Maxcess MAGPOWR DLCA NET-IP65-ECAT User manual

DLCA NET-IP65-ECAT
User Manual
EN
MI 850A366 1
MAGPOWR TENSION CONTROL

CONTENTS
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1.0 INTRODUCTION 4
1.1 About these operating instructions ................................................................. 4
1.2 Product overview............................................................................................. 5
1.3 Model number ................................................................................................ 6
1.4 Serial number.................................................................................................. 6
2.0 SAFETY 7
2.1 Instructions for use......................................................................................... 7
2.2 Symbols used.................................................................................................. 7
2.3 Basic safety information.................................................................................. 8
3.0 INSTALLATION 10
3.1 Mechanical .................................................................................................... 10
3.3 Cables used on the DLCA NET-IP65-ECAT .................................................... 13
3.3.1 Power cable ....................................................................................... 13
3.3.2 Load cell cable................................................................................... 13
3.3.3 Ethernet cable ................................................................................... 14
4.0 LED INDICATORS 15
5.0 COMMUNICATIONS INTERFACE 16
5.1 Cyclic parameters ......................................................................................... 16
5.2 Actual tension data ....................................................................................... 17
5.3 Security state ................................................................................................ 17
5.4 Status............................................................................................................ 18
5.5 Alarm............................................................................................................ 18
5.6 Command interface....................................................................................... 19
5.6.1 Command request............................................................................. 20
5.6.2 Command response .......................................................................... 24
5.7 Function information .................................................................................... 25
5.7.1 Security ............................................................................................. 25
5.7.2 Reset non-volatile (NV) memory to defaults ...................................... 26
5.7.3 Zeroing the tension ........................................................................... 26
5.8Get or set parameters ................................................................................... 26
5.8.1 Get a parameter ................................................................................ 26
5.8.2 Set a parameter ................................................................................. 26
6.0 PARAMETERS 27
6.1 Filtering ........................................................................................................ 27
6.2 Alarm setup and operation ........................................................................... 28
6.2.1 Alarm operation with hysteresis ........................................................ 29
6.3 Hardware configuration parameters.............................................................. 30

CONTENTS
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7.0 CALIBRATION 32
7.1 Precision calibration procedure..................................................................... 32
7.2 Weightless calibration procedure .................................................................. 35
7.3 Calibration errors returned ........................................................................... 38
8.0 WEB SERVER 39
8.1 Tension calibration from web pages ............................................................. 40
8.1.1 Precision calibration from web pages ................................................ 40
8.1.2 Weightless calibration from web pages ............................................. 41
8.2 Zero tension from web pages........................................................................ 41
9.0 SPECIFICATIONS 42
10.0 SERVICE 43
FIGURES
Figure 1. DLCA NET-IP65-ECAT Dimensions....................................................................... 11
Figure 2. DLCA NET-IP65-ECAT connector labels ............................................................... 12
Figure 3. DLCA NET-IP65-ECAT LED indicators................................................................... 15
Figure 4. Apply calibration tension...................................................................................... 33
Figure 5. Weightless Calibration Angles .............................................................................. 37
Figure 6. Sample web server page....................................................................................... 39
TABLES
Table 1. Power cables for DLCA NET-IP65-ECAT................................................................. 13
Table 2. Load cell cables for DLCA NET-IP65-ECAT ............................................................ 13
Table 3. Ethernet cables M12 to RJ-45................................................................................ 14
Table 4. Ethernet cables M12 to M12 .................................................................................. 14
Table 5. Calibration errors .................................................................................................. 38

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-IP65-ECAT is a 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 representing tension. The digital tension value is
available in the fieldbus data on EtherCAT®. Configuration and
calibration are available through the fieldbus interface.
There are two models of the DLCA NET-IP65-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 NET-IP651-ECAT is a one tension zone amplifier.
The two sensor inputs are from the left and right load
cells.
DLCA NET-IP652-ECAT is a two tension zone amplifier.
Each sensor input reads a separate tension zone.
The returned values of tension have only three significant
digits. The tension value can be six digits long but with three
forced zeros. No decimal point position setting is available in
the DLCA NET-IP65-ECAT.
The tension values sent over the communications interface are
channel 1 and channel 2. For the IP651-ECAT, two additional
values are sent; they are the sum and difference of channel 1
and 2. For the DLCANET2-ECAT, the sum and difference are
0. The tension values have 14-bit resolution.
The DLCA NET-IP65-ECAT has two alarms that can be
configured to sense tension limits on either of the two sensor
inputs or the total tension for the one tension zone amplifier.

