diameter gauge.
Fault cause 2： Displacement of the lens dust cover which blocks the measuring light
Fault removal 2：Mount the lens dust cover in the correct location.
Fault cause 3：Damage of light source or its driving circuit resulting in failure to emit light by the
light source
Fault removal 3：Contact the after-sales department of Shanghai On-Line.
.
Fault cause 1：The lens is irradiated directly by an external strong light (e.g. sunlight).
Fault removal 1：Block any external strong light.
Fault cause 2：Displacement of the light source or lens system
Fault removal 2：Contact the after-sales department of Shanghai On-Line.
Fault cause 1：Lens of the Gauge is badly polluted by dust etc resulting in partially blocked light
emmission
Fault removal 1：Same as for fault（1）.
Fault cause 2：The tested object is transparent (e.g. glass tube) or more than one tested object in the
measuring range.
Fault removal 2：Use the Gauge that can measure transparent object or more than one tested object
at the same time.
Fault cause：The tested object is too thin（below φ0.5mm）and located so far away from the centre
(too near to the dust cover) that proper imaging by the optical system is not possible.
Fault removal：Locate the tested object at the centre（keeping equal distance from the dust cover at
either side as far as possible）.
Fault cause：Loose connection between the main board and display panel
Fault removal：Contact the after-sales department of Shanghai On-Line
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Fault cause：Fault of software

Fault removal：Contact the after-sales department of Shanghai On-Line.
（10）Fault message：
Fault cause：Fault of hardware or circuit

（11）Fault message：
Fault cause：The Gauge is locked for over 30 inputs of wrong password.

（12）Fault message：All segments of the LEB display and the feedback control indicator flash
simultaneously.
Fault cause：Wrong setting of the feedback control parameter

Fault removal：Check the parameters relating to feedback control. The nominal shall not be set at 0.
Both the proportional coefficient and integral coefficient shall not be set at 0. Or, in the advanced
feedback mode, change of product size shall be accompanied by self rectification
4 Parameter display/setting
The parameter display mode is used to view the individual parameters. While the parameter setting mode is
used to change the existing parameter value and save the new parameter value. The parameters for
DDM-3020 Diameter Gauge can be classified into three types, i.e., working parameters, feedback control
parameters and system parameters. Press 【Parameter key】in the normal operation mode or abnormal
alarm mode to enter directly the working parameter display mode. Password is necessary to enter the
feedback control parameter or system parameter display/setting mode. Conversion among the normal
operation mode（or abnormal alarm mode）, parameter display mode and parameter setting mode is shown
below:
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4.1 Working parameter
The working parameter menu contains nominal diameter, tolerance（or positive tolerance, negative
tolerance）, lump & neck limit（or lump & neck positive limit, lump & neck negative limit）, lump & neck
detection time, feedback parameter password and system parameter password.
Press 【Parameter key】in the normal operation mode or abnormal alarm mode to enter the working
parameter display mode. The first parameter in the menu (i.e., nominal diameter) will be displayd
immediately. Press 【Increase key】 to display the previous parameter in the menu. Press 【Decrease key】
to display the next parameter in the menu.
The parameters in the menu vary with different setting of tolerance setting type, lump & neck limit setting
type and feedback control mode.
┌──────┐
│ Nominal diameter │
└──────┘
Tolerance setting type=1 Tolerance setting type=2
┌──────┐ ┌──────┐
│ Tolerance │ │ Positive tolerance │
└──────┘ └──────┘
┌──────┐
│ Negative tolerance │
└──────┘
L & N limit setting type=0 L & N limit setting type =1 L & N limit setting type=2
┌──────┐ ┌──────┐
│ L & N limit │ │L & N positive limit │
└──────┘ └──────┘
┌──────┐
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│L & N negative limit │
└──────┘
┌──────┐
│L & N detection time│
└──────┘
Feedback control mode=0 Feedback control mode=1, 2, 3
┌──────┐
│Feedback parameter password│
└──────┘
┌──────┐
│System parameter password│
└──────┘
Note：（1） When tolerance setting type=1，the positive and negative tolerances are equal. They are
combined into one single parameter tolerance.
（2） When lump & neck limit setting type=0，lump & neck detection is disabled. At this time, no
parameters relating to lump & neck detection will appear in the working parameter menu.
（3） When lump & neck limit setting type=1，the lump & neck positive and negative limits are
equal. They are combined into one single lump & neck limit.
（4） When feedback control mode=0，feedback control is disabled. At this time, no feedback
parameter password will appear in the working parameter menu, namely, the feedback control
parameter menu cannot be entered.
Let us take two examples to explain the content of the working parameter menu in different conditions and
related operating procedures. In the following chart, “↑” indicating “press 【Increase key】”， “↓”
indicating “press 【Decrease key】”，the key above a horizontal line indicating operation from left to right,
the key under a horizontal line indicating operation from right to left, the final “……” indicating return to
the first option of the menu.
（1）Tolerance setting type=1, lump & neck limit setting type=0, feedback control mode=1（factory
default）：
┌──────┐ 【Parameter key】 ┌──────┐ 【Shift key】 ┌──────┐

│Normal operation mode│←────→│ Nominal display │←────→ │ Nominal setting │
└──────┘ 【Parameter key】 └──────┘ 【Parameter key】 └──────┘
↑ ↑↓
│ ┌──────┐ 【Shift key】 ┌──────┐
├ ←────────│ Tolerance display │←────→ │ Tolerance setting
│
│ 【Parameter key】 └──────┘ 【Parameter key】 └──────┘
│ ↑↓
│ 11┌──────┐ 【Shift key】
┌──────┐
├ ←──────── │Feedback parameter password│─────→│ Password input
│
│ 【Parameter key】 └──────┘ └──────┘
│ ↑↓
│ ┌──────┐ 【Shift key】 ┌──────┐
└ ←──────── │System parameter password│─────→│ Password input │
【Parameter key】 └──────┘ └──────┘
↑↓
（2）Tolerance setting type=2, lump & neck limit setting type=1, feedback control mode=0：
┌──────┐ 【Parameter key】 ┌──────┐ 【Shift key】 ┌──────┐
│Normal operation mode│←────→│ Nominal display │←────→ │ Nominal setting │
└──────┘ 【Parameter key】 └──────┘ 【Parameter key】 └──────┘
↑ ↑↓
│ ┌──────┐ 【Shift key】 ┌──────┐
├ ←──────── │ Positive tolerance display │←────→ │Positive tolerance setting │
│ ↑↓
│ ┌──────┐ 【Shift key】 ┌──────┐

├ ←──────── │ Negative tolerance display │←────→ │ Negative tolerance setting │
│ ↑↓
│ ┌──────┐ 【Shift key】 ┌──────┐
├ ←──────── │Lump & neck limit display│←────→│Lump & neck limit setting│
│ ↑↓
│ ┌──────┐ 【Shift key】 ┌──────┐
├ ←──────── │Lump & neck time display│←────→ │Lump & neck time setting│
│【Parameter key】 └──────┘ 【Parameter key】 └──────┘
│
↑↓
│ ┌──────┐ 【Shift key】 ┌──────┐
└ ←──────── │System parameter password│─────→ │ Password input │
【Parameter key】 └──────┘ └──────┘
↑↓
4.1.1 Nominal diameter

Application：This nominal is used as the reference for diameter feedback control, out-of-tolerance alarm
and lump & neck detection. When the nominal diameter is set at 0，then （1）No diameter out-of- tolerance
detection and alarm will be carried out.（2）No lump & neck detection and alarm will be carried out.（3）
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Feedback control parameter error will appear when diameter feedback control is turned on.
Numeric area：00.000 ～ 19.999 mm.
Setting procedures : In order to change the original nominal 0 into 4.8 mm（display: 04.800），proceed as
follows:
（1）Press【Parameter key】in the normal operation mode to enter the nominal display mode:
Indicators are bright
（2）Press【Shift key】to enter the nominal setting mode，the first digit on the display “0” flashes.
（3）Press【Shift key】，the second digit “0” flashes. Press【Increase key】4 times to change “0” into “4”.
（4）Press【Shift key】，the third digit “0” flashes. Press【Increase key】 8 times （or press【Decrease
key】 2 times）to change “0” into “8”.
（5）Press【Parameter key】to save the change and return to the nominal display mode.
（6）If it is necessary to set another parameter，press【Increase key】or【Decrease key】to locate this
parameter. Otherwise press【Parameter key】to return to the normal operation mode.
4.1.2 Diameter tolerance

Application：This tolerance is used for diameter out-of-tolerance alarm. Out-of-positive-tolerance alarm is
given when the measured diameter > nominal+tolerance. Out-of-negative-tolerance alarm is given when the
measured diameter <nominal－tolerance. If the tolerance is set at 0, no diameter out-of-tolerance detection
and alarm will be carried out.
Setting procedures : In order to change the original tolerance 0.015 mm into 0.120 mm，proceed as
follows:
（1）Press【Parameter key】in the normal operation mode to enter the nominal display mode（see 4.1.1）.
（2）Press【Increase key】or【Decrease key】to locate the tolerance display mode:
Indicators are bright.
The first digit “￣” in the above indication is the mark for single tolerance.
（3）Press【Shift key】to enter the tolerance setting mode”. The second digit on the display “0” flashes.
（4）Press【Shift key】，the third digit “0” flashes. Press【Increase key】once to change “0” into “1”.
（5）Press【Shift key】，the fourth digit “1”flashes. Press【Increase key】once to change “1” into “2”.
（6）Press【Shift key】，the fifth digit “5” flashes. Press【Increase key】 5 times to change “5” into “0”.，
（7）Press【Parameter key】to save the change and return to the tolerance display mode.
4.1.3 Diameter positive tolerance

Application：The positive tolerance is used for diameter out-of-tolerance alarm. Out-of-positive-tolerance
alarm is given when the measured diameter > nominal+tolerance. If the tolerance is set at 0, no diameter
out-of-positive-tolerance detection and alarm will be carried out.
Numeric area：0.000 ～ 9.999 mm. 13
Setting procedures : In order to change the original positive tolerance 0.015 mm into 0.010 mm，proceed
as follows:
（2）Press【Increase key】or【Decrease key】to locate the positive tolerance display mode.
The first digit “￣” in the above indication is the mark for positive tolerance.
（3）Press 【Shift key】to enter the positive tolerance setting mode. The second digit on the display “0”
flashes.
（4）Press【Shift key】，the third digit “0” flashes.
（5）Press【Shift key】，the fourth digit “1” flashes.
（6）Press【Shift key】，the fifth digit “5” flashes. Press【Decrease key】5 times to change “5” into ”0”.
（7）Press【Parameter key】to save the change and return to the positive tolerance display mode.
4.1.4 Diameter negative tolerance

