Maxcess MAGPOWR DTR-65 User manual

MAGPOWR DTR-65
Digital Load Cell Amplifier
Installation and User Manual
EN
MI 850A349 1 D
MAGPOWR TENSION CONTROL

CONTENTS
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MAGPOWR DTR-65
MI 850A349 1 D
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 .............................................................................................................. 3-4
Complete DTR-65 wiring................................................................................. 3-6
Load cell wiring detail...................................................................................... 3-7
Convert wiring ................................................................................................. 3-8
From LCA to DTR-65 .................................................................................. 3-8
From DTR to DTR-65 .................................................................................. 3-9
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
DTR-65 Assembly ........................................................................................... 6-2
TROUBLESHOOTING 7-1

CONTENTS
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MAGPOWR DTR-65
MI 850A349 1 D
SPECIFICATIONS 8-1
SERVICE 9-1
APPENDIX A: DLCA FLOWCHART 10-1
FIGURES
Figure 1. DTR-65 dimensions. .......................................................................................... 3-2
Figure 2. Installation of the DTR-65 into a panel. ............................................................. 3-3
Figure 3. Complete DTR-65 wiring. .................................................................................. 3-6
Figure 4. Load cell wiring detail. ....................................................................................... 3-7
Figure 5. LCA and DTR-65 pinout. .................................................................................... 3-8
Figure 6. DTR and DTR-65 pinout..................................................................................... 3-9
Figure 7. Apply calibration tension.................................................................................... 4-7
Figure 8. Weightless calibration angles. ............................................................................ 4-9
Figure 9. Access to the DTR-65 fuses and fuse locations.................................................. 6-1
Figure 10. Re-assembly of DTR-65 boards into the enclosure.......................................... 6-3
TABLES
Table 1. Convert wiring from LCA to the DTR-65.............................................................. 3-8
Table 2. Convert wiring from a DTR to the DTR-65. ......................................................... 3-9
Table 3. Load cell diagnostic errors. ................................................................................. 4-1
Table 4. Load cell calibration errors. ............................................................................... 4-11

1–1
INTRODUCTION
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MAGPOWR DTR-65
MI 850A349 1 D
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 and the low voltage directive 2006/95/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 DTR-65
MI 850A349 1 D
Product overview
The DTR-65 is a digital tension readout and amplifier which
provides excitation voltage for load cells and amplifies the
returned millivolt signal which is proportional to applied
force into a 0 to 10 V, 4 to 20 mA, and a 0 to 1mA signal.
The DTR-65 shows the signal converted into a digital
readout in engineering units representing applied force.
The DTR-65 is panel mounted and provides IP65 protection
on the front face and IP20 protection on the back and sides.
The IP65 protection is provided by a gasket and a
membrane keypad.
All calibrations and setup are entered using a keypad and a
4-digit display. Tension is displayed using three significant
digits. The DTR-65 has a front panel tension zero button
and a digital input to remotely zero tension.
The DTR-65 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 "DTR-65"
followed by optional alphanumeric characters.
Model format: DTR-65
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 DTR-65
MI 850A349 1 D
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 DTR-65
MI 850A349 1 D
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 DTR-65
MI 850A349 1 D
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 DTR-65 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.
continued

2–4
SAFETY INSTRUCTIONS
www.maxcessintl.com
MAGPOWR DTR-65
MI 850A349 1 D
Basic safety
information
continued
WARNING –Shock may result from water or conductive particles
entering the DTR-65 enclosure due to poor gasket sealing on the
front panel.
To maintain the IP65 rating on the front panel, be sure the gasket is
properly seated between the DTR-65 front panel and the panel into
which the DTR-65 is installed.
WARNING –Death or injury can result from unexpected movement
of the machine into which the DTR-65 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.
WARNING –Death or injury from shock may result from wiring live
power to the DTR-65.
Be sure the power is turned off and locked out before wiring the
DTR-65.
WARNING –Death or injury can result from electric shocks.
Safety requirements require a connection between the DTR-65
earth ground and the PE circuit of the building or machine.
continued

2–5
SAFETY INSTRUCTIONS
www.maxcessintl.com
MAGPOWR DTR-65
MI 850A349 1 D
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 DTR-65 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 DTR-65 has been installed has been stopped and
has been secured from being turned on again.
WARNING –Death or injury from shock may result from
wiring live power to the DTR-65.
Be sure the power is turned off and locked out before wiring
the DTR-65.
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 DTR-65
MI 850A349 1 D
Mechanical
installation
WARNING –Death or injury can result from unexpected
movement of the machine into which the DTR-65 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 DTR-65 is installed has been stopped and has
been secured from being turned on again.
WARNING –Shock may result from water or conductive
particles entering the DTR-65 enclosure due to poor gasket
sealing on the front panel.
To maintain the IP65 rating on the front panel, be sure the
gasket is properly seated between the DTR-65 front panel
and the panel into which the DTR-65 is installed.

