Magpowr Maxcess DLCA NET-ECAT User manual

DLCA NET-ECAT
User Manual
EN
MI 850A365 1
MAGPOWR TENSION CONTROL

CONTENTS
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MI 850A365 1
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1.0 INTRODUCTION 5
1.1 About these operating instructions ................................................................. 5
1.2 Product overview............................................................................................. 6
1.2.1 Additional tools ................................................................................... 7
1.3 Model number ................................................................................................ 8
1.4 Serial number.................................................................................................. 8
2.0 SAFETY 9
2.1 Instructions for use......................................................................................... 9
3.0 INSTALLATION 12
3.1 Mechanical .................................................................................................... 12
3.2 Electrical ....................................................................................................... 13
3.3 Wiring diagrams............................................................................................ 13
3.4 Analog output and digital input connections ................................................ 17
4.0 OPERATION 21
4.1 Zeroing tension display................................................................................. 23
4.2 Reset parameters to defaults ........................................................................ 23
4.3 Tension over-range ...................................................................................... 23
4.4 Password protection ..................................................................................... 23
4.5 LED indicators ............................................................................................... 24
4.6 Which sensor inputs used ............................................................................. 25
4.7 Load cell excitation voltage........................................................................... 25
4.8 Programming mode ...................................................................................... 26
5.0 CALIBRATE TENSION USING MENU 27
5.1 Precision calibration...................................................................................... 27
5.2 Weightless calibration ................................................................................... 30
6.0 ENTERING MAXIMUM TENSION 33
7.0 PARAMETERS 35
7.1 Filtering ........................................................................................................ 35
7.2 Alarm setup and operation ........................................................................... 36
7.2.1 Alarm operation with hysteresis ........................................................ 37
7.3 Hardware configuration parameters.............................................................. 38
7.4 Miscellaneous parameters............................................................................. 40
7.5 Analog output scaling ................................................................................... 41
7.6 Calibrate the analog outputs (not normally changed).................................... 42
7.7 Password ...................................................................................................... 44
8.0 COMMUNICATIONS INTERFACE 45
8.1 Cyclic parameters ......................................................................................... 45
8.2 Actual tension data ....................................................................................... 46
8.3 Security state ................................................................................................ 47
8.4 Status............................................................................................................ 47

CONTENTS
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8.5 Alarm............................................................................................................ 48
8.6 Command interface....................................................................................... 48
8.6.1 Command request............................................................................. 49
8.6.2 Command response .......................................................................... 53
8.7 Function information .................................................................................... 54
8.7.1 Security ............................................................................................. 54
8.7.2 Reset non-volatile (NV) memory to defaults ...................................... 55
8.7.3 Zeroing the tension ........................................................................... 55
8.7.4 Calibrate the analog outputs (not normally used) .............................. 55
8.8 Get or set parameters ................................................................................... 57
8.8.1 Get a parameter ................................................................................ 57
8.8.2 Set a parameter ................................................................................. 57
8.9 Analog outputs scaling ................................................................................. 57
9.0 CALIBRATE TENSION THROUGH THE FIELDBUS PROCEDURE 59
9.1 Precision calibration procedure..................................................................... 59
9.2 Weightless calibrate tension procedure......................................................... 62
9.3 Calibration errors returned ........................................................................... 65
10.0 WEB SERVER 66
10.1 Tension calibration from web pages ......................................................... 67
10.1.1 Precision calibration from web pages ................................................ 67
10.1.2 Weightless calibration from web pages ............................................. 67
10.2 Zero tension from web pages.................................................................... 68
12.0 SERVICE 71
APPENDIX A: DLCA NET-ECAT FLOWCHART 72