Application：The negative tolerance is used for diameter out-of-tolerance alarm. Out-of-negative-tolerance
alarm is given when the measured diameter < nominal－negative tolerance. If the negative tolerance is set
at 0, no diameter out-of-negative-tolerance detection and alarm will be carried out

Setting procedures : In order to change the original positive tolerance 0.000 mm into 0.090 mm，proceed
as follows:
（1）Press【Parameter key】in the normal operation mode to enter the nominal display mode”（see 4.1.1）.
（2）Press【Increase key】or【Decrease key】to locate the negative tolerance display mode.
The first digit “ ” in the above indication is the mark for negative tolerance.
（3） Press【Shift key】to enter the negative tolerance setting mode. The second digit on the display “0”
flashes.
（4）Press【Shift key】，the third digit “0” flashes.
（5）Press【Shift key】，the fourth digit “0” flashes. Press【Decrease key】once to change “0” into”9”.
（6）Press【Parameter key】to save the change and return to the negative tolerance display mode.
4.1.5 Lump & neck detection limit

Application：The lump & neck detection limit is used for lump & neck defect detection and alarm. The
lump & neck defect alarm is given when the14measured diameter > nominal + lump & neck
detection limit or the measured diameter < nominal－lump & neck detection limit. If the lump & neck
detection limit is set at 0, no lump & neck defect detection and alarm will be carried out..
Setting procedures : In order to change the original lump & neck detection limit 0.05 mm into 0.20 mm，
proceed as follows:
（2）Press【Increase key】or【Decrease key】to locate the lump & neck limit display mode.
The first two digits “d￣” in the above indication are the mark for single lump & neck limit.
（3） Press【Shift key】to enter the lump & neck limit setting mode. The third digit on the display “0”
flashes.
（4）Press【Shift key】，the fourth digit “0” flashes. Press【Increase key】twice to change “0” into ”2”.
（6）Press【Parameter key】to save the change and return to the lump & neck limit display mode.
4.1.6 Lump & neck positive limit

Application：The lump & neck positive limit is used for lump defect detection and alarm. The lump & neck
defect alarm is given when the measured diameter > nominal+lump & neck positive limit. If the lump &
neck positive limit is set at 0, no lump defect detection and alarm will be carried out.
Setting procedures : In order to change the original lump & neck positive limit 0.25 mm to 0.00 mm，
proceed as follows:
（2）Press【Increase key】or【Decrease key】to locate the display mode of lump & neck positive limit.
The first two digits “d￣” in the above indication are the mark for lump & neck positive limit.
（3）Press【Shift key】to enter the setting mode of lump & neck positive limit. The third digit on the display
“0” flashes.
（4）Press【Shift key】，the fourth digit “2” flashes. Press【Decrease key】twice to change “2” into ”0”.
（6）Press【Parameter key】to save the change and return to the display mode of lump & neck positive limit.
4.1.7 Lump & neck negative limit

Application：The lump & neck negative limit is15used for neck defect detection and alarm. The lump
& neck defect alarm is given when the measured diameter < nominal－lump & neck negative limit. If the
lump & neck negative limit is set at 0, no neck defect detection and alarm will be carried out.
Setting procedures : In order to change the original lump & neck negative limit 0.20 mm into1.00 mm，
proceed as follows:
（2）Press【Increase key】or【Decrease key】to locate the display mode of lump & neck negative limit.
The first two digits “d ” in the above indication are the mark for lump & neck negative limit.
（3）Press 【Shift key】to enter the setting mode of lump & neck negative limit. The third digit on the
display “0” flashes. Press【Increase key】once to change “0” into ”1”.
（4）Press【Shift key】，the fourth digit “2” flashes. Press【Decrease key】twice to change “2” to ”0”.
（5）Press 【Parameter key】to save the change and return to the display mode of lump & neck negative
limit.
4.1.8 Lump & neck detection time

Application：The lump & neck detection time is used for lump & neck defect detection and alarm. The
detected lump & neck defect is confirmed and the lump & neck defect alarm is given when the measured
diameter > nominal + lump & neck positive limit or the measured diameter < nominal－lump & neck
negative limit lasts for a time exceeding the lump & neck detection time.
Numeric area：1 ～ 9 ms.
Setting procedures : In order to change the original lump & neck detection time 5 ms into 1 ms，proceed
as follows:
（1）Press 【Parameter key】in the normal operation mode to enter the nominal display mode（see 4.1.1）.
（2）Press【Increase key】or【Decrease key】to locate the display mode of lump & neck detection time:
The first two digits “dt” in the above indication are the mark for lump & neck detection time.
（3）Press【Shift key】to enter the setting mode of lump & neck detection time. The last digit on the display
“5” flashes. Press【Decrease key】4 times to change “5” into “1”.
（4）Press【Parameter key】to save the change and return to the display mode of lump & neck limit.
4.1.9 Feedback parameter password

Application：The password is used to enter the feedback parameter menu (i.e., the display/setting mode of
feedback control parameter) to view and change the parameter values.
Numeric area：0000 ～ 9999. The password can16be set in the system parameter menu.
Input procedures：Suppose the feedback parameter password is 1234 （factory default），proceed as
follows:
（2）Press【Increase key】 or 【Decrease key】to locate the input interface of feedback parameter
password”：
（3）Press 【Shift key】to enter the input mode of feedback parameter password. The first “－” after “F”
becomes a flashing “0”. Press【Increase key】once to change “0” into “1”.
（4）Press 【Shift key】，the second “－” becomes a flashing “0”. Press【Increase key】 twice to change
“0” into “2”.
（5）Press 【Shift key】，the third “－” becomes a flashing “0”. Press【Increase key】 3 times to change
“0” into “3”.
（6）Press【Shift key】，the fourth “－” becomes a flashing “0”. Press【Increase key】 4 times to change
“0” into “4”.
（7）Press【Parameter key】to confirm the input. When a correct password is input, the system enters the
feedback parameter menu. When a wrong password is input, the system returns to the normal
operation mode.
4.1.10 System parameter password

Application：The password is used to enter the system parameter menu to view or change the parameter
values.
Numeric area：System parameter password is 74683.
Input procedures：
（1）Press 【Parameter key】in the normal operation mode to enter the nominal display mode（see 4.1.1）.
（2）Press【Increase key】or【Decrease key】to locate the input interface of system parameter password：
The indicator is bright
（3）Press【Shift key】to enter the input mode of system parameter password. The first “－” from the left
becomes a flashing “0”. Press【Increase key】7 times（or press【Decrease key】 3 times）to change
“0” into “7”.
（4）Press【Shift key】，the second “－” becomes a flashing “0”. Press【Increase key】 4 times to change
“0” into “4”.
（5）Press【Shift key】，the third “－” becomes a flashing “0”. Press【Increase key】 6 times to change “0”
into “6”.
（6）Press【Shift key】，the fourth “－” becomes a flashing “0”. Press【Increase key】8 timesto change “0”
into “8”.
（7）Press【Shift key】，the fifth “－” becomes a flashing “0”. Press【Increase key】 3 times to change “0”
into “3”.
（8）Press【Parameter key】to confirm the input. When a correct password is input, the system enters the
system parameter menu. When a wrong17password is input, the system returns to the normal
operation mode.
4.2 Feedback control parameter

The feedback parameter menu can only be entered when the feedback control mode（contained in the
system parameter menu）=1, 2 or 3 and the correct password has been input.
When the feedback control mode=1（basic feedback control mode compatible with DDM-2020 diameter
gauge），the feedback parameter menu has the structure as follows：
┌────────┐
│Input feedback parameter password│
└────────┘
│
【Parameter key】│
┌─────────────┤
│Wrong password │Correct password
↓ ↓
┌──────┐ ┌────────┐ 【Shift key】 ┌────────┐
│Normal operation
mode│ ←──── │ PI coefficient display│ ←───→ │PI coefficient setting│
└──────┘【Parameter key】└────────┘ 【Parameter key】 └────────┘
↑ ↑↓
│ ┌────────┐ 【Shift key】 ┌────────┐
└──────── │Feedback control mode display│←───→ │Feedback control mode setting│
【Parameter key】└────────┘ 【Parameter key】└────────┘
↑↓
When the feedback control mode = 2（advanced feedback control mode for extruder control）or = 3
（advanced feedback control mode for capstan control），the feedback parameter menu has the structure as
follows：：
┌────────┐
│Input feedback parameter password│
└────────┘
│
【Parameter key │
┌─────────────┤
↓ ↓
┌──────┐ ┌───────┐ 【Shift key】 ┌───────┐
│Normal operation
mode│ ←──── │Rated line speed display│←────→ │Rated line speed setting│
└──────┘【Parameter key】 └───────┘ 【Parameter key】 └───────┘
↑ ↑↓
│ ┌───────┐ 【Shift key】 ┌───────┐
├←────────│ Wire diameter display │←────→ │ Wire diameter setting │
│【Parameter key】 └───────┘ 【Parameter key】└───────┘
│ ↑↓
│ ┌───────┐ 【Shift key】 ┌───────-┐
├←────────│Self rectification18display │ ←──-─→ │ Self rectification
ready/operation│
│【Parameter key】 └───────┘ 【Decrease key】└──────-─┘
│ ↑↓
│ ┌───────┐ 【Shift key】 ┌───────┐
├←────────│ Wire travel length display │←────→ │ Wire travel length setting │
【Parameter key】 └───────┘ 【Parameter key】 └───────┘
│ ↑↓
│ ┌───────┐ 【Shift key】 ┌───────┐
├←────────│ Integral coefficient display │←────→ │ Integral coefficient setting │
【Parameter key】 └───────┘ 【Parameter key】 └───────┘
│ ↑↓
│ ┌───────┐ 【Shift key】 ┌───────┐
├←────────│ Proportional coefficient display │←────→ │ Proportional coefficient setting
│ 【Parameter key】 └───────┘ 【Parameter key】 └───────┘
│ ↑↓
│ ┌─────────┐
├←──────── │Rectified nominal diameter display│
【Parameter key】 └─────────┘
│ ↑↓
│ ┌──────────┐
├←──────── │Rated main machine given voltage display│
【Parameter key】 └──────────┘
│ ↑↓
│ ┌────────┐ 【Shift key】┌────────┐
└←──────│Feedback control type display│←─── │Feedback control type setting│
【Parameter key└────────┘ 【Parameter key】└────────┘
↑↓
4.2.1 Setting procedures for feedback control parameter
The general procedures for setting feedback control parameter is as follows：
（1）Input the correct feedback parameter password（see 4.1.9）. Press 【Parameter key】to confirm the
input and enter the feedback parameter menu.
（2）Press【Increase key】or【Decrease key】to locate the corresponding parameter.
（3）Press【Shift key】to enter the parameter setting mode.
（4）Press【Increase key】or【Decrease key】and【Shift key】to change the parameter value.
（5）After the change has been made，press【Parameter key】to save the change and return to the parameter
display mode.
（6）If it is necessary to set another feedback control parameter，press【Increase key】or【Decrease key】
to locate the parameter. Otherwise press【Parameter key】to return to the normal operation mode.
4.2.2 Proportional-integral coefficient