3–2
INSTALLATION
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MAGPOWR DTR-65
MI 850A349 1 D
Mechanical installation
continued
1. Remove the panel jacks from the back of the DTR-65.
2. Install the DTR-65 into a standard 1/8 DIN cut-out 92 x
45 [3.62 x 1.77] (Figure 1). Make sure the gasket is
between the DTR-65 front panel and the panel into
which the DTR-65 is being installed to maintain the IP-
65 rating on the DTR-65 front panel (Figure 2, page 3-
3).
Figure 1. DTR-65 dimensions.
continued

3–3
INSTALLATION
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MAGPOWR DTR-65
MI 850A349 1 D
Mechanical
installation
continued
3. Reinstall the panel jacks from the back of the DTR-65
into the panel jack grooves in the side of the enclosure.
4. Install the set screws into the panel jack grooves and
tighten with the supplied allen wrench to secure the
DTR-65 in the panel and to form a seal on the gasket.
Tighten the set screws to a torque of 0.099 to 0.113 Nm
[14 to 16 oz. in.].
Figure 2. Installation of the DTR-65 into a panel.

3–4
INSTALLATION
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MAGPOWR DTR-65
MI 850A349 1 D
Electrical
installation
WARNING –Death or injury from shock may result from
wiring live power to the DTR-65.
Be sure the power is turned off and locked out before wiring
the DTR-65.
All wiring must comply with the essential requirements of
the appropriate standard(s) and is the responsibility of the
installer.
For fixed/permanent installation of the DTR-65, a suitable
switch or circuit-breaker must be installed as a
disconnecting device and this switch/circuit-breaker needs
to be labelled appropriately.
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.
The DTR-65 can be powered by either 100-240 VAC 50-60
Hz or by 24 VDC. Only connect to one power source.

3–5
INSTALLATION
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MAGPOWR DTR-65
MI 850A349 1 D
Electrical installation
continued
See Figure 3 for reference.
1. Connect power to the DTR-65. Only one power source is
needed.
For 100-240 VAC power
Connect 100-240 VAC to TB1 pins 1and 2 labeled AC L1
and AC L2.
For 24 VDC power
Connect a 24 VDC power supply to TB1 pins 4 and 5. Pin
4 should be positive.
2. Connect the PE of the building or machine to
TB1 pin 3 marked with the earth ground
symbol.
Note: The negative power connection, TB1 pin 5, is
internally connected TB1 pin 3. This connection is used
for EMC compliance. TB1 pin 3 is also connected to all the
terminals labeled with SHLD which are TB1 pin 10, TB2
pins 5 and 6. TB1 pin 5 is also connected to all the
terminals labeled GND, TB1 pin 11, and TB2 pins 3 and 8.
WARNING –Death or injury can result from electric shocks.
Safety requirements require a connection between the DTR-
65 earth ground 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.
3. Connect one or two load cells to TB1 pins 6, 7, 8, and 9.
See Figure 3. If using non-MAGPOWR half-bridge load
cells, see Figure 4 for wiring.
4. Calibrate the load cells by following the procedure
starting on page 4-5 (Precision) or 4-8 (Weightless).
Figure 3 on the next page shows the complete DTR-65
wiring.
Note: When using the AC supply input TB1 pin 4 does not
output +24 VDC. This pin is a power input only.

3–6
INSTALLATION
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MAGPOWR DTR-65
MI 850A349 1 D
Wiring for the DTR-65
Figure 3. Complete DTR-65 wiring.

3–7
INSTALLATION
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MAGPOWR DTR-65
MI 850A349 1 D
Wiring for the DTR-65
Figure 4. Load cell wiring detail.

3–8
INSTALLATION
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MAGPOWR DTR-65
MI 850A349 1 D
Convert wiring from
LCA to DTR-65
Table 1 shows how to convert the wiring from an LCA to the
DTR-65.
Function
LCA
Terminal
DTR-65
Terminal
+24 V
12
TB1-4
Gnd
11
TB1-5
Earth Ground
10
TB1-3
0 to 1 mA
9
TB2-4
4 to 20 mA
8
TB2-7
Gnd
7
TB2-8
0 to 10V
6
TB2-9
Shield
5
TB2-5, TB2-6, TB1-10
P+
4
TB1-9
P-
3
TB1-8
S-
2
TB1-7
S+
1
TB1-6
Table 1. Convert wiring from LCA to the DTR-65.
Figure 5. LCA and DTR-65 pinout.

3–9
INSTALLATION
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MAGPOWR DTR-65
MI 850A349 1 D
Convert wiring from
DTR to DTR-65
Table 2 shows how to convert the wiring from a DTR to the
DTR-65.
Function
DTR
Terminal
DTR-65
Terminal
AC L1
L1
TB1-1
AC L2
L2
TB1-2
Earth Ground
None
TB1-3
Gnd
GND
TB2-8
0 to10V
+OUT
TB2-9
Shield
None
TB2-5, TB2-6, TB1-10
P+
+P RED
TB1-9
P-
-P GRN
TB1-8
S-
-S BLK
TB1-7
S+
+S WHT
TB1-6
Table 2. Convert wiring from a DTR to the DTR-65.
Figure 6. DTR and DTR-65 pinout.

4–1
OPERATION
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MAGPOWR DTR-65
MI 850A349 1 D
Operation
DTR-65 control
buttons
There are three manual control buttons on the DTR-65.
[+]
=
increment
[-]
=
decrement
[]
=
zero tension, or
enter or save function
Power on
The DTR-65 will display the software version number when
power is first applied for five seconds and then the DTR-65 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 3.
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 3. Load cell diagnostic errors.