Maxcess MAGPOWR DLCA User manual

MAGPOWR DLCA
Digital Load Cell Amplifier
Installation and User Manual
EN
MI 850A348 1 E
MAGPOWR TENSION CONTROL

CONTENTS
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MAGPOWR DLCA
MI 850A348 1 E
INTRODUCTION 1-1
About these operating instructions ...................................................................... 1-1
Product overview .................................................................................................. 1-2
Model number key ............................................................................................... 1-2
SAFETY INSTRUCTIONS 2-1
Instructions for use .............................................................................................. 2-1
Safety symbols ..................................................................................................... 2-1
Basic safety information ....................................................................................... 2-3
INSTALLATION 3-1
Mechanical ........................................................................................................... 3-1
Electrical .............................................................................................................. 3-2
Complete DLCA wiring..................................................................................... 3-3
Load cell wiring detail...................................................................................... 3-4
Convert wiring from LCA to DLCA.................................................................... 3-5
DLCA and LCA Pinout ...................................................................................... 3-5
OPERATION 4-1
Power on .............................................................................................................. 4-1
Zero the tension display ....................................................................................... 4-2
Reset parameters ................................................................................................. 4-2
Tension over-range.............................................................................................. 4-2
Password protection............................................................................................. 4-2
Programming mode ............................................................................................. 4-3
Parameter number ........................................................................................... 4-3
Tension calibration............................................................................................... 4-5
Precision calibration ........................................................................................ 4-5
Weightless calibration...................................................................................... 4-8
Tension calibration errors .................................................................................. 4-11
Entering maximum tension ................................................................................ 4-12
PARAMETERS 5-1
Filtering................................................................................................................ 5-1
Analog output scaling .......................................................................................... 5-1
Alarm setup and operation................................................................................... 5-2
Digital input threshold ......................................................................................... 5-3
Calibrate the analog outputs ................................................................................ 5-3
Password.............................................................................................................. 5-4
Miscellaneous....................................................................................................... 5-5
MAINTENANCE 6-1
Fuse replacement ................................................................................................. 6-1
TROUBLESHOOTING 7-1
SPECIFICATIONS 8-1
SERVICE 9-1

CONTENTS
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MAGPOWR DLCA
MI 850A348 1 E
APPENDIX A: DLCA FLOWCHART 10-1
FIGURES
Figure 1. DLCA dimensions. .............................................................................................. 3-1
Figure 2. Complete DLCA wiring. ...................................................................................... 3-3
Figure 3. Load cell wiring detail. ....................................................................................... 3-4
Figure 4. DLCA and LCA pinout......................................................................................... 3-5
Figure 5. Apply calibration tension.................................................................................... 4-7
Figure 6. Weightless calibration angles ............................................................................. 4-9
Figure 7. Enclosure top removal........................................................................................ 6-1
TABLES
Table 1. Convert wiring from an LCA to the DLCA............................................................. 3-5
Table 2. Load cell diagnostic errors .................................................................................. 4-1
Table 3. Load cell calibration errors ................................................................................ 4-11

1–1
INTRODUCTION
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MAGPOWR DLCA
MI 850A348 1 E
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 2013, all rights reserved.
Periodically there will be updates to this manual. The latest
version is available at www.maxcessintl.com 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.

1–2
INTRODUCTION
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MAGPOWR DLCA
MI 850A348 1 E
Product overview
The DLCA is a digital load cell amplifier which provides
excitation voltage for load cells and amplifies the returned
millivolt signal which is proportional to applied force into a 0
to 10VDC, 4 to 20 maDC, and a 0 to1maDC signal. The DLCA
also shows the signal converted into a digital readout in
engineering units representing applied force. All calibrations
and setup are entered using three buttons and 4-digit
display. Tension is displayed using three significant digits.
The DLCA has a front panel tension zero button and a digital
input to remotely zero the tension. The DLCA has an alarm
output which can be programmed to activate at either a high
or low tension threshold. Load cell diagnostics run during
power-up.
Model number key
The model number and serial number are shown on the
bottom of the enclosure.
The model number consists of the base model "DLCA"
followed by optional alphanumeric characters.
Model format: DLCA
Serial number format: MMDDYYNNNL
MM = month
DD = day
YY = last two digits of the year
NNN = a sequence number
L= manufacturing location

2–1
SAFETY INSTRUCTIONS
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MAGPOWR DLCA
MI 850A348 1 E
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
Safety symbols
Information about
safety symbols
The safety instructions and symbols described in this section
are used in these operating instructions. They are used to avoid
possible dangers for users and to prevent material damage.
SIGNAL WORD
Source of danger and its results
Avoiding dangers
The signal word DANGER refers to the danger of death or
serious bodily injuries.
The signal word WARNING refers to the danger of moderate to
severe bodily injuries.
The signal word CAUTION refers to the danger of slight to
moderate bodily injuries or material damage.
The signal word NOTICE refers to the possibility of damage to
equipment.