CONTENTS
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FIGURES
Figure 1. DLCA NET dimensions.......................................................................................... 12
Figure 2. DLCA NET1 wiring using MAGPOWR load cells ..................................................... 14
Figure 3. DLCA NET2 wiring using MAGPOWR load cells ..................................................... 15
Figure 4. Non-MAGPOWR load cell wiring ........................................................................... 16
Figure 5. DLCA NET-ECAT common wiring ......................................................................... 18
Figure 6. DLCA NET1-ECAT one tension zone analog outputs wiring.................................. 19
Figure 7. DLCA NET2-ECAT two tension zone analog outputs wiring.................................. 19
Figure 8. MAGPOWR and non-MAGPOWR load cell wiring ................................................... 20
Figure 9. LED indicators ...................................................................................................... 24
Figure 10. Apply calibration tension ................................................................................... 29
Figure 11. Weightless calibration angles ............................................................................. 31
Figure 12. Apply calibration tension ................................................................................... 60
Figure 13. Weightless Calibration Angles ............................................................................ 64
Figure 14. Sample web server page..................................................................................... 66
TABLES
Table 1. Load cell diagnostic errors .................................................................................... 22
Table 2. Calibration errors .................................................................................................. 32
Table 3. Calibration errors .................................................................................................. 65

INTRODUCTION
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1.0 Introduction
1.1 About these operating instructions
All of the information herein is the exclusive proprietary
property of Maxcess International, and is disclosed with the
understanding that it will be retained in confidence and will
neither be duplicated nor copied in whole or in part nor be
used for any purpose other than for which disclosed.
Copyright 2018, all rights reserved.
Periodically there will be updates to this manual. The latest
version is available on our website or by calling your regional
office listed on the back page of this publication.
These digital load cell amplifiers must not be installed or used
in a machine or system which does not comply with the
machinery directive 2006/42/EC.
These digital load cell amplifiers were designed and
manufactured to be installed as Partly Completed Machinery
into a machine or partly completed machine.
The instructions must be read and used by all persons who
have the responsibility of installing and maintaining this digital
load cell amplifier.
These instructions must be retained and incorporated in the
technical documentation for the machine or partly completed
machinery into which the digital load cell amplifier is installed.
CE marking
This digital load cell amplifier is marked with the CE sign
according to the EMC directive 2004/108/EC.
Conventions used in this manual
All dimensions and specifications are shown in the format mm
[inches] unless specified otherwise.
Language
These are the original instructions, written in English.

INTRODUCTION
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1.2 Product overview
The DLCA NET-ECAT is a DIN rail-mounted digital load cell
amplifier that provides excitation voltage for load cells,
measures the returned force signal, and then converts this
signal into a digital value that represents tension and analog
output signals.
The digital tension value is available in the fieldbus data on
EtherCAT. Configuration and calibration is available through
the fieldbus interface.
There are two models of the DLCA NET-ECAT, one senses
tension in one tension zone and the other senses tension in
two tension zones. Each one has two sensor inputs. Each
sensor input can have up to two load cells attached.
DLCA NET1-ECAT reads load cells from one tension zone
Channel 1 reads a single load cell or a tension-sensing
roller.
Channels 1 and 2 read two separate load cells,
respectively, in a single tension zone. This would typically
be the left and right load cells.
Tension values are sent from the load cells for the left and
right inputs. Two additional values are sent on the
communications interface; they are the sum and difference
of the left and right inputs (channels 1 and 2).
DLCA NET2-ECAT reads load cells from two tension zones
Channel 1 reads load cell(s) in one tension zone —one or
two load cells or a single tension-sensing roller per zone.
Channel 2 reads load cell(s) in a second tension zone —
one or two load cells or a single tension-sensing roller per
zone.
Tension values are sent from the load cells for each
tension zone. The sum and difference values sent on the
communications interface are set to zero.

INTRODUCTION
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Product overview continued
The DLCA NET-ECAT has three alarm outputs. Two of the
alarm outputs can be configured to sense tension limits on
either of the two sensor inputs, or the total tension for the one
tension zone amplifier. The third alarm output is on when
there are no load cell wiring problems detected or power
faults. This is essentially a 'power good' indicator.
The DLCA NET-ECAT has up to four analog outputs available
that are proportional to maximum tension.
For the one tension zone amplifier, three of the outputs
are both 0 to 10 V and 0 to 20 mA. The fourth output is
a 0 to 1mA meter output.
For the two tension zone amplifier, two of the outputs
are both 0 to 10 V and 0 to 20 mA, and there are two
0 to 1 mA meter outputs.
The DLCA NET-ECAT has two digital inputs that allow remote
zeroing of the tension reading in each tension zone. There is
also a front panel "zero" button [n], which allows zeroing of
the tension zone currently being displayed.
Load cell diagnostics run during power-up and provide
information about load cell wiring problems.
The DLCA NET-ECAT has a web server interface to allow
configuration and calibration from a web browser.
1.2.1 Additional tools
Two software tools can be downloaded and installed for use
with the DLCA NET-ECAT:
The DLCA NET Data Logger software provides an easy way to
record tension data on your computer without complicated
programming.
The Terminal Tool software backs up your DLCA NET settings,
which you can then upload after a reset or replacement.
The manuals for these tools are available at
www.maxcessintl.com.

