DFE TA500-ECAT User manual

[phone] 5 Year Warranty www.dfe.com
THE TENSION CONTROL SPECIALISTS
Model TA500-ECAT
Tension Amplier
QUICK START GUIDE
EtherCAT® is a registered trademark
and patented technology, licensed by
Beckhoff Automation GmbH, Germany.

Dover Flexo Electronics
307 Pickering Road
Rochester, NH 03867-4630
U.S.A.
FOR ASSISTANCE:
TECHNICAL SERVICE - Installations, Start-Up, Troubleshooting, Repairs, Field
Service or Returns. Call [phone] and ask for
Technical Support or email us at: [email protected]
CUSTOMER SERVICE - Replacement Parts, Individual Products, Questions about
Orders, Manuals. Call [phone] and ask for Customer
Service or email us at: [email protected]
SALES - Product Information, System Application Questions or Placing Orders,
Please e-mail us at: [email protected] or call [phone]
and ask for Sales.
Telephone: [phone] Fax: [phone]
E-mail: [email protected] Internet: www.dfe.com
©2023 Dover Flexo Electronics, Inc. All rights reserved. Dover Flexo Electronics
has made reasonable effort to ensure accuracy of this document. However, NO
WARRANTY, whether expressed or implied, is given regarding the completeness or
correctness of information in this document. Dover Flexo Electronics shall not be lia-
ble for damages of any kind arising from the use or misuse of this document. Dover
Flexo Electronics reserves the right to make changes, additions, and deletions to this
document without notice and without obligation.

SAFETY
This label indicates: “Read the Manual”
Make sure you read and understand all instructions and safety precautions listed
in this manual before installing or operating your TA500-ECAT Tension Amplier.
If you have any questions concerning the operation of your device or the informa-
tion in this manual, please contact us.
Email: [email protected]
Telephone: [phone]
• Observe all warning labels.
• Never remove warning labels.
WARNING: If this equipment is not connected or operated in the manner
specied, the operating safety of this unit or of connected equipment cannot
be guaranteed.
WARNING: When working with TA500-ECAT follow the instructions below and
read the manual carefully to protect yourself from injury and the TA500-ECAT
from damage.
WARNING: Do not open the housing.

WARNING: Protect the TA500-ECAT from shocks and vibrations.
WARNING: The TA500-ECAT may become warm during normal use. Always
allow adequate ventilation around the TA500-ECAT and use care
when handling.
WARNING: Do not operate the TA500-ECAT adjacent to heat sources and do
not expose it to unnecessary thermal radiation. Ensure an ambient
temperature as specied in the technical data.
DOCUMENT CONVENTIONS
NOTES - Highlight important concepts, decisions you must make, or
the implications of those decisions.
CAUTIONS - Tell you when equipment may be damaged if the procedure is
not followed properly.
WARNINGS - Tell you when people may be injured, or equipment may be
damaged if the procedure is not followed properly.
Numbered lists indicate tasks that should be carried out in sequence:
1. First do this
2. Then do this
Bulleted lists are used for:
• Tasks that can be carried out in any order
• Itemized information

1
GENERAL DESCRIPTION
Dimensions:
The TA500-ECAT is a Tension Amplier with Quik-Cal™ push-button zero and
calibration. In addition, this tension amplier provides a tension transducer
interface with an Ethernet connection. It can be used with any DFE tension trans-
ducer (load cell) to monitor tension in any zone on web or lament processing
machinery. This device accepts commands and allows tension monitoring using
the EtherCAT® protocol.

2HARDWARE IDENTIFICATION
Status LEDS
Amplier Status Information is useful for determining the condition of the
tension amplier and its network and module operational state. Three bi-colored
LEDs located on the front of the TA500-ECAT provided this information.
Amplier Status LED
The Amplier Status LED is a bi-color red/green LED. The state of the LED
depends on the state of the amplier module. Wiring faults and/or overload con-
ditions of transducer loadcells are indicated and can be decoded using the table
below. During normal operation, the status LED is showing a solid steady green.
The amplier status information is also available of the data interface.

