Maxcess MAGPOWR DLCA NET-S1 User manual

DLCA NET-S1
User Manual
EN
MI 850A374 1 A
MAGPOWR TENSION CONTROL

CONTENTS
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DLCA NET-S1
MI 850A374 1 A
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1.0 INTRODUCTION 6
1.1 About these operating instructions ................................................................. 6
1.2 Product overview............................................................................................. 7
1.2.1 Additional tools ................................................................................... 8
1.3 Model number ................................................................................................ 9
1.4 Serial number.................................................................................................. 9
2.0 SAFETY 10
2.1 Instructions for use....................................................................................... 10
2.2 Symbols used................................................................................................ 10
2.3 Basic safety information................................................................................ 11
3.0 INSTALLATION 13
3.1 Mechanical .................................................................................................... 13
3.2 Electrical ....................................................................................................... 14
3.3 Wiring diagrams............................................................................................ 14
3.4 Analog output and digital input connections ................................................ 17
Two tension zone analog outputs ................................................................. 18
4.0 OPERATION 19
4.1 Zeroing tension display................................................................................. 21
4.2 Reset parameters to defaults ........................................................................ 21
4.3 Tension over-range ...................................................................................... 21
4.4 Password protection ..................................................................................... 21
4.5 LED indicators ............................................................................................... 22
4.6 Load cell excitation voltage........................................................................... 22
4.7 Programming mode ...................................................................................... 23
5.0 CALIBRATE TENSION USING THE KEYPAD 24
5.1 Precision calibration...................................................................................... 24
5.1.1 Calibration errors (using keypad) ...................................................... 28
6.0 ENTERING MAXIMUM TENSION 29
7.0 PARAMETERS 31
7.1 Filtering ........................................................................................................ 31
7.2 Alarm setup and operation ........................................................................... 32
7.2.1 Alarm operation with hysteresis ........................................................ 33
7.3 Hardware configuration parameters.............................................................. 34
7.4 Miscellaneous parameters............................................................................. 36
7.5 Analog output scaling ................................................................................... 37
7.6 Calibrate the analog outputs (not normally changed).................................... 38
7.7 Password ...................................................................................................... 39
8.0 COMMUNICATIONS INTERFACE 40
8.1 Cyclic parameters ......................................................................................... 40
8.2 Actual tension data ....................................................................................... 41

CONTENTS
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8.3 Security state ................................................................................................ 42
8.4 Status............................................................................................................ 42
8.5 Alarm............................................................................................................ 43
8.6 Command interface....................................................................................... 43
8.6.1 Command request............................................................................. 44
8.6.2 Command/parameter list .................................................................. 44
8.6.3 Command response .......................................................................... 48
8.7 Function information .................................................................................... 49
8.7.1 Security ............................................................................................. 49
8.7.2 Reset non-volatile (NV) memory to defaults ...................................... 50
8.7.3 Zeroing the tension ........................................................................... 50
8.7.4 Calibrate the analog outputs (not normally used) .............................. 50
8.7.5 Reset processor................................................................................. 51
8.8 Get or set parameters ................................................................................... 52
8.8.1 Get a parameter ................................................................................ 52
8.8.2 Set a parameter ................................................................................. 52
8.9 Analog outputs scaling ................................................................................. 52
9.0 CALIBRATE TENSION THROUGH THE FIELDBUS PROCEDURE 54
9.1 Precision calibration procedure..................................................................... 55
9.1.1 Calibration errors returned................................................................ 59
10.0 WEB SERVER 60
10.2 Web pages ................................................................................................ 61
10.3 Calibrate tension from web pages............................................................. 62
10.3.1 Precision calibration from web pages ................................................ 62
10.4 Zero tension from web pages.................................................................... 63
11.0 SPECIFICATIONS 64
12.0 SERVICE 66
APPENDIX A: DLCA NET-S1 FLOWCHART 67

CONTENTS
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FIGURES
Figure 1. DLCA NET-S1 dimensions .................................................................................... 13
Figure 2. DLCA NET2-S1 wiring using MAGPOWR load cells ................................................ 15
Figure 3. Non-MAGPOWR load cell wiring ........................................................................... 16
Figure 4. DLCA NET-S1 common wiring.............................................................................. 17
Figure 5. DLCA NET2-S1 two tension zone analog outputs wiring ...................................... 18
Figure 6. LED indicators ...................................................................................................... 22
Figure 7. Apply calibration tension...................................................................................... 27
Figure 8. Apply calibration tension...................................................................................... 54
Figure 9. Sample web server page....................................................................................... 61
TABLES
Table 1. Load cell diagnostic errors .................................................................................... 20
Table 2. Calibration errors .................................................................................................. 28
Table 3. Calibration errors .................................................................................................. 59

CONTENTS
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MI 850A374 1 A
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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 2019, 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.

CONTENTS
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1.2 Product overview
The DLCA NET-S1 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
tension is displayed on the DLCA NET-S1 device.
The tension values have at least 14-bit resolution.
The digital tension value is available in the fieldbus data on Modbus
TCP/IP, Ethernet/IP or PROFINET IO. Configuration and calibration is
available through the fieldbus interface.
The DLCA NET-S1 is a two tension zone amplifier which subtracts a
portion of web tension on channel 2 from the roll weight on
channel 1. This is for a special weighing application in which the
roll weight is combined with a portion of web tension on channel 1.
The internal math prevents the web tension from affecting the roll
weight shown on channel 1.
Each sensor input can have up to two load cells attached.
Tension values are sent from the load cells for each tension zone.
Channel 1 is roll weight and channel 2 is the web tension. The sum
and difference values sent on the communications interface are set
to zero.

