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Installation and User Manual

1. nennen nnn nnne nnns 4 8 Tension calibration errors a aaa nnne nennen nnne nnne nnne nnn 4 11 Entering maximum tension sssini eee eee eene een hehehe nennen nenne nennen 4 12 PARAMETERS 5 1 Te EE 5 1 Analog output scaling eese nennen nennen nnne nnne nn nnne nnne rrr nn nnn 5 Alarm setup and operatlon eene nennen emen nennen nnne nnne 5 2 Digital impaCthresh g u s aS usa Sa nennen nnne nnns 5 3 Calibrate the analog outputs a menn enne nnns nnns 5 3 PassWOIG iei tefte missio Mun use URL LIUM LL M onus 5 4 Miscellaneous ort re Dr rio oet e res ec ieee Cu miae s iine 5 4 MAINTENANCE 6 1 Fuse Replacement ie ais 6 1 TROUBLESHOOTING 7 1 SPECIFICATIONS 8 1 SERVICE 9 1 www maxcessintl com MAGPOWR DLCA MI 850A348 1 A CONTENTS APPENDIX A DLCA FLOWCHART 10 1 FIGURES Figure 1 DLCA dimenslons occccoccccnncnncnnnnonncnnnnnncnnnnnonnrnnnnnnnonnrnonnnnnnrnrnnnnnnrnnnnnernrnrnnnnenanicon 3 1 Figure 2 Complete DLCA wiring occccocccocccnccncnconnnnnnncncnonnnonnrnononnnonnrnnnannnnnnnnnrnrncnnnnnenaricnn 3 3 Figure 3 Load cell wiring detail oocccconcncconncoccnnocacncnnnnnonacnnnnnnnonnrnnnnnnnnnnnnonarncnnnnnenanicnns 3 4 Figure 4 DLCA and LCA pinout nennen nnne n nsns ne nr rines ranas nre nra 3 5 Figure 5 Apply calibration tension nennen nnn nnne nnne nnns nnn 4 7 Figure 6 Weightless calibration angles nennen
2. 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 www maxcessintl com MAGPOWR DLCA MI 850A348 1 A 3 3 INSTALLATION Wiring for the DLCA 0 TO 10V OR 0 TO 1mA 0 TO 10V 4 TO 20mA METER 2 24V GND SIGNAL DEVICE 13 14 15 16 17 18 19 20 21 22 23 24 5059525525 i ALARM IS CONTACT CLOSURE Oo O u u O o x c f65t 33 S S 3 t SHIELD o CLOSE FOR TENSION ZERO O MAGPOWR MAGPOWR LOAD LOAD CELL CELL Figure 2 Complete DLCA wiring www maxcessintl com MAGPOWR DLCA MI 850A348 1 A 3 4 INSTALLATION Wiring for the DLCA Two MAGPOWR One MAGPOWR Load Cells Load Cell x zZ x Z EO ESB a m G mx m G mx 1 1 T 1 1 o o D n o o D D 6 7 8 9 6
3. 5 VDC 100mA Maximum 1 5 to 100 mV V 0 to 10 VDC 2k minimum load 4 to 20 mADC 450 ohm maximum load 0 1 mADC 1k maximum load 0 10 VDC open circuit 30 VDC maximum 0 4 ADC maximum 40 VDC isolation 24 VDC maximum 5V or 24V selectable threshold Max null drift 0 02 of load cell rating per Max null drift 0 02 of load cell rating per Max null drift 0 02 of load cell rating per OQ A 0 A Max null drift 0 07 of load cell rating per CE TUV Rheinland of North America to UL61010 1 and CAN CSA C22 2 No 61010 1 and CB Certificate to IEC61010 1 RoHS MI 8504348 1 A 9 1 Service requests and replacement parts SERVICE To request service or to get replacement parts contact one of the following addresses or your regional office listed at the bottom of this page Fife 222 West Memorial Rd Oklahoma City OK 73114 USA Phone 1 405 755 1600 Fax Web www maxcessintl com 1 405 755 8425 Fife Tidland GmbH Max Planck Strasse 8 65779 Kelkheim Deutschland Telefon 49 6195 7002 0 Fax 49 6195 7002 933 Web www maxcess eu When ordering replacement parts please indicate where possible part number drawing number and model description If itis necessary to return the DLCA for service care must be taken to properly package the unit to prevent damage during shipment If possible use the original shipping containers MAXCESS WEBEX 3 C cC NORTH CENTRAL AND SOUT
4. 7 8 9 Two Half Bridge Non MAGPOWR One Half Bridge Non MAGPOWR 500mv Load Cells 500mv Load Cell o oO D D D 6 7 8 9 8 le s Els Ke E e Precision Bridge Completion S gt Resistors Contact Load Cell Manufacturer for Values Figure 3 Load cell wiring detail www maxcessintl com MAGPOWR DLCA MI 850A348 1 A 3 5 INSTALLATION 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 O tol 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 oo NEO o 13 14 15 16 17 18 19 20 21 23 24 2 eu MAGPOWR onm DIGITAL LOAD CELL AMPLIFIER MODEL LGA LOAD CELL AMPLIFIER INPUT 24 VDC 100 mA OUTPUT 12 VDC MAX 20 mA o z 294 DLCA ER am QOO M Figure 4 DLCA and LCA pinout www maxcessintl com MAGPOWR DLCA MI 8504348 1 A 4 1 OPERATION Operation DLCA control buttons There are three manual control buttons on the DLCA DLCA increment Gi OQ KO decrement 27 zero tension or enter or save function Power on The DLCA will display the software version number when power is first applied fo
