DFE TRUETENSION TA1 User manual

INSTRUCTION MANUAL
TRUETENSIONTM Model TA1
Tension Amplifier
DOC 801-2568 R2

Dover Flexo Electronics
307 Pickering Road
Rochester, NH 03867- 4630
U.S.A.
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©2020 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 liable 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
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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 TA1 True Tension Amplifier. If you have any questions
concerning the operation of your device or the information 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 specified, the
operating safety of this unit or of connected equipment cannot be guaranteed.
!WARNING: The isolated output is designed to prevent ground loops and noise. It is not
intended or approved for safety isolation of hazardous voltages. Do not install unit where the
isolated circuit and chassis ground are more than 40 Vpk differential.

Table of Contents
1.0 Overview / Device Description
1.1 General Description ...................................... 1
1.2 Specifications................................................ 1
1.3 Features ........................................................ 1
2.0 Installation
2.1 Dimensions .................................................. 2
2.2 Mounting the Unit ......................................... 2
2.3 Standard Electrical Connections .................. 3
2.4 Optional Electrical Connections ................... 5
3.0 Operation
3.1 Hardware Identification ................................ 6
3.2 Calibration .................................................... 6
4.0 Operation
4.1 Troubleshooting ........................................... 8
APPENDIX A:
Transducer Connections .......................................... 9
Terms and Conditions ...................................... 11
Figures:
1 Dimensions ................................................... 2
2 Removing From DIN Rail .............................. 2
3 Convert to Screw Mount .............................. 3
4 Power Input Connections.............................. 3
5 Tension Output Electrical Connections ........ 3
6 Transducer Electrical Connections............... 4
7 Cal A/B Electical Connections ..................... 5
8 Remote Cal and Zero Connections ............. 5
9 Locations of Zero/Cal Buttons and
Status LED ................................................... 6
10 Web Path ...................................................... 7
11 Electrical Connections for Transducer
Models C, and F............................................ 9
12 Electrical Connections for Transducer
Models NW, RFA, TR, LT and VNW ............ 10

1OVERVIEW / DEVICE DESCRIPTION
1.1 General Description
The TA1 TrueTension™Amplifier with Quik-Cal™push-button zero and calibration is a
compact, versatile single-channel tension transducer interface. It can be used with DFE
tension transducers to monitor tension in any zone on web or filament processing
machinery.
The TA1 amplifier is powered by 24 VDC and supplies an excitation signal to connected
tension transducers installed in a machine's web path. The amplifier boosts the millivolt-
level tension-signal input from a DFE tension transducer (or transducer pair) to output a
proportional 0-10 VDC (isolated) and 4-20 mA signal to a PLC, drive or display meter.
The standard configuration for the TA1 is a 3.9"H x 4.41"D x 0.89"W enclosure with
connector terminals that mounts in a vertical orientation onto a DIN rail. The unit can
also be screw mounted. The TA1 is CE marked.
1.2 Specifications
Power Input: Voltage: 24 VDC +/- 10%, Current: 0.1 ADC typical, internal fusing PTC
resettable
Temperature Range: 32EF to 122EF (0EC to 50EC)
Tension Amplifier Accuracy: +/- 1/2% drift at ambient maximum
Tension Outputs: Output 1: 0-10 VDC isolated from 24 VDC input GND
Output 2: 4-20 mA isolated from 24 VDC input GND
Calibration Range: Up to 50:1
Processor: 32 Bit
Weight: 0.25 lbs (114g)
Resolutions: ADC - 16,777,216(24 Bit), DAC - 4,096 (12 Bit)
1.3 Features
•Quik-Cal™ push-button zero and calibration eliminates pot adjustments to make
calibrating simple and fast.
•10% or 25% Calibration Ratio. Full output when tension is at 10 or 4 times the
calibration weight.
•DIN Rail Clip. To be used with 35 mm DIN rail. Can be converted to screw mount.
•2 Tension Outputs. Outputs a 0-10 VDC and 4-20 mA proportionate signal to a
PLC, drive, or display meter.
•Dual Calibration. Allows two calibration settings. Dual calibration example
applications:
a. One set of transducers operating in a wide tension range. Dual calibration and
dual meter scale is used to enhance the resolution of indicated tension.
b. One set of transducers that may be subject to two different wrap angles or web
paths. In this case a dual meter scale may, or may not, be required.
•Status LED. Green LED flashes to verify ZERO and CALIBRATION, and indicates
presence of power and proper circuit operation. If power is on and no faults are
detected, LED will be on solid. LED will flash momentarily to indicate acceptance of
a ZERO or CALIBRATION button push.
1