Application：This parameter is used for diameter feedback control（basic mode），for details, see Chapter
5. This paramer appears only when feedback control mode = 1（basic mode）.
19
Numeric area：0000 ～ 9999.
Setting procedures：In order to change the original proportional-integral coefficient 1515（factory default）
into 1810，proceed as follows:
（1）Input the correct feedback parameter password（see 4.1.9）.
（2）Press 【Parameter key】 to confirm the input and enter the feedback parameter menu. When feedback
control mode=1，the first of the displayd parameters is proportional-integral coefficient. The first
digit “P” in the following indication is the mark for proportional-integral coefficient：
（3）Press 【Shift key】to enter the setting mode of proportional-integral coefficient. The second digit on
the display “1” flashes.
（4）Press【Shift key】，the third digit “5” flashes. Press【Increase key】 3 times to change “5” into “8”.
（5）Press【Shift key】，the fourth digit “1” flashes.
（6）Press【Shift key】，the fifth digit “5” flashes. Press【Decrease key】 5 times to change “5” into “0”.
（7）Press 【Parameter key】to save the change and return to the display mode of proportional-integral
coefficient.
4.2.3 Feedback control type

Application：This parameter is used to determine the method to turn on/turn off diameter feedback control.
For details, see Chapter 5.
Numeric area：Auto=automatic，NAnu=manual.
Input procedures：In order to change the original feedback control type “Manual” （factory default）into
“Auto”，proceed as follows:
（1） Input the correct feedback parameter password (see 4.1.9). Press【Parameter key】to enter the
feedback parameter menu.
（2）Press 【Increase key】or【Decrease key】to locate the display mode of feedback control type. For
manual control, the following indication appears：
（3）Press【Shift key】to enter the setting mode of feedback control type. At this time all the 4 letters NAnu
flash simultaneously.
（4）Press【Increase key】to change NAnu into Auto (automatic). For autmatic control, the following
indication appears：
Note：Press 【Increase key】 to change the original NAnu（manual） into Auto（automatic）.

Conversely, press【Decrease key】to change20the original Auto（automatic）into NAnu（manual）.
（5）Press【Parameter key】to save the change and return to the display mode of feedback control type.
4.2.4 Rated line speed

Application：This parameter is the rated line spped of the production line. It is used for diameter feedback
control（advanced mode）.
Numeric area：0000 ～ 2999 m/min.
Display format：Suppose the pre-set rated line speed is1200 m/min, the corresponding indication will be as
follows：
The letter U in the above indication is the mark for rated line speed.
Setting procedures：See 4.2.1.
4.2.5 Conductor diameter

Application：This parameter stands for the wire diameter before extrusion. It is used for diameter feedback
control（advanced mode）.
Display format：Suppose the pre-set conductor diameter is1.5 mm, the corresponding indication will be as
follows：
The letter d in the above indication is the mark for conductor diameter
4.2.6 Self rectification interface

Application：When used for diameter feedback control（advanced mode），this interface determines
automatically the control parameters including integral coefficient, proportional coefficient and conversion
coefficient of line speed and saves nominal diameter and conductor diameter.
Display format：Self rectification interface consists of three modes, i.e., display, ready and operation.
（1）Press 【Increase key】 or 【Decrease key】to locate the self rectification display mode in the feedback
parameter menu：
（2）Press 【Shift key】 in the self rectification display mode to enter the self rectification ready mode
where,
Indicators are bright. The measured diameter flashes on the digital display. All segments of
the LEB display are dark. Once the system enters 21this mode，it will not quit it automatically. It is only
possible to manualy press 【Increase key】 to enter the self rectification operation mode or press
【Decrease key】to return to the self rectification display mode.
（3）Press【Increase key】in the self rectification ready mode to enter the self rectification operation mode
where,
Indicators are bright. The measured diameter flashes on the digital display. The feedback
control output is displayd on the LEB display. After self rectification has been completed, the system will
save automatically the result of rectification and return to the normal operation mode. At the same time, it
will turn on automatically diameter feedback control. Press【Decrease key】during self rectification to stop
the operation and return to the self rectification display mode.
4.2.7 Wire travel length

Application：This parameter is used for diameter feedback control (advanced mode). It stands for the
distance that the wire travels from the extruder to the Gauge. If the Gauge is mounted after the capstan,
wire travel length will include the length of wire wound on the castan wheel.
Numeric area：00.0 ～ 99.9 m.
Display format：Suppose the pre-set wire travel length is12.5 m, the corresponding indication will be as
follows：
“L―” in the above indication is the mark for wire travel length.
4.2.8 Integral coefficient

Application： This parameter is used for diameter feedback control（advanced mode）. It may be
automatically set by the self rectification process or manually set..
Numeric area：00 ～ 99%.
Display format：Suppose the pre-set integral coefficienti is 50%，the corresponding indication will be as
follows：：
“CI―” in the above indication is the mark for integral coefficient

4.2.9 Proportional coefficient

Application： This parameter is used for diameter feedback control（advanced mode）. It may be
22
automatically set by the self rectification process or manually set.
Numeric area：00 ～ 99%.
Display format：Suppose the pre-set proportional coefficient is 30%，the corresponding indication will be
as follows：：
“CP―” in the above indication is the mark for proportional coefficient
4.2.9 Rectified nominal diameter

Application：This read-only parameter is used for diameter feedback control（advanced mode）. It is saved
automaticallyby the self rectification process to mark the size of the rectified product.
Display format：Suppose the rectified product has nominal diameter of 6.5 mm，the corresponding
indication will be as follows：：
“―” in the above indication is the mark for rectified nominal diameter
4.2.10 Rated main machine given voltage

Application： This read-only parameter is used for diameter feedback control（advanced mode）. It is saved
automatically by the self rectification process. The main machine here may refer to the extruder（when
feedback control mode=2）or the capstan（when feedback control mode=3）.
Numeric area：0.0 ～ 9.9 V.
Display format: Suppose the rated main machine given voltage saved by the self rectification process is
5V，the corresponding indication will be as follows：：
“EU―” in the above indication is the mark for rated main machine given voltage.
4.3 System parameters

Only when the correct system parameter password has been input can the system parameter menu be
entered to view or change the parameter values. Some parameters cannot be changed due to the specific
gauge configuration. The structure of the system parameter menu is shown below. In the following chart,
“↑” indicating “press【Increase key】”，“↓” indicating “press【Decrease key】”，the key above a horizontal
line indicating operation from left to right, the key under a horizontal line indicating operation from right to
left, the final “……” indicating return to the first option of the menu（i.e., communication work mode
display）. 23
4.3.1 System parameter setting
The general procedures to set system parameters are as follows：
（1）Input the correct system parameter password (see 4.1.10). Press 【Parameter key】to confirm the input
and enter the system parameter menu.
（2）Press【Increase key】or【Decrease key】to locate the corresponding parameter.
（3） If it is allowed to change the parameter value，press【Shift key】to enter the parameter setting mode.
（4）Press 【Increase key】or【Decrease key】and【Shift key】to change the parameter value.
（5）After the change has been made, press 【Parameter key】 to save the change and return to the
（6）If it is necessary to set another system parameter，press【Increase key】or【Decrease key】to locate
the parameter. Otherwise press【Parameter key】to return to the normal operation mode.
<Note 1> Only when the communication work mode is Con（peripheral equipment interface mode），can the
the external communication (adapter work) mode be available.
┌────────┐
│Input system parameter password│
└────────┘
│
【Parameter key】│
┌───────────── ┤
↓ ↓
┌──────┐ ┌────────┐ 【Shift key】 ┌────────┐
│Normal operation
mode│ ←──── │Comm work mode display │←───→ │Comm work mode setting│
└──────┘【Parameter key】└────────┘ 【Parameter key】└────────┘
↑ ↑↓
│ ┌────────┐ 【Shift key】 ┌────────┐
<Note 1> ├←───────-│External comm mode display │←───→ │External comm mode setting│
│ 【Parameter key】└────────┘ 【Parameter key └────────┘
│ ↑↓
│ ┌────────┐ 【Shift key】 ┌────────┐
├←───────-│ Slave machine address display │←───→│ Slave machine address setting
│
│【Parameter key】└────────┘ 【Parameter key└────────┘
│ ↑↓
│ ┌────────┐ 【Shift key】 ┌────────┐
├←───────-│ Comm baud rate display │←───→│ Comm baud rate setting │
【Parameter key】 └────────┘ 【Parameter key】 └────────┘
│ ↑↓
│ ┌────────┐ 【Shift key】 ┌────────┐
├←───────-│ Data frame format display │←───→│ Data frame format setting │
│ ↑↓
24
│ ┌────────┐ 【Shift key】┌────────┐
<Note2> ├←───────- │Feedback work mode display│←───→ │Feedback work mode setting│
│【Parameter key】└────────┘ 【Parameter key】└────────┘
│ ↑↓
│ ┌────────┐ 【Shift key】 ┌────────┐
├←───────-│Feedback para password display│────→ │Feedback para password setting│
【Parameter key└────────┘ 【Parameter key】└────────┘
│ ↑↓
│ ┌────────┐ 【Shift key】 ┌────────┐
├←───────-│Tolerance setting type display│────→ │Tolerance setting type setting│
│ ↑↓
│ ┌────────┐ 【Shift key】┌────────┐
<Note2> ├←───────- │Lump & neck limit type display│←───→│Lump & neck limit type setting│
│ ↑↓
│ ┌────────┐ 【Shift key】 ┌────────┐
<Note2> ├←───────-│Gauge measuring mode display│←───→ │Gauge measuring mode setting│
│ ↑↓
│ ┌────────┐ 【Shift key】 ┌────────┐
├←───────- │Data refresh rate display│←───→ │Data refresh rate setting│
│【Parameter key】 └────────┘ 【Parameter key】└────────┘
│ ↑↓
│ ┌────────┐ 【Shift key】┌────────┐
<Note2> ├←───────-│Display resolution display│←───→ │Display resolution setting│
│ ↑↓
│ ┌────────┐ 【Shift key】 ┌────────┐
<Note2> ├←───────-│ Data correction display │←───→ │ Data correction setting │
│ 【Parameter key】└────────┘ 【Parameter key】└────────┘
│ ↑↓
│ ┌────────┐ 【Shift key】 ┌────────┐