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Product overview continued
The DLCA NET-S1 has three alarm outputs. Two of the alarm
outputs can be configured to sense tension limits on either of
the two sensor inputs. 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-S1 has four analog outputs that represent
tension; see Section 3.4.
The DLCA NET-S1 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-S1 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-S1:
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-S1
settings, which you can then upload after a reset or
replacement.
The manuals for these tools are available at
www.maxcessintl.com.

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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 2 to denote number of
tension zones the product will read, followed by "S1".
Available models
DLCA NET2-S1 –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-S1 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 64.
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-S1 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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MI 850A374 1 A
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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-S1 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-S1 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-S1 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-S1 to a 35 mm DIN rail.
See Figure 1. for DLCA NET-S1 dimensions.
Figure 1. DLCA NET-S1 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
Figure 2: DLCA NET-S1 wiring connections using MAGPOWR load
cells
Figure 3: 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 NET2-S1 wiring using MAGPOWR load cells
DLCA NET2-S1
two tension zones,
one load cell from each zone
DLCA NET2-S1
two tension zones,
one or two load cells
from each zone
Figure 2. DLCA NET2-S1 wiring using MAGPOWR load cells

INSTALLATION
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3.3.2 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 3. Non-MAGPOWR load cell wiring

INSTALLATION
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3.4 Analog output and digital input connections
DLCA NET2-S1: 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 Figure 4 and 5.
Figure 4. DLCA NET-S1 common wiring

INSTALLATION
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Two tension zone analog outputs
Figure 5. DLCA NET2-S1 two tension zone analog outputs wiring

OPERATION
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4.0 Operation
There are four control buttons on the DLCA NET-S1.
[+] = increment
[-] = decrement
[] = enter or save function*
[n] = zero the displayed tension
(the zero button)
* For clarity, these instructions use the word [ENTER] instead of the symbol [].
Power on
The DLCA NET-S1 will display the software version number
when power is first applied for five seconds and then the DLCA
NET-S1 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 1.
To exit from the load cell diagnostic error
-Press [Enter] and the tension will be displayed.
-The error display will be canceled after 45 seconds and
then tension will be displayed.
-If no errors are detected, the tension will be displayed.
Display
Meaning
Sensor 1
Sensor 2
Er 1
Sensor 1 White (S+) or Black (S-) wire
disconnected.
Good
Er 2
Sensor 1 Red (P+) wire disconnected.
Good
Er 3
Sensor 1 Green (P-) wire disconnected.
Good
Er 4
Sensor 1 Failure or other wiring error.
Example: Green and White wire are
swapped, etc.
Good
Er 8
Good
Sensor 2 White (S+) or Black (S-) wire
disconnected.
Er 9
Sensor 1 White (S+) or Black (S-) wire
disconnected.
Sensor 2 White (S+) or Black (S-) wire
disconnected.
Er 10
Sensor 1 Red (P+) wire disconnected.
Sensor 2 White (S+) or Black (S-) wire
disconnected.
Er 11
Sensor 1 Green (P-) wire disconnected.
Sensor 2 White (S+) or Black (S-) wire
disconnected.

OPERATION
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Display
Meaning
Sensor 1
Sensor 2
Er 12
Sensor 1 Failure or other wiring error.
Example: Green and White wire are
swapped, etc.
Sensor 2 White (S+) or Black (S-) wire
disconnected.
Er 16
Good
Sensor 2 Red (P+) wire disconnected.
Er 17
Sensor 1 White (S+) or Black (S-) wire
disconnected.
Sensor 2 Red (P+) wire disconnected.
Er 18
Sensor 1 Red (P+) wire disconnected.
Sensor 2 Red (P+) wire disconnected.
Er 19
Sensor 1 Green (P-) wire disconnected.
Sensor 2 Red (P+) wire disconnected.
Er 20
Sensor 1 Failure or other wiring error.
Example: Green and White wire are
swapped, etc.
Sensor 2 Red (P+) wire disconnected.
Er 24
Good
Sensor 2 Green (P-) wire disconnected.
Er 25
Sensor 1 White (S+) or Black (S-) wire
disconnected.
Sensor 2 Green (P-) wire disconnected.
Er 26
Sensor 1 Red (P+) wire disconnected.
Sensor 2 Green (P-) wire disconnected.
Er 27
Sensor 1 Green (P-) wire disconnected.
Sensor 2 Green (P-) wire disconnected.
Er 28
Sensor 1 Failure or other wiring error.
Example: Green and White wire are
swapped, etc.
Sensor 2 Green (P-) wire disconnected.
Er 32
Good
Sensor 2 Failure or other wiring error.
Example: Green and White wire are
swapped.
Er 33
Sensor 1 White (S+) or Black (S-) wire
disconnected.
Sensor 2 Failure or other wiring error.
Example: Green and White wire are
swapped.
Er 34
Sensor 1 Red (P+) wire disconnected.
Sensor 2 Failure or other wiring error.
Example: Green and White wire are
swapped.
Er 35
Sensor 1 Green (P-) wire disconnected.
Sensor 2 Failure or other wiring error.
Example: Green and White wire are
swapped.
Er 36
Sensor 1 Failure or other wiring error.
Example: Green and White wire are
swapped.
Sensor 2 Failure or other wiring error.
Example: Green and White wire are
swapped.
Table 1. Load cell diagnostic errors