5. VOLTAGE 20mA OUTPUT 0 CURRENT 20mA OUTPUT 10096 CURRENT 1mA OUTPUT 0 VOLTAGE 1mA OUTPUT 100 VOLTAGE DIGITAL INPUT THRESHOLD ALARM ACTIVATION TYPE ALARM HIGH COMPARE VALUE ALARM LOW COMPARE VALUE ALARM HYSTERESIS PERCENT ALARM ON DELAY TIME ALARM OFF DELAY TIME TENSION NUMBER FORMAT TENSION POLARITY DECIMAL POINT POSITION lt C0 14 C0 2 C0 3 4 C0 4H gt 100 5 Datt 1000 0 0500 D P POSITION LOAD CELL SENSITIVITY LOAD CELL RATING MAXIMUM TENSION WEB WRAP ANGLE ANGLE FROM FORCE DIRECTION START WEIGHTLESS CALIBRATION DLCA FLOWCHART LEGEND PRESS PLUS PRESS MINUS PRESS ZERO PRESS AND HOLD PLUS AND MINUS FOR 2 SECONDS PRESS AND HOLD ZERO FOR 2 SECONDS ODo 1 0 0 0 0 0 0000 10V OUTPUT CAL 0 0000 0000 CAL 10096 CAL 0 FIRMWARE VERSION EXIT FROM MENU MODE 10V OUTPUT 20mA OUTPUT 20mA OUTPUT 1mA O fo 0000 mA OUTPUT CAL 100 0000 0000 UTPUT CAL 0 1 CAL 100 www maxcessintl com MAGPOWR DLCA MI 850A348 1 A
6. 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 www maxcessintl com MAGPOWR DLCA MI 8504348 1 A 1 2 INTRODUCTION 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 O to 10VDC 4 to 20 maDC and a 0 tol maDC 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 fo
7. is 6195 MAGPOWR DLCA MI 8504348 1 A 8 1 SPECIFICATIONS General Supply voltage range Supply current Internal fuse Temperature range Operating Storage Enclosure Climatic class Relative humidity Pollution degree Dimensions Display Display decimal point Maximum gain Tare Adjustment www maxcessintl com MAGPOWR DLCA 24 VDC 10 Proper earth grounding is required Note that the negative supply and earth ground are interconnected The power supply must have an SELV output such as Puls ML15 241 Mean Well MDR 20 24 or equivalent The Mean Well MDR 20 24 can be purchased from Fife as part number 93157 024 0 14 A max 2 5 A fast blow Bussman GBD2 50 or Littelfuse 21702 5 0 to 50 C 32 to 122 F 20 to 80 C 4 to 1 76 F IP20 3K3 EN60721 5 to 85 2 IEC664 1 Height 58 9 mm 2 32 in Length 70 0 mm 2 76 in Width 86 0 mm 3 39 in 4 digit LED 3 digit tension resolution selectable position 32 1 90 of Load Cell Rating MI 8504348 1 A 8 2 SPECIFICATIONS Inputs and outputs Load cell excitation Load cell sensitivity 0 10V analog output 4 20mA analog output 0 1mA or 0 10V analog output Alarm output Digital input zero tension Temperature drift Tension display 0 10V output 4 20mA output 0 1mA 0 10V output Certifications and environmental compatibility Product certifications www maxcessintl com MAGPOWR DLCA 5 VDC or 7
8. seconds until the display starts flashing to store the parameter Range 0 9990 continued www maxcessintl com MAGPOWR DLCA MI 8504348 1 A 4 7 OPERATION Tension calibration Precision calibration continued Display now shows C1 5 Apply the calibration load to the load cell using a temporary web or rope and a known weight entered in C1 4 The temporaray web should follow the normal web path When using a rope the rope should be centered on the rollers See Figure 5 Press to start calibration The display will show a wait screen and then display PASS for a successful calibration or an error code to indicate an issue with the calibration Temporary web Sensing roll 3 Weight W Y Figure 5 Apply calibration tension From either the passing or error screen press to return to displaying tension See the calibration errors in Table 3 on page 4 11 www maxcessintl com MAGPOWR DLCA MI 850A348 1A 4 8 OPERATION Tension calibration Weightless calibration Use this method when applying a known weight is not convenient or desired For Precision Calibration method see page 4 5 Enter the programming mode by pressing and holding and for two seconds Use the and or buttons to go to parameter P 01 Press 2 to see the present load cell excitation voltage Select either 5V or 7 5V When using MAGPOWR load cells select 7 5V Press and ho
