Maxcess MAGPOWR TLC-B Load Cell User manual

MAGPOWR TLC-B Load Cell
User Manual
EN
MI 850A356 1 A
MAGPOWR TENSION CONTROL

CONTENT
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MAGPOWR TLC-B
MI 850A356 1 A
INTRODUCTION 1-1
About these operating instructions ...................................................................... 1-1
Product overview .................................................................................................. 1-2
SAFETY INSTRUCTIONS 2-1
Instructions for use .............................................................................................. 2-1
Symbols used ....................................................................................................... 2-2
Proper use............................................................................................................ 2-3
Installation and commissioning............................................................................ 2-3
Maintenance and repair........................................................................................ 2-3
Decommissioning................................................................................................. 2-3
MOUNTING DIMENSIONS 3-1
Product dimensions.............................................................................................. 3-1
Shaft length requirements.................................................................................... 3-1
Shaft and roller diameters .................................................................................... 3-2
INSTALLATION 4-1
Load cell mounting options.................................................................................. 4-1
Flange mount .................................................................................................. 4-1
Pillow block mount .......................................................................................... 4-1
General installation .............................................................................................. 4-2
Resultant force polarity ................................................................................... 4-3
Default wiring.................................................................................................. 4-3
Flange mounting ............................................................................................. 4-4
Pillow block mounting ..................................................................................... 4-5
Bearing and shaft installation ............................................................................... 4-6
Inside machine frame ...................................................................................... 4-7
Outside machine frame ................................................................................. 4-10
MAINTENANCE 5-1
Lubrication ........................................................................................................... 5-1
MODEL NUMBER KEY 6-1
Available models .................................................................................................. 6-1
PRODUCT SPECIFICATIONS 7-1
SERVICE AND PARTS 8-1

1-1
INTRODUCTION
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MAGPOWR TLC-B
MI 850A356 1 A
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 2017, all rights reserved.
Periodically there will be updates to this manual. The latest
version is available on our website or by calling the number
on the back of this publication.
These load cell devices must not be installed or used in a
machine or system which does not comply with the
machinery directive 2006/42/EC.
These load cell devices 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 these
load cell devices.
These instructions must be retained and incorporated in the
technical documentation for the machine or partly completed
machinery into which the load cell device is installed.
CE marking
Only the 2006/42/EC Machinery directive applies to these
devices and they are not marked with the CE sign.
Electromagnetic Compatibility (EMC)
The load cell device is inherently benign in terms of
electromagnetic compatibility and the EMC directive has not
been applied. The electromagnetic compatibility of the load
cell device can only be assessed in connection with the entire
electrical installation including the control. The machine
builder who installs this partly completed machinery into a
machine is responsible for compliance with the EMC
directive.
Language
These are the original instructions, written in English.

1-2
INTRODUCTION
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MAGPOWR TLC-B
MI 850A356 1 A
Product overview
The MAGPOWR TLC-B Load Cells are extremely accurate devices
used to measure tension in any unwind, rewind, or intermediate
web processing application.
The load cells are to be mounted in a machine supporting an
idler roll in a part of the machine where measurement of web
tension is desired.
The low-profile design minimizes space requirements for the
load cells inside the machine frames, thus maximizing the
potential for web width. Additionally, the load cells can be
mounted on the outside of the machine frame, eliminating any
machine space dedicated to the load cells on the web side.
TLC-B Load Cells also offer the flexibility of mounting on top of
frames, using additional brackets and other accessories.
MAGPOWR TLC-B Load Cells are ruggedly constructed from steel
with mechanical overload stops in both force directions to
eliminate load cell damage and the need to recalibrate even after
extreme overloads.
A full Wheatstone bridge arrangement of four foil strain gages is
used in each load cell for the most accurate means of measuring
web tension with very low temperature drift. In addition, all load
cells incorporate a dual beam construction design to ensure
linear output under all loading conditions.
TLC-B Load Cells can be mounted to the machine frame directly
on a vertical surface or horizontally using pillow block brackets
(MAGPOWR Part No. TLCB-PBK).
TLC-B Load Cells couple to the customer’s idler roll journals
using internal self-aligning bearings supplied by the customer or
purchased from MAGPOWR as an accessory (Part No. 30A23-7).

2-1
SAFETY INSTRUCTIONS
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MAGPOWR TLC-B
MI 850A356 1 A
Instructions for
use
To ensure safe and problem free installation of the load cell
device, the load cell 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 load cell. 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
Information about
safety instructions
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 TLC-B
MI 850A356 1 A
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 TLC-B
MI 850A356 1 A
Basic safety
information
Proper use
The load cell devices are intended to be used on machines or
systems to monitor the tension in a web.
Indoor operation.
Improper use
Operation outside the technical specifications
Operation in an Ex-area or intrinsically safe area, unless used
with a MAGPOWR IS2 barrier.
Any other use than the proper use shall be deemed
inappropriate
Installation and commissioning
Any load cell device that is damaged must not be installed or
put into operation.
Only perform installation, maintenance or repair tasks on the
load cell device when the machine has been stopped and is
secured from being turned on.
Only perform installation, maintenance or repair tasks on the
load cell device when there is no electrical power in the
system.
The load cell device must be securely mounted before being
placed in operation.
No modifications may be made to the load cell device.
Do not place electrical cables under mechanical strain.
Maintenance and repair
Warning –Danger of injury from crushing
Maintenance and repair tasks on the load cell device must be
performed only when the machine has been stopped and has
been secured from being turned on again.
Decommissioning
The load cell must be disposed of in accordance with all the
applicable national, state and local regulations.