INTRODUCTION
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1.3 Model number
The model number and the serial number are shown on the
enclosure. The model number consists of the base model
DLCA NET followed by the numeral 1 or 2 to denote number of
tension zones the product will read, followed by "ECAT".
Available models
DLCA NET1-ECAT –One tension zone amplifier
DLCA NET2-ECAT –Two tension zone amplifier
1.4 Serial number
Serial Number format is MMDDYYNNNL
MM = month
DD = day
YY = last two digits of the year
NNN = a sequence number
L = manufacturing location

SAFETY INSTRUCTIONS
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2.0 Safety
2.1 Instructions for use
To ensure safe and problem free installation of the digital load
cell amplifier, the digital load cell amplifier must be properly
transported and stored, professionally installed and placed in
operation. Proper operation and maintenance will ensure a long
service life of the device. Only persons who are acquainted with
the installation, commissioning, operation and maintenance of
the system and who possess the necessary qualifications for
their activities may work on the digital load cell amplifier.
Note: The safety information may not be comprehensive.
Please note the following:
-The content of these operating instructions
-Any safety instructions on the device
-The machine manufacturer’s specifications
-All national, state, and local requirements for installation,
accident prevention and environmental protection
2.2 Symbols used
The following safety identification symbols are used in
these operating instructions.
WARNING/CAUTION –General danger or important note
Reference to general hazards that may result in bodily
injuries or damage to device or material.
WARNING/CAUTION –Danger due to crushing
Reference to danger of injury caused by crushing.
WARNING/CAUTION –Danger due to cutting
Reference to danger of injury caused by cutting.
WARNING/CAUTION –Danger due to voltage, electric shock
Reference to danger of injury caused by electric shock due
to voltage.
WARNING/CAUTION –Danger due to hot surfaces
Reference to risk of injury caused by burning.

SAFETY INSTRUCTIONS
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2.3 Basic safety information
Proper use
The DLCA NET-ECAT load cell amplifier is intended to be used
on machines or systems to amplify the signal from MAGPOWR
or competitor load cells.
For indoor operation, see environmental specifications on
page 69.
Improper use
-Operation outside the technical specifications
-Operation in an Ex-area or intrinsically safe area.
-Outdoor operation.
-Any other use than the proper use shall be deemed
inappropriate.
Installation and commissioning
-Any digital load cell amplifier which is damaged must not
be installed or put into operation.
-Only perform installation, maintenance or repair tasks on
the digital load cell amplifier when the machine into which
the DLCA NET-ECAT is installed has been stopped and is
secured from being turned on.
-Only perform installation, maintenance or repair tasks on
the digital load cell amplifier when there is no electrical
power in the system.
-The digital load cell amplifier must be securely mounted
before being placed in operation.
-Only replacement parts obtained from Maxcess may be
used.
-No modifications may be made to the digital load cell
amplifier.
-Do not place electrical cables under mechanical strain.
WARNING –Death or injury can result from static electric
shocks.
Moving webs of material can produce large static voltage
potentials. Protect against electric shocks by installing a
conductive connection between the terminal marked with the
PE symbol TB1.3 and the PE circuit of the building or machine.

SAFETY INSTRUCTIONS
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Basic safety information continued
WARNING –Death or injury can result from unexpected
movement of the machine into which the DLCA NET-ECAT is
installed.
Protect against unexpected movement by removing electrical
power from the digital load cell amplifier and the machine
into which the digital load cell amplifier is being installed.
Operation
None, as tasks from the operator are generally not required.
Maintenance and repair
WARNING –Death or injury can result from unexpected
movement of the machine into which the DLCA NET-ECAT is
installed.
Protect against unexpected movement by removing electrical
power from the digital load cell amplifier and the machine
into which the digital load cell amplifier is installed.
WARNING –Danger of injury from crushing.
Maintenance and repair tasks on the digital load cell
amplifier must be performed only when the machine into
which the DLCA NET-ECAT has been installed has been
stopped and has been secured from being turned on again.
Decommissioning
The digital load cell amplifier must be disposed of in
accordance with all the applicable national, state and local
regulations.