INTRODUCTION
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Product overview continued
Zeroing of tension can be performed with a command through
the fieldbus interface for each of the tension zones.
Load cell diagnostics run during power-up and provide
information about load cell wiring problems.
The DLCA NET-IP65-ECAT has a web server interface to allow
configuration and calibration from a web browser.
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-IP65 followed by the numeral 1 or 2 to denote number of
tension zones the product will read, followed by "ECAT".
Available models
DLCA NET-IP651-ECAT One tension zone amplifier
DLCA NET-IP652-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-IP65-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 42.
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-IP65-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 green wire in the power
cable 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-IP65-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.
CAUTION –Damage to the DLCA NET-IP65-ECAT can result
from liquids entering the enclosure.
Do not violate the IP65 rating by drilling holes in the enclosure.
Always cover any unused connectors with the protective caps
that are supplied with your product.
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-IP65-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-IP65-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
3.1 Mechanical
Refer to 5.2 for cables used on the DLCA NET-IP65-ECAT.
1. Mount the DLCA NET-IP65-ECAT to a flat surface with 4
bolts and nuts. See Figure 1 for DLCA NET-IP65-ECAT
dimensions.
2. Connect a 24 VDC ±10% power supply to the power cable
leads; red wire is +24V and black wire is common.
3. Connect the PE of the building or machine to the green
power cable wire.
Note: The negative power connection (black wire) is
internally connected to the PE connection green wire. This
connection is used for EMC compliance.
4. Connect one to four load cells using the load cell cables.
5. Connect the Ethernet ports into a fieldbus network or
computer.
See Figure 2 for connector labeling.

INSTALLATION
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3.2
Figure 1. DLCA NET-IP65-ECAT Dimensions

INSTALLATION
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1
Channel 1 load cell inputs
2
Channel 2 load cell inputs
3
Ethernet port 1
4
Ethernet port 2
5
Power
Figure 2. DLCA NET-IP65-ECAT connector labels

INSTALLATION
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3.3 Cables used on the DLCA NET-IP65-ECAT
3.3.1 Power cable
The power cable has an M12 connector on one end and leads
on the other end. Table 1shows the lengths available; the five
meter length is standard. The maximum length is 50 meters.
Model
Length
(meters)
Model
Length
(meters)
IP65PWRCBL5M
5
IP65PWRCBL30M
30
IP65PWRCBL10M
10
IP65PWRCBL35M
35
IP65PWRCBL15M
15
IP65PWRCBL40M
40
IP65PWRCBL20M
20
IP65PWRCBL45M
45
IP65PWRCBL25M
25
IP65PWRCBL50M
50
Table 1. Power cables for DLCA NET-IP65-ECAT
3.3.2 Load cell cable
The load cell cable has an M12 connector on each end. Table 2
shows the lengths available. The five meter length is standard.
Lengths above 60 meters are not recommended, but can be
special ordered.
Part Number
Length
(meters)
Part Number
Length
(meters)
29IP65LCCBL5M
5
29IP65LCCBL35M
35
29IP65LCCBL10M
10
29IP65LCCBL40M
40
29IP65LCCBL15M
15
29IP65LCCBL45M
45
29IP65LCCBL20M
20
29IP65LCCBL50M
50
29IP65LCCBL25M
25
29IP65LCCBL55M
55
29IP65LCCBL30M
30
29IP65LCCBL60M
60
Table 2. Load cell cables for DLCA NET-IP65-ECAT