3-1
MOUNTING DIMENSIONS
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MAGPOWR TLC-B
MI 850A356 1 A
Product dimensions
TLC-B
Note: Cable connector adds 20 mm [0.80 inches] to overall height; see page 4-4.
1
Customer supplied
Shaft length requirements
(in millimeters; for reference only)
Mount outside machine frames
Mount inside machine frames

3-2
MOUNTING DIMENSIONS
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MAGPOWR TLC-B
MI 850A356 1 A
Shaft and roller
diameters
When mounting inside the machine frame, clearance is required
for the installation fasteners. See dimensions illustrated below.
If 'Y' will be less than 50 mm [2.0 inches], then the roller
diameter 'X' should be less than the diameter of the intended
mounting bolt circle:
3-bolt pattern: 150 mm [3.5 inches] maximum
4-bolt pattern: 135 mm [3.0 inches] maximum
Roller and shaft with shoulder (dust seal installed)
Roller with no shoulder (no dust seal)

4-1
INSTALLATION
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MAGPOWR TLC-B
MI 850A356 1 A
Load cell mounting options
Flange mount (on vertical machine frame)
Inside frame
Outside frame
Pillow block mount (on horizontal machine frame; configurations vary)
Inside brackets
Outside brackets

4-2
INSTALLATION
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MAGPOWR TLC-B
MI 850A356 1 A
General installation
CAUTION –Possible damage to load cell.
Do not hammer on the load cell.
CAUTION –Possible damage to load cell.
Do not disassemble the load cell –there are no serviceable
parts inside the unit.
WARNING –Danger of injury from crushing.
Maintenance and repair tasks on the load cell device must be
performed only when the machine has been stopped and has
been secured from being turned on again.
The TLC-B load cells must be mounted on a clean flat surface
where the wrap angle of the web does not change.
The centerline of the load cell must be positioned so that it
bisects the wrap angle of the web. The load cell must be rotated
so that the resultant force is aligned with the connector.
The resultant force can be toward or away from the connector.
See page 4-3.
General mounting instructions
Flange mount: page 4-4
Pillow block mount: page 4-5
Web tension
Resultant force
Web tension

4-3
INSTALLATION
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MAGPOWR TLC-B
MI 850A356 1 A
Resultant force
polarity
The label on the load cell indicates the output polarity based on
the resultant force direction in relation to the connector.
Default wiring
Cable wiring diagram
+ Power
Pin 1 (A)
Red
+ Signal
Pin 2 (B)
White
- Signal
Pin 3 (C)
Black
- Power
Pin 4 (D)
Green
When the resultant force is pointing
away from the connector the output
voltage is positive (+).
When the resultant force
is pointing toward the connector
the output voltage is negative (-).
Polarity auto-sensing
MAGPOWR readout devices and tension controllers with the
polarity auto-sensing feature automatically sense output polarity
regardless of the load cell orientation. Refer to your product
manual to determine whether your device has auto-sensing.
If your device does not support polarity auto-sensing, you will
need to manually reverse the polarity if the resultant force is
pointing toward the connector (output voltage is negative).
Exchange the (-S) and the (+S) wires at the device terminal block.

4-4
INSTALLATION
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MAGPOWR TLC-B
MI 850A356 1 A
Flange mounting
The TLC-B Load Cell can be mounted using one of two bolt
patterns:
3-hole on a 150 mm bolt circle
4-hole on a 135 mm bolt circle
Before installation, each machine frame must be prepared with a
100 mm hole for the load cell hub and M8x1 (or 5/16")
threaded holes for the fasteners.
Use M8 or 5/16" bolts to mount the load cell to vertical machine
frames. Minimum fastener length is 70 mm [2.75 inches].
See page 3-2 for maximum roller diameters when mounting
inside the machine frame.

4-5
INSTALLATION
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MAGPOWR TLC-B
MI 850A356 1 A
Pillow block
mounting
When using the optional pillow block bracket, the load cell can
be rotated in 30° increments to align the resultant force with
the connector.
One bracket per load cell required;
-MAGPOWR Part No. TLCB-PBK
Fasteners
Mount load cell to pillow block bracket (kit included)
-M8 bolts
-Minimum fastener length is 75 mm [3.0 inches]
Mount brackets to horizontal machine frames
-M16 or 11/16" bolts
-Minimum fastener length is 25 mm [1.0 inch]
Detailed installation procedures begin on page 4-6.