2–2
SAFETY INSTRUCTIONS
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MAGPOWR DLCA
MI 850A348 1 E
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.

2–3
SAFETY INSTRUCTIONS
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MAGPOWR DLCA
MI 850A348 1 E
Basic safety
information
Proper use
The digital load cell amplifier is intended to be used on machines
or systems to amplify the signal from MAGPOWR or competitor load
cells.
Indoor operation, see environmental specifications.
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 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, pin 5,
and the PE circuit of the building or machine.
WARNING –Death or injury can result from unexpected movement
of the machine into which the DLCA 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.

2–4
SAFETY INSTRUCTIONS
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MAGPOWR DLCA
MI 850A348 1 E
Basic safety
information
(Continued)
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 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 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.

3–1
INSTALLATION
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MAGPOWR DLCA
MI 850A348 1 E
Mechanical
installation
WARNING –Death or injury can result from unexpected
movement of the machine into which the DLCA 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 is installed has been stopped and has
been secured from being turned on again.
1. Install the DLCA on a DIN 35 rail. Figure 1 shows the
DLCA dimensions.
Figure 1. DLCA dimensions.

3–2
INSTALLATION
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MAGPOWR DLCA
MI 850A348 1 E
Electrical
installation
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, pin 5, and the PE circuit of the building or
machine.
CAUTION –Never place electrical cables under mechanical
strain. Always provide mechanical support of wiring with
either clamps or flexible or rigid conduit.
All wiring must comply with the essential requirements of
the appropriate standard(s) and is the responsibility of the
installer.
Wiring to the digital load cell amplifier must be insulated
copper wire with a temperature rating of at least 80⁰C. The
wire size must be at least 0.34 mm2(22 AWG). Use twisted
pair cable for the power. Use shielded cable for the load cell
and analog output wiring.
1. Connect a 24 VDC +/-10% power supply to pins 3 and 4
of the terminal blocks. Pin 3 should be positive and pin 4
should be negative. See Figure 2.
2. Connect the PE of the building or machine to terminal
block pin 5.
Note: The negative power connection, pin 4, is internally
connected to the PE connection. This connection is only
used for EMC compliance.
3. Connect one or two load cells to terminals 6, 7, 8, and 9.
See Figure 2. If using non-MAGPOWR half-bridge load
cells, see Figure 3 for wiring.
4. Calibrate the load cells by following the procedure
starting on page 4-5 (Precision) or 4-8 (Weightless).
Figure 2 on the next page shows the complete DLCA wiring.

3–3
INSTALLATION
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MAGPOWR DLCA
MI 850A348 1 E
Wiring for the DLCA
Figure 2. Complete DLCA wiring.

3–4
INSTALLATION
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MAGPOWR DLCA
MI 850A348 1 E
Wiring for the DLCA
Figure 3. Load cell wiring detail.

3–5
INSTALLATION
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MAGPOWR DLCA
MI 850A348 1 E
Convert wiring from
an LCA to the DLCA
Table 1 shows how to convert the wiring from an LCA to the
DLCA.
Function
LCA Terminal
DLCA Terminal
+24V
12
3
Gnd
11
4
PE
10
5
0 to1 mA
9
21
4 to 20 mA
8
18
Gnd
7
17
0 to10V
6
16
Shield
5
10, 19, or 20
P+
4
9
P-
3
8
S-
2
7
S+
1
6
Table 1. Convert wiring from an LCA to the DLCA
Figure 4. DLCA and LCA pinout

4–1
OPERATION
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MAGPOWR DLCA
MI 850A348 1 E
Operation
DLCA control
buttons
There are three manual control buttons on the DLCA.
[+]
=
increment
[-]
=
decrement
[]
=
zero tension, or
enter or save function
Power on
The DLCA will display the software version number when power
is first applied for five seconds and then the DLCA will start
displaying the tension. During the software version display,
diagnostics are performed on the load cells and any errors are
displayed.
The load cell diagnostic errors are shown in Table 2.
To exit from the load cell diagnostic error, press [] and the
tension will be displayed.
If no errors are detected, the tension will be displayed.
Display
Meaning
Er 10
Sensor White (S+) or Black (S-) wire disconnected.
Er 11
Sensor Red (P+) wire disconnected.
Er 12
Sensor Green (P-) wire disconnected.
Er 13
Sensor Failure or other miswiring error. Example: Green and White wire are
swapped, etc.
Table 2. Load cell diagnostic errors