INSTALLATION
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3.0 Installation
Use shielded cable for all cables except for power cable.
3.1 Mechanical
1. Mount the DLCA NET to a 35 mm DIN rail.
See Figure 1 for DLCA NET dimensions.
Figure 1. DLCA NET dimensions

INSTALLATION
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3.2 Electrical
1. Connect a 24 VDC ±10% power supply to TB1.1 (+24V) and TB1.2
(COM).
2. Connect the PE of the building or machine to terminal TB1.3 (PE).
Note: The negative power connection TB1.2 is internally
connected to the PE connection TB1.3. This connection is used for
EMC compliance.
3. Connect one or two load cells to each sensor input on TB2 and
TB3.
4. Connect the Ethernet ports into a fieldbus network or computer.
5. Connect analog outputs, if desired.
3.3 Wiring diagrams
Figures 2 and 3: DLCA NET wiring connections using MAGPOWR
load cells
Figure 4: Connecting non-MAGPOWR load cells
TB2 is Channel 1 or Tension Zone 1 input.
TB3 is Channel 2 or Tension Zone 2 input.
P1+ and P2+
Positive excitation
P1- and P2-
Negative excitation
S1+ and S2+
Positive signal
S1- and S2-
Negative signal

INSTALLATION
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3.3.1 DLCA NET1 wiring using MAGPOWR load cells
DLCA NET1
one load cell or
tension-sensing roller
from one tension zone
DLCA NET1
one or two load cells
from one tension zone
Figure 2. DLCA NET1 wiring using MAGPOWR load cells

INSTALLATION
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3.3.2 DLCA NET2 wiring using MAGPOWR load cells
DLCA NET2
two tension zones,
one load cell from each zone
DLCA NET2
two tension zones,
one or two load cells
from each zone
Figure 3. DLCA NET2 wiring using MAGPOWR load cells

INSTALLATION
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3.3.3 Non-MAGPOWR load cell wiring
Two Half Bridge
500 mV Load Cells
One Half Bridge
500 mV Load Cells
*Precision bridge completion resistors; contact load cell manufacturer for values.
Figure 4. Non-MAGPOWR load cell wiring

INSTALLATION
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3.4 Analog output and digital input connections
DLCA NET1-ECAT: One tension zone amplifier
Output 1 is channel 1. (TB7.1, TB7.2, and TB7.3)
Output 2 is channel 2. (TB7.4, TB7.5, and TB7.6)
Output 3 is the sum of channel 1 and channel 2. (TB7.7, TB7.8,
and TB7.6)
The meter output is the sum tension signal. (TB6.1 and TB6.2)
Digital Input 1 will zero the tension. (TB4.2 and TB4.3)
DLCA NET2-ECAT: Two tension zone amplifier
Output 1 is Tension Zone 1. (TB7.1, TB7.2, and TB7.3)
Output 2 is Tension Zone 2. (TB7.4, TB7.5, and TB7.6)
The meter output is for Tension Zone 1. (TB6.1 and TB6.2)
The second meter output is for Tension Zone 2. (TB7.8 and
TB7.6).
Digital input 1 will zero the tension in zone 1. (TB4.2 and TB4.3)
Digital input 2 will zero the tension in zone 2. (TB4.1 and TB4.3).
The digital inputs are active high. There is a parameter to set the
voltage threshold for the digital inputs to either 5V or 24V logic.
Alarm output 3 is used for the power good signal.
See Figures 5, 6, and 7.

INSTALLATION
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Figure 5. DLCA NET-ECAT common wiring

INSTALLATION
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Figure 6. DLCA NET1-ECAT one tension zone analog outputs wiring
Figure 7. DLCA NET2-ECAT two tension zone analog outputs wiring

INSTALLATION
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Figure 8. MAGPOWR and non-MAGPOWR load cell wiring