4-6
INSTALLATION
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MAGPOWR TLC-B
MI 850A356 1 A
Bearing and shaft
installation
The TLC-B load cell is designed to use a 2208 self-aligning
bearing. These bearings can be used for both live and dead
shaft applications.
The bearing is supplied by the customer or it can be ordered
separately from MAGPOWR (Part No. 30A23-7). All
MAGPOWR TLC-B load cells are shipped with two large
internal retaining rings to secure the bearing in the load cell.
The shaft (40 mm journal diameter only) is held in place by
smaller external retaining rings installed in grooves on each
side of the bearing.
For a shaft with a 45 mm to 40 mm shoulder, the shaft is
held by a retaining ring outboard of the bearing and a
machined shoulder inboard (shown below). See illustrations
on the following pages for installation procedure.
A dust seal is available for the 45 mm shaft only.
Thermal expansion of the shaft can be accommodated by
using the two internal retaining rings in only one load cell.
1
Shaft 45 mm shoulder shown *
7
Load cell
2
Dust seal (optional; see IP ratings on page 7-1)
8
Overload pins
3
Socket head cap screw M4 x 8
9
Bearing **
4
Cover, inboard
10
Retaining ring, external **
5
Retaining ring, internal, inboard
11
Retaining ring, internal, outboard
6
Connector
12
Cover, outboard
*
**
40 mm if not using dust seal
Customer supplied or purchase from Maxcess
Note: Items 5 and 11 are the same part number, and are distinguished here by description.

4-7
INSTALLATION
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MAGPOWR TLC-B
MI 850A356 1 A
Bearing and shaft installation –continued
Inside machine frame
Use the illustration on page 4-6 for reference.
Note the overload pins that are loose inside the covers. Ensure that they are in place before
reinstalling the covers. NOTE: A fixed load cell uses two large retaining rings to secure the
bearing; a floating load cell uses none.
On one load cell only:
1. Remove the inboard cover and install the
inboard retaining ring. Note the overload
pins that are loose inside the cover. Ensure
that they are in place before reinstalling the
cover.
NOTE: The large retaining rings are for a
fixed load cell only.
2. Remove three M4 screws and outboard
cover. (Note the overload pins.)
3. If using a dust seal (45 mm shaft only),
install it on the shaft as shown.
4. Slide the load cell assembly onto the shaft
until the snap ring groove (a) is accessible.
Continued next page

4-8
INSTALLATION
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MAGPOWR TLC-B
MI 850A356 1 A
Bearing and shaft installation
Inside machine frame mounting –continued
5. Install the bearing on the shaft and secure
with the snap ring.
6. Slide the load cell assembly back over the
bearing.
7. Push the dust seal into the pocket of the
cover until inboard faces are flush. Do not
over-compress.
8. Install the outboard retaining ring.
9. Ensure that the overload pins are in place
and reinstall the outboard cover.
Repeat this procedure at the other end of the shaft.
To maintain the axial play required for thermal expansion, do not install the two
large retaining rings in the other load cell.
Continued next page

4-9
INSTALLATION
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MAGPOWR TLC-B
MI 850A356 1 A
Bearing and shaft installation
Inside machine frame mounting –continued
Installing the shaft assembly
1. Align the shaft assembly between the machine frames
and slide the floating load cell inboard until the hubs fit
between the frames. There will be some axial clearance to
allow for fit. If the assembly will not fit between the
frames, check the shaft length. See page 3-1.
2. Slide the shaft assembly up until the hubs align with the
registers in the frames.
3. Make sure the hubs are engaged in the frame.
4. Secure the load cells with fasteners (minimum fastener
length is 70 mm [2.75 inches].
Fixed
Floating

4-10
INSTALLATION
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MAGPOWR TLC-B
MI 850A356 1 A
Bearing and shaft installation –continued
Outside machine frame
Use the illustration on page 4-6 for reference.
Note the overload pins that are loose inside the covers. Ensure that they are in place before reinstalling
the covers. NOTE: A fixed load cell uses two large retaining rings to secure the bearing; a floating load
cell uses none.
On one load cell only:
1. Remove the inboard cover and install the
inboard retaining ring. Note the overload
pins that are loose inside the cover.
Ensure that they are in place before
reinstalling the cover.
NOTE: The large retaining rings are for a
fixed load cell only.
2. With the outboard cover removed, align
the load cell with the mounting holes in
the machine frame.
3. If using a dust seal (45 mm shaft only),
install it on the shaft.
4. Insert the shaft through the machine
frame and into the load cell until the snap
ring groove (a) for the bearing is
accessible.
5. Install the bearing onto the shaft and
secure it with the small retainer ring.
6. Install the large retaining ring.
Continued next page

4-11
INSTALLATION
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MAGPOWR TLC-B
MI 850A356 1 A
Bearing and shaft installation
Outside machine frame mounting –continued
7. Ensure the overload pins are in place and
reinstall the outboard cover.
8. Fasten the load cell to the machine frame
using customer provided fasteners.
Minimum fastener length is 70 mm
[2.75 inches].
Repeat the procedure at the other end of the shaft.
To maintain the axial play required for thermal expansion, do not install the two
large retaining rings in the other load cell.