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]
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and ask for Sales.
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©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.