Off Power off.
Steady Green Normal operation.
Green, 1 Flash Device not calibrated.
Green, 2 Flash Over Range Condition: Once calibrated the TA500-ECAT will
indicate an over range or under range condition by setting the
error code to ‘Outside Cal Range’. The error is active once -20%
or 120% tension is exceeded - Action Required: To clear this error
the tension must be brought back into range, or a new calibration
will need to be performed to do so.
Red, 3 Flash Wiring Error: Will alert until the load cells are wired correctly -
Action Required: Check wiring and retry. Check for loose wires
at the terminal blocks, check for shorts, and be sure the load
cells are connected. If the transducers need trouble shooting
– contact tech support for assistance. Overload Condition (LT
Transducer): Will intermittently alert if overload is reached -
Action Required: Check that the tension range does not exceed
the transducer load rating. Reduce wrap angle to reduce effective
net force exerted on load cell.
Red, 4 Flash Excitation Failure or Wiring Error - Action Required: Check for
shorts in the transducer / load cell wiring. If the transducers need
trouble shooting – contact tech support for assistance.
STATUS LED STATE DEFINITION
3
HARDWARE IDENTIFICATION

Off Init.
Blinking Pre-operational.
Single Flash Safe-operational.
Flashes Initialization or bootstrap.
On Operational.
RUN LED ETHERCAT® STATE
4HARDWARE IDENTIFICATION
RUN LED
The RUN LED is a bi-color red/green LED. The state of the LED depends on the
state of the network adapter module.

5
HARDWARE IDENTIFICATION
Off No error.
Blinking Invalid conguration.
Single Flash Unsolicited state change.
Double Flash Application watchdog timeout.
Flickering Booting error.
On PDI watchdog timeout.
ERR LED
The ERR LED is a bi-color red/green LED. The state of the LED depends on status
of the CIP (Common Industrial Protocol) connection.
ERR LED ETHERCAT® STATE

6INITIAL UNBOXING AND MOUNTING
The unit is DIN rail mountable, compatible with 35mm DIN rails. To install snap
on to DIN rail. To remove from the DIN rail, use a screwdriver and release the
clamp at bottom of the unit as shown below.

7
INITIAL UNBOXING AND MOUNTING
TA500 devices shall be mounted vertically. Zero-stacking is allowed when
operating at or below the maximum temperature specication (104°F / 40°C).
Care should be taken to observe the ambient temperature and minimize exposure
to adjacent sources of thermal radiation. Operating in excess temperatures may
cause performance issues.

STANDARD ELECTRICAL CONNECTIONS
8
POWER INPUT
• Pin 1: Power GND
• Pin 2: +24 VDC
• Pin 3: No connect
• Pin 4: Shield
(Tied to Functional Earth Ground Connection)
SIGNAL OUTPUT 0-10V, 4-20 mA
• Pin 5: Signal GND
• Pin 6: No connect
• Pin 7: Output 1 - V OUT 0-10V
• Pin 8: Output 2 - I OUT 4-20 mA
CAUTION – Use care when wiring as incorrect wiring can cause damage
to the unit.

9
STANDARD ELECTRICAL CONNECTIONS
TRANSDUCER LOAD CELL CONNECTIONS
• Pin 9: - SIGNAL
• Pin 10: - EXCITATION
• Pin 11: + EXCITATION
• Pin 12: Shield (Tied to Functional Earth Ground Connection)
• Pin 13: + SIGNAL
• Pin 14: + EXCITATION
• Pin 15: - EXCITATION
• Pin 16: Shield (Tied to Functional Earth Ground Connection)

10 STANDARD ELECTRICAL CONNECTIONS
TA500-ECAT meets the European Union's Low Voltage Directive and
EMC Directive only when installation is done correctly. To meet the EMC Directive,
a proper transducer installation, including shielded cables must be used.

11
A functional earth connection is provided to make contact with the DIN rail.
Functional earth is a current path of low impedance between current circuits and
earth, which is used to increase the interference immunity.
Connect the mounting rail to functional earth potential. Please note that
the impedance of the connecting cable has to be kept low.
FUNCTIONAL EARTH CONNECTIONS

12 ETHERNET PORT 1 & 2 CONNECTIONS
Ethernet Interface RJ45 connectors Details:
The Ethernet interface capability is 10/100Mbit, full or half duplex operation.
Ethernet Cord set is recommended to be CAT-5 cable, shielded (STP). The pinout
connection is standard and is provided below for reference.