4–2
OPERATION
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MAGPOWR DLCA
MI 850A348 1 E
Zeroing tension
display
While displaying tension, press [] for two seconds to zero the
displayed tension and output.
Connecting the digital input (Zero) to either +5V or +24V for
greater than 500 ms will zero the displayed tension and
output.
This function will work only when the following conditions are
met:
when displaying tension and not if in the parameter menu,
when not in calibration,
if zeroing has not been locked out when a password has
locked the DLCA.
Reset parameters to
defaults
Press and hold [+] and [] while turning power on to the DLCA.
The display will show "dEF" for four seconds while the
parameters are reset to defaults.
This does not reset the calibrate analog outputs parameters
C0.1 through C0.6. These parameters are calibrated at the
factory for the component tolerances on each board. The
password is reset and the DLCA will be unlocked.
Tension over-range
The tension reading display will flash when the displayed
tension exceeds the maximum tension set in either parameter
C1.3 or C2.5.
Password protection
The DLCA allows a password to be set which prevents changes
to the parameters or performing a calibration. When locked, all
parameters can be viewed. Only zeroing tension is allowed
while the password has locked the DLCA, unless zeroing has
been locked out.

4–3
OPERATION
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MAGPOWR DLCA
MI 850A348 1 E
Programming
mode
the pm
Press and hold [+] and [-] for two seconds.
the pm
P[+][-] two
Also: While showing parameter P.24, you may press [] to exit
the menu and return to displaying the tension.
Parameter number
While in the programming mode, the display shows P.xx, where
xx is the parameter number.
Press [+] or [-] to increment or decrement the parameter
number. Press [] to enter the data entry mode for a
parameter. Use [+] or [-] to change the value of a parameter.
Press [] and release to cancel the data change and return to
the menu. Press [] and hold for two seconds (until the display
starts flashing) to save the changed parameter. If the data has
been changed and the data has not been saved, after five
seconds of no button activity the display will flash indicating
the data needs to be saved.
The CAL1 and CAL2 menus are sub-menus which are used to
step the operator through the calibration sequence. Press []
when a CALx menu is showing to get into the sub-menu. The
parameters will now be labeled Cx.y.

4–4
OPERATION
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MAGPOWR DLCA
MI 850A348 1 E
Programming
mode
Parameter number
continued
When in the programming mode and no buttons have been
pressed for two minutes, the DLCA exits the programming
mode and returns to displaying tension. This menu time-out is
not active once any of the calibration loops have been entered.
The DLCA allows a password to be set which prevents changes
to the parameters or performing a calibration. When locked, all
parameters can be viewed. Only zeroing tension is allowed
while the password has locked the DLCA, unless zeroing has
been locked out.

4–5
OPERATION
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MAGPOWR DLCA
MI 850A348 1 E
Tension calibration
The DLCA allows either precision calibration or weightless
calibration. The Precision Calibration method is described
below. Weightless Calibration begins on page 4-8.
Calibration can only be performed when the password has not
locked the DLCA. To unlock the DLCA, see the Password
parameter P.00 on page 5-4.
Precision calibration
Use this method when applying a known weight with a rope in
the web path to the load cells for calibration. Typically this
should be 10% of the load cell rating or greater.
Enter the programming mode by pressing and holding [+] and
[-] for two seconds.
Use the [+] and/or [-] buttons to go to parameter P.01. Press
[] to see the present load cell excitaion voltage. Select either
5V or 7.5V. When using MAGPOWR load cells select 7.5V. Press
and hold [] for two seconds (until the display starts flashing)
to store the changes.
Use the [+] and/or [-] buttons to go to "CAL1". Press [] to
enter the CAL1 sub-menu.
Display now shows C1.1. Unload the load cell roller and press
[]. The DLCA will now zero out the idler roll weight and show
a wait display. After zeroing the DLCA will automatically
increment to the next parameter.
continued

4–6
OPERATION
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MAGPOWR DLCA
MI 850A348 1 E
Tension calibration
Precision calibration
continued
Display now shows C1.2. Press [] and select the decimal point
position for tension. Press and hold [] for two seconds (until
the display starts flashing) to store the decimal point position
chosen.
Display now shows C1.3. Press [] and enter the maximum
tension. Press and hold [] for two seconds (until the display
starts flashing) to store the parameter. This value scales the
output. The output will be at 10 volts or 20 mA when the
measured tension matches this value.
Display now shows C1.4. Press [] and enter the calibration
tension that will be applied to the load cell. Press and hold []
for two seconds (until the display starts flashing) to store the
parameter.
continued