FIGURE 1 - Dimensions
2INSTALLATION
2.1. Dimensions
2.2 Mounting the Unit
The unit is DIN rail mountable, compatible with DIN35mm rail. Snap on to mount. To
remove from the DIN rail, use a screwdriver and release the clamp as shown below.
FIGURE 2 - Removing from DIN Rail
2

FIGURE 3 - Convert to Screw Mount
2.2 Mounting the Unit continued...
The unit can also be screw mounted. By adjusting the top and bottom clips to the outer
positions.
2.3 Standard Electrical Connections
1. Power Input
Power should be sourced to the TA1 on Pins 1 (GND) and 2 (+24 VDC)
FIGURE 4 - Power Input Connections
2. Tension Output
The tension output signal is provided in two options:
• 0-10 V is available on Pins 5 (Return) and 7 (0-10 V)
• 4-20 mA is available on Pins 5 (Return) and 8 (4-20 mA)
FIGURE 5 - Tension Output Electrical Connections
3

2.3 Standard Electrical Connections continued....
3. Transducers / Load Cells
FIGURE 6 - Transducer Electrical Connections
(See Appendix A for full Electrical Connections)
Below is label on left side of unit:
4

2.4 Optional Electrical Connections
1. CAL A/B (Dual Calibration)
Dual Calibration allows two calibration settings. To operate the TA1 amplifier in the
Calibration A configuration the connection to PIN 6 must be left open.
To operate the TA1 in the Calibration B configuration the 24V must be applied to PIN
6. A switch can be used as shown below. If a PLC or alternate source for 24V is
utilized be sure that the source has a common Ground with PIN 1. If you do not need
dual calibration no connection needs to be made to PIN 6.
FIGURE 7 - Cal A/B Electrical Connections
(See Appendix A for full Electrical Connections)
2. Remote Calibrate and Zero
FIGURE 8 - Remote Calibration and Zero Connections
(See Appendix A for full Electrical Connections)
5

FIGURE 9 - Location of Zero, Cal Buttons and Status LED
3OPERATION
3.1 Hardware Identification
3.2 Calibration
A calibration process must be performed before your amplifier is ready to indicate
tension. Select an appropriate calibration weight. The weight determines the value of
web tension that will produce full output of the TA1. For example: A 15 lb weight will
result in full output at 150 lbs tension if the 10% calibration is performed. If a calibration
of 25% is used, a calibration weight of 15 lbs will result in a full output at 60 lbs tension).
The first step of any calibration is Zeroing out the amplifier.
1. ZERO: Ensure nothing is hanging on or pressing on the transducer roll (including 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 rapid flash 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. CALIBRATION: During the calibration the transducer(s) should be loaded. Fasten
one end of the rope in the machine and thread the other end around the transducer
roll in exactly the same path the web will take. Be sure the rope does not pass
around any driven rolls, drag bars, or anything else that can affect tension. Ideally
the rope should hit an idler roll immediately before and after the tension sensing roll.
It does not have to pass over any other rollers once these three are strung. Attach
the weight to the free end of the rope as shown in Figure 10. The weight should not
touch anything. Wait for the weight to stop swinging.
6

FIGURE 10 - Web Path
3.2 Calibration continued....
To calibrate at 10%:
Push and Hold the Cal Button (About 1 Second) until confirmation 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 10 Seconds) until you see two sets of confirmation
blinks. Then release the button. The output will read 25% of full scale after calibration. If
no blink, inadequate Cal weight used.
Remove the weight and observe the output. It should read 0 VDC or 4 mA with nothing
touching the tension sensing roller.
Calibration weight percentage is 25% of full scale.
Your TA1 is now calibrated and ready for operation.
7

4TROUBLESHOOTING
4.1 Troubleshooting
The TA1 is running normally when the status LED is showing a solid green. If it is not
staying on and is blinking, refer to the list of blink sequences indicating errors. Perform
the action required to clear them. Contact Technical Support if you need additional
help.
Normal operation: Solid Green
• 1 Blink = No Calibration Performed
Action Required: Perform Calibration.TA1 is not factory calibrated. A calibration
must be performed at the customers site. Each calibration is specific to the
installation configuration. If using CAL B – a separate calibration must be performed.
• 2 Blinks = Outside Cal Range
Once calibrated the TA1 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.
• 3 Blinks
Wiring Error:
- Will alert until the load cells are wired correctly.
-Action Required: Check wiring and retry. Refer to page 4. 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 intermittenly 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.
• 4 Blinks = 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.
• 5 Blinks = DAC/ADC Internal Failure
Action Required: Contact DFE for replacement.
8

FIGURE 11 - Electrical Connections for Models C & F Transducers
APPENDIX A: Transducer Connections
9

APPENDIX A: Transducer Connections continued...
Figure 12 - Electrical Connections for NW, RFA, TR, LT & VNW Transducers
10

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11

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