INSTALLATION
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3.3.3 Ethernet cable
The Ethernet1 cable has an M12 connector on one end and an RJ-45
connector on the other end. Table 3 shows the lengths available; the
five meter length is standard.
Lengths above 60 meters are not recommended, but can be special
ordered.
Part Number
Length
(meters)
Part Number
Length
(meters)
29L92724009
5
29L92724016
30
29L92724012
10
29L92724017
40
29L92724013
15
29L92724018
50
29L92724014
20
29L92724019
60
29L92724015
25
Table 3. Ethernet cables M12 to RJ-45
The Ethernet cable to daisy chain two or more DLCA NET-IP65-ECAT
together has an M12 connector on each end; see Table 4 for the
part numbers.
Part Number
Length
(meters)
Part Number
Length
(meters)
29L9411005
5
29L94111030
30
29L94111010
10
29L94111040
40
29L94111015
15
29L94111050
50
29L94111020
20
29L94111060
60
29L94111025
25
Table 4. Ethernet cables M12 to M12

LED INDICATORS
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4.0 LED indicators
The LEDs on the DLCA NET-IP65-ECAT provide status
information.
Figure 3. DLCA NET-IP65-ECAT LED indicators
1
Power (Yellow)
The power LED shows power good or a fault. If power is
good and there are no faults, the power LED is on.
If there is a fault detected, the power LED is flashing. One
flash per second means the load cell check has failed.
Two flashes per second means there is a voltage error on
either the load cell excitation, internal 12V or internal 5V
supplies.
The load cell check only runs during power-up. The
voltage monitoring check runs continuously.
2
Ethernet Link / Activity (Green)
These indicators show link status and activity on each of
the Ethernet ports.
3
EtherCAT Run status (Green)
4
EtherCAT Error status (Red)

COMMUNICATIONS INTERFACE
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5.0 Communications interface
An electronic datasheet is available for EtherCAT.
5.1 Cyclic parameters
The cyclic parameters are available to read tension and status
from the DLCA NET-IP65-ECAT and to send commands and
parameters to the DLCA NET-IP65-ECAT.
RO = Read only
WO = Write only
uint16 = unsigned 16-bit integer
int32 = signed 32-bit integer
uint32 = unsigned 32-bit integer.
Parameter
Data Type
Input Data (Cyclic)
Command Request
uint32 –WO
Command Request Parameter
uint32 –WO
Output Data (Cyclic)
Command Response
uint32 –RO
Command Response Parameter
uint32 –RO
Tension 1
int32 –RO
Tension 2
int32 - RO
Tension Sum (T1+T2)
int32 –RO
Tension Diff (T1-T2)
int32 –RO
Security State
uint16 –RO
Status
uint16 –RO
Alarm
uint16 –RO

COMMUNICATIONS INTERFACE
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5.2 Actual tension data
Tension is read from the DLCA NET-IP65-ECAT in the four cyclic
parameters Tension 1, Tension 2, Tension Sum, and Tension
Difference.
The tension value is a 32-bit signed integer and is scaled to be 160
times the Maximum Tension value ignoring the decimal point
position set by parameter 0x207 or 0x217.
The tension reading will be at least 14-bit resolution when the
maximum tension is 3 significant digits. Lower resolution will
result if maximum tension is less than 3 significant digits.
In a One Tension Zone amplifier
Tension 1 is the value of tension read on tension channel 1.
Tension 2 is the value of tension read on tension channel 2.
Tension Sum is the summation of the tension on channels 1 and 2.
Tension Difference is the tension on channel 1 minus the tension
on channel 2.
In a Two Tension Zone amplifier
Tension 1 is the value of tension read on tension channel 1.
Tension 2 is the value of tension read on tension channel 2.
Tension Sum and Tension Difference are always 0.
5.3 Security state
The status of security is shown in the Security State cyclic
parameter.
Value
Status
0
System is unlocked and changes can be made.
1
System is locked and changes cannot be made.