├←───────- │ Display brightness display │←───→ │Display brightness setting │
│ ↑↓
│ ┌────────┐
├←───────- │Software/hardware version number display│
│【Parameter key】└────────┘ 25
│ ↑↓
│ ┌────────┐
├←───────- │Master board serial-number display│
│【Parameter key】 └────────┘
│ ↑↓
│ ┌────────┐ 【Shift key】┌────────┐
├←───────- │Alarm output config display│←───→ │Alarm output config setting│
│ ↑↓
│ ┌────────┐
└←───────- │ Communication state display │
【Parameter key】 └────────┘
↑↓
<Note 2> Whether or not these parameters can be set depends on the Gauge configuration. Only when the
Gauge has the corresponding function can the parameter value be changed.
4.3.2 Communication parameters

These system parameters include communication work mode, external communication (adapter work)
mode, slave machine address, communication baud rate, communication data frame format（data bit,
number of stop bits and parity check system）and communication state display. They are used to control the
RS-485 serial comm. interface of the Gauge. For functions of the individual parameters, display format and
setting procedures, see Chapter 6: Communication interface.
4.3.3 Feedback work mode

Application：This parameter is used to determine the work mode of diameter feedback control. Its setting
depends on the Gauge configuration. Only when the Gauge has the advanced feedback control work mode
can the parameter be set at 2 or 3.
Numeric area：0=diameter feedback control disabled，1=basic feedback control mode（compatible with
DDM-2020 diameter gauge），2=advanced feedback control mode（used to control the extruder），
3=advanced feedback control mode（used for to control the capstan）.
Note: When the feedback work mode=0,（1）No feedback parameter password is contained in the working
parameter menu，i.e., it is impossible to enter the feedback parameter menu.（2）In the normal operation
mode, the LEB is used to display relative diameter deviation.
Display format：Suppose the pre-set feedback work mode is 1（basic feedback control mode），the
corresponding indication will be as follows：：
The indicator is bright.
“Fdb” in the above indication is the mark for feedback work mode.
Setting procedures: See 4.3.1.
4.3.4 Feedback parameter password

26
Application：This parameter is used to determine the password to enter the feedback control parameter
menu.
Display format： Suppose the pre-set feedback parameter password is 1234（factory default），the
corresponding indication will be as follows：
：
“F” in the above indication is the mark for feedback parameter password.
4.3.5 Diameter tolerance setting type

Application：This parameter is used to determine the diameter tolerance setting type in the working
parameter menu.
Numeric area：1=positive and negative tolerances are equal. They are combined into one single tolerance.
2= positive and negative tolerances are unequal. Positive and negative tolerances need to be set separately.
Display format：Suppose the pre-set tolerance setting is 1（factory default），the corresponding indication
will be as follows：：
“dEF” in the above indication is the mark for tolerance setting.

4.3.6 Setting type of lump & neck detection limit

Application：This parameter is used to determine the setting type of lump & neck detection limit in the
working parameter menu. The setting depends on the Gauge configuration. Only when the Gauge has the
function of lump & neck detection can the parameter be set at 1 or 2.
Numeric area：0=Lump & neck detection disabled. 1= Positive and negative limits are equal. They are
combined int one single lump & neck detection limit. 2= Positive and negative limits are unequal，they need
to be set separately.
Note：When lump & neck detection limit=0, no parameters relating to lump & neck detection will be
contained in the working parameter menu, including lump & neck detection limit（or positive limit and
negative limit）and lump & neck detection time.
Display format：Suppose the pre-set setting type of lump & neck detection limit is 0（factory default），the
：
““LUP”” in the above indication is the mark for setting type of lump & neck detection limit.
27
4.3.7 Gauge measuring mode
Application：This parameter is used to determine the work mode of gauge measurement. The setting
depends on the Gauge configuration. Only when the Gauge has the function of measuring transparent body
can the parameter be set at 11.
Numeric area：10=Normal measuring mode，11=Transparent body measuring mode.
Display format：Suppose the pre-set measuring mode is 10（normal measuring mode），the corresponding
“NN” in the above indication is the mark for gauge measuring mode.
4.3.8 Display data refresh rate

Application：This parameter is used to determine the display data（measured diameter）refresh rate in the
normal operation .
Numeric area：2.5, 3.3, 5 and 10 indication/s
Display format：Suppose the pre-set display data refresh rate is 2.5（factory default），the corresponding
“dr” in the above indication is the mark for display data refresh rate.
Setting procedures：In order to set the display data refresh rate at 10 indication/s，proceed as follows:：
（1）Input the correct system parameter password （see 4.1.10）. Press 【Parameter key】to confirm the
input and enter the system parameter menu.
（2）Press【Increase key】or【Decrease key】to locate the parameter display data refresh rate.
（3）Press【Shift key】to enter the parameter setting mode. The last two digits “2.5” flash.
（4）Press【Increase key】3 times to change “2.5” into“10”.
（5）Press【Parameter key】to save the change and return to the parameter display mode.
4.3.9 Display resolution

Application：This parameter is used to determine the display data （measured diameter） resolution and
unit. The setting depends on the Gauge configuration. Only when the Gauge allows changing the display
resolution and unit can this parameter be set.
Numeric area: 2=0.01 mm, 3=0.001 mm, 4=0.0001 mm, 14=0.0001 in.
Display format：Suppose the pre-set display resolution is 3（factory default），the corresponding indication
will be as follows：：
28
“ddu” in the above indication is the mark for display resolution.
4.3.10 Display data correction

Application：This parameter is used to determine the display data（measured diameter）correction in the
normal operation mode. The setting depends on the Gauge configuration. Only when the Gauge allows the
display value correction can this parameter be set.
Numeric area：－99～0～+99 display readouts. The exact size depends on the display resolution and unit.
For example, if the display resolution is 0.001 mm，the corresponding correction will be －0.099～+0.099
mm.
Note：This parameter is used mainly for correcting the measurement deviation caused by some factors (e.g.,
wet wire or cable and shrinkage by cooling). The correction is accomplished by adding a constant to or
substracting a constant from the measurement. For this reason, this correction is not applicable universally.
It shall be used separately for a specific size.
Display format：Suppose the pre-set display data correction is 0（factory default），the corresponding
“dc” in the above indication is the mark for display data correction.
Setting procedures：In order to change the original display data correction “0” into “－12”，proceed as
follows:：
（1）Input the correct system parameter password （see 4.1.10）. Press 【Parameter key】to confirm the
input and enter the system parameter menu.
（2）Press【Increase key】or【Decrease key】to locate the parameter display data correction.
（3）If the setting is allowed，press 【Shift key】 to enter the parameter setting mode. The third digit “0”
flashes.
（4）Press【Decrease key】to change “0” into “－”.（if the original digit is “－”，press 【Increase key】
to change “－” into “0”）.
（5）Press【Shift key】, the fourth digit “0” flashes. Press【Increase key】once to change “0” into “1”.
（6）Press【Shift key】，the fifth digit “0” flashes. Press【Increase key】twice to change “0” into “2”.
（7）Press【Parameter key】to save the change and return to the parameter display mode.
4.3.11 Digital display brightness

Application：This parameter is used to set digital display brightness.
Numeric area：0=50%，1=67%，2=75% and 3=100%.
Display format：Suppose the pre-set digital display brightness is 2（factory default），the corresponding
29
dbr” in the above indication is the mark for digital display brightness.
4.3.12 Software/hardware version number of the Gauge

Application：This read-only parameter stands for the version number of the hardware and programme of
the Gauge main board.
Numeric area：1.01～7.31，where the number before the decimal point is the the version number of
hardware while that after the decimal point is the the version number of software
Display format：Suppose the current version number of hardware is 1 and that of the software is 3，the
corresponding indication will be as follows：：
“u ” in the above indication is the mark for software/hardware version number of the Gauge.
4.3.13 Main board serial number of the Gauge

Application：This read-only parameter stands for the main board serial number of the Gauge.
Numeric area：The serial number is classified into 6 groups, i.e., A, B, C, D, E and F. Each group has
numeric value of 0001～9999.
Display format：Suppose the current main board serial number of the Gauge is 0.0001 of group A，the
：
4.3.14 Alarm output configuration

Application：This parameter is used to determine the action conditions of the alarm output contact of the
DSP-3A Monitor，For details, see Chapter 5.
Display format：Suppose the pre-set alarm output configuration is 77（factory default），the corresponding
“AL” in the above indication is the mark for alarm output configuration.
5 Feedback control and out-of-tolerance alarm

30
Aided by DSP-3A Monitor, DDM-3020 Diameter Gauge can easily perform the function of diameter
feedback control，i.e., to control the screw speed of the extruder or the capstan speed according to the
deviation between the measured diameter and set nominal so that the actual diameter is as near to the
nominal as possible.
5.1 DSP-3A Monitor