9. zero not zeroing tension Displayed tension is reading negative value with increasing tension Cannot change parameters or perform calibration www maxcessintl com Sensor White S or Black S wire disconnected Sensor Red P wire disconnected Sensor Green P wire disconnected Sensor Failure or other mis wiring error Example Green and White wire swapped etc No power Check sensor wiring Check sensor wiring Check sensor wiring Check sensor wiring Check power wiring Figure 2 DLCA wiring Figure 2 DLCA wiring Figure 2 DLCA wiring Figure 2 DLCA wiring Figure 2 DLCA wiring Fuse blown Analog output shorted Check fuse in DLCA Check Analog output wiring Fuse ratings in Specifications p 8 1 Fuse Replacement p 6 1 Figure 2 DLCA wiring Analog output range misconfigured Check parameters P 06 through P0 11 Analog output not calibrated Alarm not wired correctly Perform output calibration CALO Check alarm wiring Figure 2 DLCA wiring Alarm not configured correctly Remote zero input not wired correctly Check parameters P 13 through P 18 Check remote zero wiring Figure 2 DLCA wiring Digital input threshold level not set correctly Tension polarity is wrong Password protection is active Check parameter P 12 Check parameter P 20 Enter the password into P 00 to unlock the DLCA The master unlock password
10. 1mA output current volts 0 100 00 10 00 when the tension is O P 11 Sets the O to 1mA output current volts 10 100 00 10 00 when the tension is equal to maximum tension The voltage value entered in P 10 and P 11 represents the current value in milliamps when divided by 10 www maxcessintl com MAGPOWR DLCA MI 8504348 1 A 5 2 PARAMETERS Alarm setup and operation The following parameters describe the setup and operation of the alarm output Parameter Description Default Range P 13 Sets the alarm activation type 0 0 3 0 2 Alarm ON when tension is above the alarm high compare value 1 2 Alarm ON when tension is below the alarm low compare value 2 Alarm ON when tension is either above the alarm high compare value or below the alarm low compare value 3 2 Alarm ON when tension is below the alarm high compare value and above the alarm low compare value P 14 Alarm high compare value 500 0 9990 P 15 Alarm low compare value 0 0 9990 P 16 Alarm hysteresis percent 0 Hysteresis percent is a percentage of maximum 000 0 100 0 tension value in C1 3 or C2 5 P 17 Alarm ON delay time The alarm ON output is 0 00 00 99 99 delayed by this number of seconds P 18 Alarm OFF delay time The alarm OFF output is 0 delayed by this number of seconds 00 00 99 99 Alarm operation with hysteresis Alarm activation type 0 Alarm turns on when tension is gr
11. H AMERICA Tel 1 405 755 1600 Fax 1 405 755 8425 sales maxcessintl com www maxcessintl com INDIA Tel 91 22 27602633 Fax 91 22 27602634 india maxcessintl com www maxcess in EUROPE MIDDLE EAST AND AFRICA Tel 49 6195 7002 0 Fax 49 6195 7002 933 sales maxcess eu www maxcess eu JAPAN Tel 81 43 421 1622 Fax 81 43 421 2895 japan maxcessintl com www maxcess jp CHINA Tel 86 756 881 9398 Fax 86 756 881 9393 info maxcessintl com cn www maxcessintl com cn KOREA TAIWAN AND SE ASIA Tel 65 9620 3883 Fax 65 6235 4818 asia maxcessintl com 2013 Maxcess 10 1 APPENDIX A DLCA Flowchart lo S l J CU g 3 QUU e o g e V LE l U o CO i UU e wo g k i Se i me 3 N j LA a TU U n d CL UU Im CO ae U N k 2e me CO ji O o ae me N e 2 P 21 aa g N N ee PASSWORD EXCITATION VOLTAGE PASS Ci Ia 0 EX UNLOAD D P POSITION MAX TENSION CALIBRATION APPLY CAL SENSOR TENSION TENSION PASS Er1 00 000 002 1 SENSOR DISPLAY FILTER FREQ 0 10V OUTPUT FILTER FREQ 4 20mA OUTPUT FILTER FREQ 0 1mA OUTPUT FILTER FREQ 10V OUTPUT 0 9o VOLTAGE 10V OUTPUT 100