13
CALIBRATION
A calibration process must be performed before your amplier is ready to indicate
tension. The following should already be completed prior to calibration.
• Attach power connection to the unit
• Attached the transducer (load cell) connections
• Attached the analog signal output connection if used
• Attached the ethernet data connection if used
• Power the unit
• Status indication of the unit should indicate no status errors, however it may
indicate that the device is not calibrated or is in an overloaded condition if the
device was previously calibrated – see status LEDs
The TA500-ECAT can be used as an amplier with or without an
EtherCAT® connection established.
There are two methods to calibrate the TA500-ECAT
• Traditional Push Button Calibration
• Calibration through the EtherCAT® interface
Both of the above methods require zeroing the amplier with no weight or
load on the transducer load cells. Once zeroed, a calibration weight or load can be
applied equal to 10% or 25% of the full range desired.

14 TRADITIONAL PUSH BUTTON CALIBRATION
This calibration process is easy and produces a unitless proportional 2-point
calibration. An appropriate calibration weight will need to be selected. The weight
determines the value of web tension that will be produced at full output of the
TA500-ECAT. The TA500-ECAT allows calibration to be performed with 10% or
25% of the full range desired.
For example: A 15 lb weight will result in a scaled range of 0-150 lbs of tension if
a 10% calibration is performed. Analog output values of tension are always unit-
less and proportional to tension.
1. ZERO: Ensure nothing is hanging on or pressing on the transducer roll (includ-
ing the calibration rope). Press the ZERO pushbutton on the unit front panel for at
least 1 second. The unit will automatically adjust and store the tension zero value
one second after the button is pressed. The unit will rapidly ash the green status
LED to indicate the zero has been stored. Release the button. The Output1 will
read 0 VDC and Output2 will read 4 mA.
2. CALIBRATE: Hang weight as indicated below. Wait for weight to stop swinging.
W
Same Wrap
Angle as Web Transducer Roll
Idler Roll
Weight
T
RIGHT WAY
WRONG WAY
W
T

15
TRADITIONAL PUSH BUTTON CALIBRATION
WEB PAGE INTERFACE CALIBRATION
See Manual for instructions.
CALIBRATION USING THE ETHERCAT® INTERFACE
ESI le can be found on the product web page,
see Manual for instructions.
To calibrate at 10%: Push and Hold the Cal Button (About 1 Second) until conr-
mation blinks, then release the button. The output will read 10% of full scale after
calibration.
To calibrate at 25%: Push and Hold Cal Button (About 5 Seconds) until you see
two sets of conrmation blinks. Then release the button. The output will read
25% of full scale after calibration. (If no conrmation blink occurs, inadequate
calibration weight may have been used)
After calibration: Remove the weight and observe the output. It should read
0 VDC or 4 mA with nothing touching the tension sensing roller.
Once calibrated, tension data is also available over the network connec-
tion, however it should be noted that the calibration performed can be considered
unitless and rangeless unless the value in the CalRange Register and the CalUnits
register at calibration was valid. In this case the TENSION_P may be the most
desirable tension register. See Accessing Tension Data for more information.

Engineered • Supported
Manufactured In The USA
©2023 Dover Flexo Electronics, Inc.
All Rights Reserved
0410 Doc 801-2585
307 Pickering Rd, Rochester, NH 03867 USA
Phone: [phone] • FAX: [phone] • Email: [email protected] • Website: www.dfe.com
THE TENSION CONTROL SPECIALISTS
DOVER FLEXO ELECTRONICS, INC.
To view or download the TA500-ECAT Instruction Manual go to:
https://dfe.com/products/tension-ampliers/
ta500-ecat-tension-load-cell-amplier-signal-conditioner/
Please call Technical Support if you need assistance.
E-mail: [email protected]
EtherCAT® is a registered trademark and patented technology,
licensed by Beckhoff Automation GmbH, Germany.