5.1.1 Main technical data
Power supply: 100～240V AC, 50～60Hz
Power consumption: < 5W
Operating temperature: 0～45
Atmospheric humidity: ≤ 90%（free of condense water）
Display format: 5-digit LED digital display
Comm interface RS-485
Max commun distance: 1000 m
Control input: －10V～＋10V，input impedance 50 kΩ
Control output: －10V～＋10V，max 10 mA
Alarm output: Relay contact，max load 3A, 250VAC
Dimensions: 48 mm×96 mm×112 mm
5.1.2 Panel and display
Figure 5-1 Panel of DSP-3A Monitor
（1）5-digit LED digital display is used to display the measured diameter or fault message.
In normal operation, the measured diameter is displayd, which is equal to that displayd on the panel of
the Gauge
When the Gauge is faulty, the fault message is displayd, which is equal to that displayd on the panel of
the Gauge. For details, see 3.6.
When the communication with the Gauge is abnormal, the following is displayed:
31
（2）10-segment LEB (light-emitting bar) display is used to display the diameter feedback control
output.
When all the 10 segments are dark, the diameter feedback control is turned off.
When the central two segments are bright, the diameter feedback control is turned on but the output is
very small（near 0）.
Beginning from the midpoint, when the segment(s) to the left is(are) bright, the diameter feedback
control output is negative; when the segment(s) to the right is(are) bright, the diameter feedback control
output is positive. The more number of segments are bright, the greater the output will be. When feedback
control output is saturated, the 5 segments on the left flash (indicating saturation in the negative direction)
or the 5 segments on the right flash (indicating saturation in the positive direction).
All the 10 segments flash simultaneously indicates abnormal operation of the Gauge or feedback control
parameter error.
（3）AL indicator (red)：A bright indicator indicates that the alarm relay acted and thus the alarm contacts
are closed. A dark indicator indicates that the alarm relay did not act and thus the alarm contacts are open.
（4）CM indicator (green)：A bright indicator indicates that the external control switch is open, enabling
feedback control. A dark indicator indicates that the external control switch is closed, disabling feedback
control.
5.1.3 Description of the terminals

K1 K2 10V VIN GIN GOT VOT
9 10 11 12 13 14 15 16
1 2 3 4 5 6 7 8
L N AL1 AL2 SG SA SB SR
Figure 5-2 Terminal arrangement（back view）
32
Termminal No. Name Description
──────────────────────────────────────
1 L Phase wire of power supply（220VAC）
2 N Neutral of power supply（220VAC）
3 AL1 Alarm contact output（the internal realy contacts are closed at alarm）
4 AL2 Alarm contact output （AL1 is connected to AL2 at alarm）
5 SG RS-485 comm interface：Signal ground
6 SA RS-485 comm interface：Bus A
7 SB RS-485 comm interface：Bus B
8 SR RS-485 comm interface：Terminal to connect the resistance for termination
impedance match
9 ─ Not used
10 K1 Signal to disable diameter feedback control（feedback control is disabled
when K1 is connected to K2,）
11 K2 Signal to disable diameter feedback control
12 10V －10V, 5mA voltage output（used for the basic mode of feedback control）
13 VIN Given voltage input（signal end：－10V～+10V）
14 GIN Given voltage input（ground end：0V）
15 GOT Control voltage output（ground end：0V）
16 VOT Control voltage output（signal end：－10V～+10V）
──────────────────────────────────────
5.1.4 Mounting and wiring
DSP-3A Monitor employs a 48 mm×96 mm standard instrument chassis. In order to mount the monitor, a
44 mm（h）×92 mm（w）rectangular hole shall be cut on the control cabinet panel. Then the monitor shall
be inserted into the hole from the front and fixed on the cabinet panel with the enclosed screws.
.
Figure 5-3 Mounting hole and monitor mounting
33
Figure 5-4 Wiring diagram 1：Only diameter display
Figure 5-5 Wiring diagram 2：Diameter display and alarm
34
Figure 5-6 Wiring diagram 3: Basic mode of feedback control
Wiring discription：
（1）Connect pin ① and ② at the communication interface of the Diameter Gauge to the terminal 7 and 6
of DSP-3A Monitor respectively using a twisted pair having copper conductor size not samller than 0.5
mm2 and characteristic impedance of 120 Ω.
（2）The signal ground（pin ── terminal 5）may be the shield of the twisted pair or another wire. The
signal ground may be omitted with short bus length (up to 50m) and weak field interference.
（3）If DSP-3A Monitor is the last peripheral equipment on the RS-485 communication bus, terminal 7
shall be connected to terminal 8（connection of the resistance for termination impedance match）.
（4）The external alarm may be alarm lamp, buzzer or electric bell with operating voltage of 220VAC.
（5）Terminal 10 and 11 of the Monitor are used to turn on/off diameter feedback control in the automatic
mode（see 4.2.3）: When they are disconnected, feedback control is enabled. When they are connected,
feedback control is disabled. Generally, they are connected to the normally closed auxiliary contacts of the
contactor in the main circuit of the motor under control or to the feedback control switch on the control
cabinet panel.
（6）Terminal 12, 13 and 14 of the Monitor shall be connected to a potentiometer for adjusting the
feedback control output amplitude. DSP-3A Monitor has a dedicated potentiometer in its accessories,
which may be connected to these terminals.
（7）Terminal 15 and 16 of the Monitor are for feedback control output. They shall be connected in series
to the high end of the motor speed regulating potentiometer（i.e., the end where the max given voltage is
present）. The procedures are as follows： Locate the high end of the speed regulating potentiometer. Cut
off the wire connected to this end to produce two cut ends A and B. If the feedback signal is to control
the extruder, end A shall be connected to terminal 15 and end B to terminal16. If the feedback signal is
to control the capstan, end A shall be connected to terminal 16 and end B to terminal 15.
5.2 Basic mode of diameter feedback control

The basic mode of feedback control has functions compatible with the previous generation diameter gauge.
It may be substituted for the combination of DDM-2020（diameter gauge）and BFD-2（feedback control
buffer）. In order to use the basic mode of feedback control，please wire the system according to Figure 5-6.
The portions in the diagram represented by dotted lines are optional. They may be selected based on the
practical conditions.
The related parameters must be set before diameter feedback control is used. These include feedback work
mode, feedback control work mode, proportional-integral coefficient and nominal diameter.
5.2.1 Feedback work mode

This parameter is contained in the system parameter menu. It shall be set at 1 when the basic mode of
feedback control is to be used.
5.2.2 Feedback control work mode

This parameter is contained in the feedback parameter menu. It shall be set at manual mode or auto mode
as necessary.
（1）Manual mode: The advantages are simple wiring（the control contacts on Terminal 10 and 11 of the
Monitor are not needed）and flexible control（diameter feedback control can be turned on/off at will by
pressing 【Increase key】 /
【Decrease key】 on the Gauge panel）. The disadvantage is that diameter feedback
control must be turned on/off by pressing【Increase35key】/【Decrease key】on the Gauge panel by the
operator.
Be sure to turn off diameter feedback control when the line is stopped.
（2）Auto mode: The advantages are that manual intervention is not needed during normal operation and
that turn-on/off of diameter feedback is controlled by the control contacts connected to Terminal 10 and 11
of the Monitor (When these contacts are closed, diameter feedback control will be turned off. When these
contacts are open, diameter feedback control will be turned-on after 20s lag time). The disadvantage is
relative complicated wiring (Terminal 10 and 11 of the Monitor must be connected to appropriate external
control contacts. These contacts must be open when the line is started and closed when the line is stopped).
Besides, a switch may be connected in parallel to these contacts to manually stop diameter feedback control
if necessary.
（3）Warning：Diameter feedback control must be turned off when the line is stopped.
This is because the diameter feedback control system employs an improved PI adjuster containing in its
interior an integral ring. If feedback control is not turned off when the line is stopped, the internal integrator
will be saturated, resulting in unsteady system and large oscillation when the line is started again
5.2.3 Proportional-integral coefficient

This parameter is contained in the feedback parameter men. It consists of Proportional coefficient and
Integral coefficient as shown below:
（1）The integral coefficient is the first two digits of the the parameter. Effective numeric area: 01～30.
The integral coefficient determines the speed at which to eliminate the diameter deviation during the
feedback control process. The greater the coefficient is, the faster the diameter deviation will be eliminated.
But too fast elimination of the diameter deviation will result in unsteady system. Conversely, the smaller
the coefficient is, the slower the diameter deviation will be eliminated and the steadier the system will be.
For this reason, the value of the integral coefficient shall be selected considering both speed and stability.
Generally, the integral coefficient can be determined by the following procedures：
Suppose the line speed during normal operation V（m/min）= V/60（m/s）and the wire travel length from the
extruder head to the Gauge is L（m），then the time it takes for the wire to travel from the extruder head to
the Gauge T = 60×L÷V（s）.
Therefore,
Integral coefficient = 30÷（2×T+1）= 30÷（120×L÷V +1）
This is the theoretic value of the integral coefficient. In practical application, this value must be modified
appropriately based on the commissioning.
【Example 1】The line speed V=600m/min. The diameter gauge is mounted after the capstan. The length of
the cooling trough is 6m. The length of the wire wound on the capstan wheel is 8m. Then the wire travel
length L=6+8=14m. 36
Therefore,
Integral coefficient = 30÷（120×L÷V +1）= 30÷（120×14÷600 +1）=7.9
The integral coefficient after rounding=8.
【Example 2】 The line speed V=100 m/min. The diameter gauge is mounted before the cooling trough
and 0.5m from the extruder head. Then the wire travel length L=0.5m.
Therefore,
Integral coefficient = 30÷（120×L÷V +1）= 30÷（120×0.5÷100 +1）=18.75
The integral coefficient after rounding=19
（2）The Proportional coefficient is the last two digits of the the parameter. Effective numeric area: 01～
25.
The proportional coefficient determines the size of the proportional in the feedback control output. Its
value can be calculated using the following equition：
Proportional coefficient = 25×（D2 — d2）÷ D2
Where,
D=Insulation diameter，d=Conductor diameter before extrusion. In practical application, this value
must be modified appropriately based on the commissioning.
【Example 3】Suppose the conductor diameter d=1.5 mm and the insulation diameter D=2.2 mm，then
Proportional coefficient = 25×（2.22 — 1.52）÷ 2.22 = 13.4
The proportional coefficient after rounding=13
5.2.4 Nominal diameter