COMMUNICATIONS INTERFACE
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5.4 Status
The Status cyclic parameter shows power good, power failure
errors, and load cell check errors.
The lower 8 bits show power good or the power error. The upper
8 bits show the type of load cell check error that occurred.
The load cell check only runs during power-up. The voltage
monitoring check runs continuously.
Lower 8-bits:
0xXX00 = Power On, No Faults
0xXX01 = 5V power failure
0xXX02 = 12V power failure
0xXX04 = Load Cell power failure
Upper 8-bits
0x00XX = No Error
0x01XX = Sensor 1, white or black wire disconnected
0x02XX = Sensor 1, red wire disconnected
0x03XX = Sensor 1, green wire disconnected
0x04XX = Sensor 1, failure (check wiring or load cell damaged)
0x08XX = Sensor 2, white or black wire disconnected
0x10XX = Sensor 2, red wire disconnected
0x18XX = Sensor 2, green wire disconnected
0x20XX = Sensor 2, failure (check wiring or load cell damaged)
5.5 Alarm
The Alarm cyclic parameter shows the Alarm 1 and Alarm 2 state.
Bit 0 is the status of alarm 1.
Bit 1 is the status of alarm 2.
Bit = 0, Alarm OFF
Bit = 1, Alarm ON

COMMUNICATIONS INTERFACE
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5.6 Command interface
Commands are entered into the Command Request register.
Parameters are read or written by a value in the Command
Request Parameter. To write a parameter value, the value must be
set in the Command Request Parameter before the Command
Request is entered. See section 5.6.1 for all the available
commands and parameters.
After a Command Request has been entered the interface will
respond with a reply in the Command Response. When reading a
parameter the Command Response Parameter will contain the
value of the parameter. See section 5.6.2 for the command
response messages.
The Command Response will show a busy status while executing
commands and once the command processing is complete, the
Command Response will show either an error message or a
completed message. Once the command has returned with either
an error or completed message then a command of 0 must be
sent in the Command Request before sending another command.
The commands are used to perform calibrations and zeroing of
tension and also to get and set the value of the parameters in the
DLCA NET-IP65-ECAT.

COMMUNICATIONS INTERFACE
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5.6.1 Command request
Commands start at 0x0 and continue to 0x1FF.
Parameters start at 0x200 and continue to 0x3FF.
For parameters, add 0x1000 for a Write and 0x0000 for a Read to
the parameter number.
Command/parameter list
WO = Write Only, RO = Read only, RW = Read and Write
The parameter Class specifies which group this parameter
belongs to in the DLCA NET-IP65-ECAT. The class can be
communication (Comm), parameter (Parm), load cell calibration
(LC Cal), or output calibration (Out Cal). This classification is used
when resetting parameters to defaults with the NV Reset
commands.
Data types
int16 = signed 16-bit integer
uint32 = unsigned 32-bit integer
int32 = signed 32-bit integer
float = 32-bit single precision floating point number
Some commands and parameters are not useful for the two
tension zone DLCA NET-IP65-ECAT.
Command/
Parameter Number
Function or Parameter
Type
Class
Data Type
and R/W
Explanation
Hex
Decimal
0x000
0
Idle
Function
None
WO
0x001
1
Zero Calibrate Zone 1
Function
None
WO
See 7.1 or 7.2
0x002
2
Precision Calibrate Zone 1
Function
None
WO
See 7.1
0x003
3
Weightless Calibrate Zone 1
Function
None
WO
See 7.1
0x004
4
Zero Calibrate Zone 2
Function
None
WO
See 7.1 or 7.2
0x005
5
Precision Calibrate Zone 2
Function
None
WO
See 7.2
0x006
6
Weightless Calibrate Zone 2
Function
None
WO
See 7.2
0x007
7
Cal Output 0, 10V, 0%
Function
None
WO
N/A on IP65
0x008
8
Cal Output 0, 10V, 100%
Function
None
WO
N/A on IP65
0x009
9
Cal Output 0, 20mA, 0%
Function
None
WO
N/A on IP65
0x00A
10
Cal Output 0, 20mA, 100%
Function
None
WO
N/A on IP65
0x00B
11
Cal Output 1, 10V, 0%
Function
None
WO
N/A on IP65
0x00C
12
Cal Output 1, 10V, 100%
Function
None
WO
N/A on IP65
0x00D
13
Cal Output 1, 20mA, 0%
Function
None
WO
N/A on IP65
0x00E
14
Cal Output 1, 20mA, 100%
Function
None
WO
N/A on IP65
Command
Read or write