This parameter is contained in the working parameter menu. It shall be set according to the requirement for
the diameter of the wire or cable. In some cases, proper compensation shall be made（e.g., if the Gauge is
mounted before the cooling trough, the set nominal diameter shall be increased somewhat due to shrinkage
during the cooling process）.
5.2.5 Commissioning
After the Gauge and Monitor have been mounted and the wiring has been completed, commission the
feedback control system with the following procedures：
（1）Set the related parameters according to 5.2.1—5.2.4. Be sure to set the feedback control work mode at
manual mode during the commissioning.
（2） Take a sample wire having diameter slightly larger than the nominal（For example, if the nominal is
set at 2mm，take a sample wire having diameter of 2.1～2.4mm）. Start the line and make it run at low
speed. Mount the above sample wire on the guide pulley of the Gauge. Press【Increase key】to turn on
feedback control.
（3）Observe the line operation. If the feedback control system controls the extruder, the screw shall turn at
a lower speed. If the feedback control system controls the capstan, the capstan wheel shall turn at a higher
speed. If the observed speed variation is contrary to the above mentioned, exchange the two wires
connected to Terminal 15 and 16 of the Monitor.
（4）Press 【Decrease key】to turn off feedback control. Start the line and make it run at normal speed until
the wire diameter becomes stable and slightly larger37than the set nominal. Press【Increase key】to turn on
diameter feedback control. Observe the variation of wire diameter.
（A）If the wire diameter approaches the set nomial fast and steadily without obvious fluctuation, the
commissioing is finished.
（B）If the wire diameter approaches the set nomial slowly taking a long time, increase the proportional
coefficient.
（C）If the wire diameter fluctuates sharply without reaching a steady value, decrease the proportional
coefficient.
Adjust the proportional coefficient with the a.m. method to achieve a good feedback control effect.（If good
effect can not be achieved by adjusting the proportional coefficient, adjust appropriately the the integral
coefficient）
（5）After commissioning, set the feedback control work mode at auto mode if necessary.
Waring：The function of diameter feedback control shall be properly appreciated.

（1）Feedback control can only provide fine adjustment of the wire diameter. It is necessary to roughly
adjust the wire diameter so that it is near the nominal (error ≤10%) and remains stable there before
turning on diameter feedback control.（2）The function of diameter feedback is to control the mean wire
diameter to the vicinity of the set nominal. It cannot eliminate fast fluctuation of the wire diameter, which
can only be guaranteed by the stability of the equipment of the line.
6 Communication interface
The standard configuration of DDM-3020 Diameter Gauge includes a 2-wire half-duplex RS-485
communication interface. It is used for connection of the peripheral equipment produced by Shanghai
On-Line, such as the Monitor, large screen remote display, analogue output unit and communication
adapter. It may be also connected to an industry computer, PLC and touch panel.
6.1 Work mode

The communication interface can be configured to operate in one of the following two work modes：（1）
The peripheral equipment interface mode, in which the Gauge acts as the master communication equipment
and the communication protocol of Shanghai On-Line is employed. This mode is used for connection of the
peripheral equipment produced by Shanghai On-Line.（2）Modbus RTU protocol mode, in which the Gauge
acts as a slave communication equipment and Modbus RTU communication protocol of Modicon Inc is
employed. This mode is used for connection of the industry computer, PLC and touch panel compatible
with the protocol.
6.1.1 Setting of the communication interface work mode

The communication interface work mode shall be set by the parameter communication work mode
contained in the system parameter menu. The factory default is the peripheral equipment interface mode. In
order to change the setting, proceed as follows:
（1）Press【Parameter key】in the normal operation mode to enter the working parameter display mode.
（2）Press 【Increase key】 or 【Decrease key】to locate the input interface of the system parameter
password, where:
38
（3）Input the system parameter password “74683”. The exact procedures are as follows:
Press 【Shift key】，the first “―” from the left on the digital display becomes a flashing “0”. Press
【Increase key】 or 【Decrease key】 to change “0” into “7”. Press 【Shift key】again，the first digit
indicates “7” while the second “―” becomes a flashing“0”. Press【Increase key】or【Decrease key】to
change “0” into “4”. Change the remaining three “―”’s into the required number in the same way and
press【Parameter key】.
（4）The system enters the system parameter display mode, where the first displayd parameter is the
communication work mode：
The first two digits indicating “C―” on the above indication are the mark for the communication work
mode. The last three digits indicate the corresponding parameter value. “Con” stands for the peripheral
equipment interface mode while “rtu” stands for the Modbus RTU protocol mode.
（5）In order to change the communication work mode，press 【Shift key】to enter the system parameter
setting mode. At this time the last three digits flash. Press【Increase key】or【Decrease key】to change the
value：Press【Increase key】 to change the original “Con” into “rtu”. Conversely, press【Decrease key】
to change the original “rtu” into “Con”.
（6）After the change has been made，press 【Parameter key】 to save the change and return to the system
（7） If it is not necessary to change another parameter，press【Parameter key】once more to return to the
normal operation mode.
（8） If it is necessary to change another parameter, press【Increase key】or【Decrease key】in the system
parameter display mode to locate the parameter to be changed. Then press 【Shift key】to enter the system
parameter setting mode to make the change.
6.1.2 Setting of slave machine address

In the Modbus RTU protocol mode, the Gauge as a slave machine（or son machine as opposed to the master
machine）in the RS-485 communication networks must have an exclusive address. The factory default of
the slave machine address is 01. In order to change the setting, proceed as follows：
（1）Enter the system parameter display mode（see 6.1.1(1)―(3)）.
（2）Press【Increase key】or【Decrease key】to locate the display interface of the parameter slave machine
address（Suppose the original slave machine address=01，i.e., factory default）：
The first two digits in the above indication “CA” is the mark for slave machine address. The last two digits
“01” are the corresponding parameter value.
（3）Press 【Shift key】to enter the system parameter setting mode. At this time, the third digit “0” flashes.
Press【Increase key】or【Decrease key】to change its value.
（4）After the change has been made, press【Shift key】，the fourh digit “1” flashes. Press【Increase key】
or【Decrease key】to change its value. 39
（5） After the change has been made，press 【Parameter key】to save the change and return to the system
parameter display mode to locate the parameter to be changed. Then press【Shift key】to enter the system
6.1.3 Setting of communication baud rate

In the Modbus RTU protocol mode，the factory default of the communication baud rate of the Gauge is
19200 bps. In order to change the setting, proceed as follows:：
（2）Press【Increase key】or【Decrease key】to locate the display interface of the parameter communication
baud rate（Suppose the original communication baud rate=19200 bps = 19.2 kbps，i.e., factory default）：
The first two digits in the above indication “Cb” is the mark for communication baud rate. The last three
digits “19.2” are the corresponding parameter value.
（3）Press 【Shift key】to enter the system parameter setting mode. At this time, the last three digits “19.2”
flash simultaneously. Press【Increase key】or【Decrease key】to change its value.
（4）After the change has been made，press【Parameter key】to save the change and return to the system
（5） If it is not necessary to change another parameter，press【Parameter key】 once more to return to the
parameter display mode to locate the parameter to be changed. Then press 【Shift key】to enter the system
6.1.4 Setting of communication data bit and parity check system

In the Modbus RTU protocol mode，the factory default of the Gauge is：8 data bits, 1 stop bit and even
parity check. In order to change the setting，proceed as follows:：
（2）Press 【Increase key】or【Decrease key】 to locate the display interface of the parameter
communication data bit and parity check system.（Suppose the oriniginal setting is 8 data bits,1 stop bit and
even parity check = E81，i.e., factory default）：
The first two digits in the above indication “CC” is the mark for communication data bit and parity check
systeme. The last three digits “E81” are the corresponding parameter value.
（3）Press 【Shift key】to enter the system parameter40setting mode. At this time, the last three digits “E81”
flash simultaneously. Press 【Increase key】or【Decrease key】to change the value. The Modbus RTU
protocol allows three options as follows: E81（8 data bits, 1 stop bit and even parity check）, o81（8 data bits,
1 stop bit and odd parity check）and N82（8 data bits, 2 stop bits and no parity check）.
（4）After the change has been made，press【Parameter key】to save the change and return to the system
parameter display mode to locate the parameter to be changed. Then press【Shift key】to enter the system
6.2 Peripheral equipment interface mode

When the communication interface operates in the peripheral equipment interface mode，the Gauge as the
master equipment in the RS-485 networks sends a read and write request every 0.5s to the slave equipment
connected to the Gauge. The slave equipment, after having received the request, performs related
operations and sends response data to DDM-3020 Diameter Gauge. A set of DDM-3020 Diameter Gauge
can be connected to maximum 5 sets of peripheral equipment. The connections between the Gauge and sets
of peripheral equipment are shown below:
Figure 5 Communication connections between the Gauge and peripheral equipment
Note：
（1）End A and B of each equipment shall be connected using a twisted pair having copper conductor size
not samller than 0.5 mm2 and characteristic impedance of 120 Ω.
（2）The signal ground（wire G）may be the shield of the twisted pair or another wire. The signal ground
may be omitted with short bus length (up to 50m) and weak field interference.
（3）The last peripheral equipment on the bus (peripheral equipment 5 in the above Figure) must be
connected to a resistance for termination impedance match. Each peripheral equipment has in its interior
this resistance. The only thing to do is to connect it to the related terminal according to the operating
directions. Except for the last peripheral equipment, no other peripheral equipment on the bus shall be
connected to the resistance for termination impedance match.
If normal communication is not possible between the Gauge and peripheral equipment when they are
properly connected, check if the system parameter communication work mode is set at “Con”. For details,
see 6.1.1. 41
6.2.1 Commonly used peripheral equipment
The peripheral equipment produced or being developed by Shanghai Online includes the following:
（1） DSP-3A Monitor, for remote display of the measured diameter and implementation of diameter
feedback control.
（2）DSP-3S/DSP-3D large remote display（single /double side display）, in which large LED digitron is
used to display the measured diameter for ease of monitoring
（3）COM-3S serial communication adapter.
6.2.2 Serial communication adapter

6.2.2.1 Application
COM-3S is the serial communication adapter produced specifically for DDM-3 Diameter Gauge by
Shanghai Online. It is used mainly for the following cases:
（1）If both connection of the peripheral equipment of Shanghai Online（e.g. connection of DSP-3A
Monitor for feedback control） and communication with the upper computer（e.g. connection to the central
control computer for remote data acquisition and processing）are necessary, set the work mode of the
Gauge communication interface at ”Con”（peripheral equipment interface mode） to connect DSP-3A
Monitor and COM-3S serial communication adapter. Communication with the master equipment such as
induatry computer and PLC can be achieved by this adapter.
（2）One RS-485 communication bus allows connecting only one set of DDM-3020 Diameter Gauge.
Because one RS-485 communication bus allows connecting only one set of the equipment with polarity
bias circuit and only one of the bus ends can be connected to the resistance for termination impedance
match while each set of DDM-3020 is provided with polarity bias circuit and resistance for termination
impedance match inside its communication interface. COM-3S Adapter can be used to connect multiple
sets of DDM-3020 Diameter Gauge to one RS-485 communication bus because it is not provided with
polarity bias circuit and with the adapter it is possible to determine the connection of the resistance for
termination impedance match from the outside.
6.2.2.2 Work mode

The work mode of the serial communication adapter is determined by the external communication (adapter
work) mode contained in the system parameter menu of DDM-3020 Diameter Gauge. Such parameters in
the menu as slave machine address, baude rate, data frame format（i.e., data bit, number of stop bit and
parity check system）are employed, because at this time the work mode of the Gauge communication
interface is set at “Con”（peripheral equipment interfacemode）and thus the above parameters are not
employed.
The display format of the system parameter external communication (adapter work) mode is shown below
（Suppose the setting is “rtu” mode）：
The first two digits in the above indication “C—” is the mark for external communication (adapter work)
mode. This parameter is set in a similar way as that for the communication work mode in 6.1.1. But it has
no Con（peripheral equipment interface）mode.
42
6.3 Modbus RTU mode
6.3.1 General description of the protocol
The data communication by DDM-3020 Diameter Gauge employs the Modbus serial link protocol. It is a
master/slave protocol. The diameter gauge as a slave equipment can only accept the request and command
by the master equipment（e.g., industry computer, PLC etc）and make response. At one time, only one
master point (also called master machine) and one or more slave points (also called slave machine，max
number 247 ) are connected to the same serial bus. Modbus communication is always initiated by the
master point. A slave point will not send out data until it receives a request from the master point. A slave
point will never communicate with another slave point. The master point will initiate only one Modbus
transaction at one time.
6.3.2 Connection of physical layer

The physical layer for data communication of DDM-3020 Diameter Gauge is connected through RS-485
interface. If the master equipment employs a RS-232C communication interface，a RS232C/RS485 adapter
shall be used to convert it into a RS-485 interface. Then the master equipment can be connected to the
Gauge. A twisted pair with characteristic impedance of 120 Ω shall be used to connect the communication
interface （4-pin aircraft plug）on the bottom of the Gauge to the communication interface of the master
equipment.
The signal on the individual pins of the communication interface（4-pin aircraft plug）of DDM-3020
Diameter Gauge is as follow:
1：RS-485 signal B ------------- Connected to RS-485 bus B
2：RS-485 signal A ------------- Connected to RS-485 bus A
3：Signal ground GND ---------Connected to signal ground（Note1）
4：Power output（15V, 50mA）------ Not connected（Note 2）
Note 1: For short communication distance（≤ 50m），the signal ground may be not connected.
Note 2: The communication interface of the Gauge can provide a DC power supply of 15V 50mA to the
outside to be used as a small capacity power supply for isolater-converter etc. When this kind of power
supply is used, short circuit and overload shall be avoided to protect the power module in the Gauge.
Note 3: As DDM-3020 Diameter Gauge is provided with a 120Ω resistance for termination impedance
match and polarity bias circuit inside the communication interface, it must be used as a termination of the
RS-485 bus. The other end of the bus shall be also connected to a 120Ω resistance for termination
impedance match.
6.3.3 Serial interface configuration

When the RS-485 serial communication interface of DDM-3020 Diameter Gauge is configured as the
Modbus RTU mode，the default communication parameters will be：
Baud rate 19200 bps
Data bit 8 bit
Stop bit 1 bit
Parity check system Even parity check
The default communication parameters can be changed if necessary. Baud rate can be set at 1200, 2400,
4800, 9600, 19200, 38400 and 57600 bps. Data bit and parity check system can be set at Even parity check ,
8 data bit and 1 stop bit, Odd parity check, 8 data bit and 1 stop bit and No parity check , 8 data bit and 2
stop bits. For the setting procedures, see 6.1. 43
6.3.4 Modbus RTU protocol
During a communication, the master equipment on the RS-485 bus sends out a command. When this
communication command reaches the slave equipment, the equipment with the corresponding address code
will accept the command and perform the related task if there is no error. Then the slave equipment will
send back the results of the performance to the sender. The information sent back includes address code,
the function code to perform the operation and data and cyclic redundancy check (CRC) code after the
operation has been performed. No information will be sent if there is any error.
6.3.4.1 Information frame format

START Start structure Lag（≥ the time to transmit 3.5 bytes）
ADDR Address code 1 byte（8 bits）
CS Function code 1 byte（8 bits）
DATA Data field N bytes（N×8 bits）
CRC CRC code 2 bytes（16 bits）
END End structure Lag（≥ the time to transmit 3.5 bytes）
6.3.4.2 Start structure and end structure

The start/end structures indicate the start/end of a data frame. They are produced by the sender of the data
frame by idling the RS-485 bus for at least the time to transmit 3.5 bytes. The data bytes in a data frame
must be sent continuously. A frame with an interval ≥ the time to transmit 1.5 bytes will be regarded as
invalid and abandoned.
That the bus is found to have idled for the time to transmit 3.5 bytes at the receiving-end means a new data
frame starts. That the bus is found to have idled for the time to transmit 3.5 bytes during the process of
receiving a data frame means the data frame has been received. If the bus is found to have idled for the time
longer than the time to transmit 1.5 bytes but shorter than the time to transmit 3.5 bytes during the process
of receiving a data frame, the data frame will be regarded as invalid and abandoned and the receiver will
wait for the next start structure.
6.3.4.3 Address code

The address code is the first data byte in the information frame transmitted during each communication.
The standard Modbus RTU protocol supports the slave machine address codes of 1-247. The address codes
allowed by DDM-3020 Diameter Gauge are 01-99. The address code can be set on the Gauge panel. For
the setting procedures, see 6.1.
6.3.4.4 Function code

The function code is the second data byte in the information frame transmitted during each
communication. The Modbus RTU communication protocol defines the function codes as 1～127
(0x01～0x7F). The following function codes are employed by DDM-2030 Diameter Gauge:
03 Read keep register Read one or more keep registers with contiuous addresses.
04 Read input register Read one or more input registers with contiuous addresses
06 Write single register Write a 16-bit data into a keep register
44
The function code 04 is used to read the content of the input register, a read-only register, e.g., diameter
measurement, out-of-tolence alarm etc.
The function codes 03 and 06 are used to read and write the keep register, e.g., set nominal, tolerance
etc.
6.3.4.5 Data field

（1）The data field of the request frame of function 03（read keep register）contains 4 bytes：
Byte 3： Register start address read（high byte）
Byte 4： Register start address read（low byte）
Byte 5： Register quantity read（high byte）
Byte 6： Register quantity read（low byte）
The data field of the response frame sent-back after the request has been properly performed contains 2N+1
bytes（N is the register quantity read）：
Byte 3： Number of bytes of subsequent data（=2N）
Byte 4～3+2N： Value of the N registers read（high byte followed by low byte）
（2） The data field of the request frame and response frame of function 04（read input register）has the
same structure as that of function 03.
（3）The data field of the request frame of function 06（write single register）contains 4 bytes：
Byte 3： Register address（high byte）
Byte 4： Register address（low byte）
Byte 5： Register value to be wrriten（high byte）
Byte 6： Register value to be wrriten（low byte）
The response frame sent-back after the request has been properly performed has the same data field as that
of the request frame.
6.3.4.6 Abnormal response frame

When the slave machine operates abnormally during the process of performing the request, an abnormal
response frame will be sent back which has the following structure：
START Start structure Lag（≥ the time to transmit 3.5 bytes）
ADDR Address code 1 byte，slave machine address
ES Error code 1 byte, =The original function code+128（decimal）or +80h（hexadecimal）
EC Abnormal code 1 byte
CRC CRC code 2 bytes（16 bits）
END End structure Lag（≥ the time to transmit 3.5 bytes）
The error code= The original function code +128（decimal） or +80h（hexadecimal）. For example: For
function 03 request，the error code=83h (hexadecimal). The abnormal code is defined as 01=Non-supported
function code，02=Register address error，03= Data error，04=Performance failure.
6.3.4.7 CRC check

The Modbus RTU communication protocol employs cyclic redundancy check (CRC) to control the
transmmission error. The sender calculates the CRC code of address code, function code and all the data in
data field and sends it out with the data（The CRC code consists of 2 bytes. The low byte will be sent first）.
The receiver after having received the data frame will re-calculate the CRC code and compare the result
with the received CRC code. The data frame will be regarded as valid if the two CRC codes are equal.
Otherwise the data frame will be regarded as invalid.45
Method of calculating CRC code：At first a 16-bit register shall be pre-installed with all 1. Then the
subsequent operations shall be performed between the register value and the contintious 8-bit bytes in the
message. Note that only the 8 data bits participate in the operation to generate CRC code. The start bit, stop
bit and parity check bit will not participate in the calculations. During the process to generate CRC code, an
XOP operation is performed between each 8-bit character and the register value. Then the result shall be
shifted to the least significant bit (LSB) for 1 bit while the maximum significant bit (MSB) shall be filled
with 0. Then the least significant bit (LSB) shall be taken and checked. If LSB=1，an XOR operation shall
be performed between the register value and a fixed pre-set value（binary 1010 0000 0000 0001 or
hexadecimal A001h）. If LSB=0，no XOR operation shall be performed. This process shall be repeated until
8 shifts (for one byte) have been completed. After the last shift（the 8th shift）and related operations have
been completed, an XOR operation shall be performed between the next 8-bit byte and the current register
value and this process shall be repeated 8 times as above mentioned. The final register value obtained after
all the bytes in the message have been used for operation will be the CRC code. In summary, the process to
generate CRC code is as follows：
（1）Insall a 16-bit register with hexadecimal FFFFh (all1) and call it CRC Register.
（2） Perform an XOR operation between the first 8-bit byte in the message and the low byte of the 16-bit
CRC register. The result shall be placed in the CRC register.
（3）Shift the CRC register to the right (to LSB) for one bit. Fill the maximum significant bit (MSB) with 0.
Then taken and check the least significant bit (LSB).
（4）If LSB=0, repeat procedure（3）to start another shift.
If LSB=1, perform an XOR operation between the register value and a constant A001h (1010 0000
0000 0001).
（5）Repeat procedures 3 and 4 until 8 shifts have been completed. At this time the operation on this byte
has been finished.
（6）Repeat procedures 2 ~ 5 on the next byte in the message. Continue this operation until all the bytes in
the message have been processed.
（7）The final content of CRC register is CRC code.
6.4 Examples of information frame

Suppose the Gauge（slave machine）address is 01 and all data are expressed in the hexadecimal system.
（1）Read measured diameter
Request frame： 01 04 00 0B 00 01 40 08
Response frame： 01 04 02 XX YY RR RR
Of which, XX and YY are the high byte and low byte of the measured diameter，RR RR are 2-byte
CRC codes.
Result：Measured diameter = 256×(XX) + (YY)，unit: micrometer（µm）.
（2）Read nominal diameter
Request frame： 01 03 00 65 00 01 94 15
Response frame： 01 03 02 XX YY RR RR
Of which, XX and YY are the high byte and low byte of the nominal diameter，RR RR are 2-byte
CRC codes.
Result：Nominal diameter = 256×(XX) + (YY)，unit: micrometer（µm）.
（3）Write nominal diameter
Requirement：Write nominal diameter = 4.5 mm = 4500 µm（hexadecimal = 1194h）into the Gauge.
Request frame： 01 06 00 65 11 4694 94 2A
Response frame： 01 06 00 65 11 94 94 2A
6.5 Register address assignment

The following table lists the register address, register name and data format for fuction codes 04,03 and 06.
Note：（1）Register addresses are expresssed in decimal numbers beginning from 0000.（2）For certain
configuration software（e.g. Kingview）and PLC，the register addresses begin from 0001. When these
software are used, the given register address shall be added by 1. For example, the register address of the
measured diameter shall be 0011+1=0012.（3） Read/write at the reserved register address （e.g., 0004,
0100 etc）will result in the abnormality Register address error（abnormal code=02）.（4） If the register
value in the request frame to write into a register （function code 06） exceeds the numeric area allowed by
the Gauge, an abnormal response Data error will be made（abnormal code=03）.
6.5.1 Registers（read-only）for function code 04

──────────────────────────────────────
Address Name Data format and area
──────────────────────────────────────
0000 （Reserved）
0001 Gauge size code 0x0014=DDM-3020 Diameter Gauge
0002 Soft-/hardware version number 0x0102=Ver 1.02
0003 Gauge configuration （Note1）
0004-0010 （Reserved）
0011 Measured diameter 0～19999，unit: µm
0012 Gauge mode （Note 2）
0013 Location of wire centre 0～65535，0=Lower end，65535=Upper end
0014 Alarm（out-of-tolerance, lump & neck）（Note 3）
0015 Lump & neck counter 0～9999
0016 Feedback control output -4095～+4095，bit 15 is the sign bit
0017 Feedback control mode （Note 4）
──────────────────────────────────────
6.5.2 Registers for function codes 03 and 06（read/write）

──────────────────────────────────────
Address Name Data format and area
──────────────────────────────────────
0100 （Reserved）
0101 Nominal diameter 0～19999，unit: µm
0102 Positive tolerance 0～9999，unit: µm
0103 Negative tolerance 0～9999，unit: µm
0104 Lump & neck positive limit 0～9990，unit: µm
0105 Lump & neck negative limit 0～9990，unit: µm
0106 Lump & neck detection time47resolution 1～9, unit: ms
0120 Feedback control work mode （Note 5）
0121 Feedback PID proportional coefficient 0～99，meaning 00～99%
0122 Feedback PID integral coefficient 0～99，meaning 00～99%
0123 Wire diameter 0～19990，unit: µm
0124 Rated line speed 0～2999，unit: m/min
0125 Wire travel length 0～999，unit: ×0.1m
0126 Rectified nominal diameter 0～19990，unit: µm
0127 Rated master machine given voltage 0～99，unit: ×0.1V
0128 Basic mode PID coefficient 0～9999
0140 Work mode 10=Normal，11=Transparent body
0141 Display refresh rate （Note 6）
0142 Display resolution and unit: （Note 7）
0143 Display value correction -99～+99
0144 Tolerance setting type （Note 8）
0145 Lump & neck detection setting type （Note 9）
0146 External alarm contact setting （Note 10）
──────────────────────────────────────
Note 1: Indicating the functions of the Gauge. The binary bits have the meaning as follows：
Bit 0： 0=Absence of transparent body work mode，1=Presence of transparent body work mode.
Bit 1： 0=Absence of lump & neck detection， 1=Presence of lump & neck detection.
Bit 2： 0=Display resolution setting disabled， 1=Display resolution setting enabled.
Bit 3： 0=Display value correction disabled， 1=Display value correction enabled，
Bit 4： 0=Absence of feedback control， 1=Presence of feedback control
Bit 15-5 Reserved（=0）.
Note 2: Indicating the current work mode of the Gauge. The binary bits have the meaning as follows：
Bit 0=1：Absence of tested object Bit 1：（Reserved）
Bit 2=1：Tested object too high Bit 3=1：Tested object too low
Bit 4=1：Multiple wires Bit 5=1：Lens badly polluted
Bit 6=1：Inteference by ambient stray light Bit 7=1：Absence of measuring light
Bit 8=1：Gauge locked（over 31 inputs of wrong password）.
Bit 9=1：Software fault Bit 10=1：Hardware fault
Bit 11=1：Internal system fault Bit 12=1：Panel commuincation fault
Bit 15-13：Reserved
Note 3: Indicating the current alarm mode of the Gauge. The binary bits have the meaning as follows：
Bit 0=1：Alarm for too thick tested wire Bit 1=1：Alarm for too thin tested wire
Bit 2=1：Lump & neck defects detected during the current work cycle（100ms）
Bit 7-3：Reserved
Bit 8=1：Too thick alarm（hold） Bit 9=1：Too thin alarm（hold）
Bit 10=1：Lump & neck alarm（hold） Bit 11-14：Reserved
Bit 15： External alarm contacts output（0=open，1=closed）.
48
Note 4 Indicating the operating mode of the feedback control system. The binary bits have the meaning
as follows：
Bit 1-0: Feedback operating mode（00=turn-off，01=self rectification，10=frozen，11=turn-on）
Bit 2=1：Positive output saturated Bit 3=1：Negative output saturated
Bit 6=0: Manual work mode， Bit 6=1: Auto work mode
Bit 7=1：Feedback control parameter error
Note 5: Feedback control work mode：

0=Absence of feedback control
1=Traditional control work mode（compatible with the previous generation DDM-2020）.
2=Advanced control work mode（to control the extruder）.
3=Advanced control work mode（to control the capstan）.
Note 6: Display data refresh rate：

0=2.5 indication/s, 1=3.3 indication/s, 2=5 indication/s, 3=10 indication/s
Note 7: Display resolution and unit:

0=0.01mm, 1=0.001mm, 2=0.0001 mm, 3=0.0001in
Note 8: Tolerance setting type：

1= Positive and negative tolerances are equal, hence only one tolerance needs to be set.
2= Positive and negative tolerances are unequal, hence they need to be set sepaerately.
Note 9: Lump & neck detection setting type：

0=Absence of lump & neck detection
1= Positive and negative tolerances of lump & neck detection are equal, hence only one tolerance needs
to be set.
2= Positive and negative tolerances of lump & neck detection are unequal, hence they need to be set
seperately.
Note 10: Used to set the behavour of the external alarm contacts. The binary bits have the meaning as
follows：
Bit 0：Diameter out-of-positive-tolerance alarm
Bit 1：Diameter out-of-negative-tolerance alarm
Bit 2：Lump & neck alarm（hold, manual re-set needed）
Bit 3：Reserved
Bit 4：Abnormal operation by the Gauge
Bit 5：Abnormal feedback control（output saturation and feedback control parameter error）
Bit 6：Absence of tested object
Bit 7：Diameter out-of-tolerance alarm（hold, manual re-set needed）
Bit 15-8： Reserved
When a binary bit=1 and the abnormalury represented by it is detected by the Gauge, the external
output alarm contacts will be closed. When a binary bit=0, the abnormalury represented by it will be
ignored by the Gauge.
49

DDM-3020 Diameter Gauge

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Newlead trade Suzhou Co.

DDM-3020 Diameter Gauge for

No2401,Jingchang Tech park, Suzhou city,JiangSu province,China

1.1 Service conditions and packing size

1.2 Principal technical data

1.3 Complete set of machine 1

───────Diameter measuring head

─────────── Set screws of the measuring head

──────────── Support column inner tube

─────────── Set screws of the support column inner tube

──────────── Support column outer tube

─────────── Set screws of the support column outer tube

Figure 1-1 Mounting of the diameter measuring head and support

2.2 Mounting procedures

3 Panel display and operation

3.2 Gauge operating mode

3.3 Status indicator

the negative tolerance (i.e., the wire is too thin).

the positive tolerance (i.e., the wire is too thick).

control parameter display/setting in the parameter setting mode.

feedback control parameter error in the abnormal alarm mode.

3.4 Function of the individual keys

3.5 Normal operation

Press【Lump & neck key】

Press 【Lump & neck key】

3.5.2 LEB (light-emitting bar) display

3.6 Abnormal alarm

（1） Fault message：

Fault cause：Lens of the Gauge is badly polluted by dust etc.

（2） Fault message：

（3） Fault message：

（4） Fault message：

（5） Fault message：

（6） Fault message：

（7） Fault message：

（8） Fault message：

Fault cause：Fault of software

Fault cause：Fault of hardware or circuit

Fault cause：The Gauge is locked for over 30 inputs of wrong password.

Fault cause：Wrong setting of the feedback control parameter

Tolerance setting type=1 Tolerance setting type=2

┌──────┐ 【Parameter key】 ┌──────┐ 【Shift key】 ┌──────┐

│ ┌──────┐ 【Shift key】 ┌──────┐

4.1.1 Nominal diameter

Indicators are bright

4.1.2 Diameter tolerance

Indicators are bright.

4.1.3 Diameter positive tolerance

Indicators are bright

4.1.4 Diameter negative tolerance

Numeric area：0.000 ～ 9.999 mm.

Indicators are bright

4.1.5 Lump & neck detection limit

Indicators are bright

4.1.6 Lump & neck positive limit

Indicators are bright

4.1.7 Lump & neck negative limit

Indicators are bright

4.1.8 Lump & neck detection time