12. MAGPOWR TENSION CONTROL A tms MAGPOWR MAGPOWR DLCA Digital Load Cell Amplifier Installation and User Manual DIGITAL LOAD CELL AMPLIFIER XCESS DLCA gt Z MI 850A348 1 A CONTENTS INTRODUCTION 1 1 About these operating instructions ooccccocncccocncnonnnonnnnnnanononnnnnnnnnonnnnonnrncnnnnonanons 1 1 Prod ct oVerview iiec e ce RIS ICE MO 1 2 Model number Keya re ra r aaa aa eene nnnm nnne nnne nsns n eser n E Ear ue 1 2 SAFETY INSTRUCTIONS 2 1 Instr ctions tor Us ia 2 1 Safety symbols a io 2 1 Basic safety information ooccccocncccocncononnonncncnnnncnnnnnnrnrncnnnnnonnrnnnnnnnnnnnnrnrnrnnanennrncnns 2 3 INSTALLATION 3 1 Mechanical ms EN 3 1 Electrical gari ad EE est eege 3 2 Complete DLCA wirlng eene nennen nnnm enne nnne nnne nnn 3 3 Load cell wiring detail 3 4 Convert wiring from LCAtoDECHA nennen nnne nnne nnne 3 5 DECA and e Tue ot e rtt etes rere e does ed ores 3 5 OPERATION 4 1 POWT OI suyos k E TOTO EID DIU OI LII IET 4 1 Zero the tension display 4 2 R set par meters occi eebe EE REENEN EE EES ENG 4 2 T nsion overzrange strain repre 4 2 Password Drotecon esee nennen nenne nnne nsns n aser E e d Eia 4 2 Programming mode nennen nnne nnne nsns rase rn rise rese sr rsen nnns 4 3 Parameter number u anita ed edere dees 4 3 T nsion calibratiOn oes co esaet oes ihe tt id 4 5 Precision calibratiom a trataba 4 5 Weightless caltbratlon
13. alue scales the output The output will be at 10 volts or 20 mA when the measured tension matches this value The maximum output voltage or current is set by parameters P 07 P 09 and P 11 Range 0 9990 Figure 6 Weightless calibration angles X Web wrap angle Y Angle from force direction Arrow Continued www maxcessintl com MAGPOWR DLCA MI 8504348 1 A 4 10 OPERATION Tension calibration Weightless calibration continued Display now shows C2 6 Press and enter the web wrap angle in degrees This is the angle over which the web touches the idler roller Press and hold for two seconds until the display starts flashing to store the parameter Refer to Figure 6 for the wrap angle X Range 0 180 0 Display now shows C2 7 Press 2 and enter the angle from the force direction arrow or center line in degrees This is the angle between the resultant force from the web tension and the force direction arrow of the load cell or centerline of the load cell The maximum value is 45 degrees Press and hold 2 for two seconds until the display starts flashing to store the parameter Refer to Figure 6 for the angle from force direction Y Range 00 0 45 0 Display now shows C2 8 Press to start the weightless calibration The display will show a wait screen and then display PASS for a successful calibration or an error code to indicate an issue with the calibration From eith
14. cal 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 ampl
15. d or buttons to go to parameter P 01 Press 2 to see the present load cell excitation 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 CALI sub menu Display now shows C1 1 Unload the load cell roller and press 2 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 www maxcessintl com MAGPOWR DLCA MI 8504348 1 A 4 6 OPERATION 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 Range 0000 0000 000 0 00 00 0 000 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 The maximum output voltage or current is set by parameters P 07 P 09 and P 11 Range 0 9990 Display now shows C1 4 Press and enter the calibration tension that will be applied to the load cell Press and hold for two
16. eater than High value Alarm turns off when tension is less than HighValue HysteresisPercent MaximumTension Alarm activation type 1 Alarm turns on when tension is less than Low value Alarm turns off when tension is greater than LowValue HysteresisPercent MaximumTension Alarm activation type 2 Alarm turns on when tension is greater than High value or less than Low value Alarm turns off when tension is less than HighValue HysteresisPercent MaximumTension and when tension is greater than LowValue HysteresisPercent MaximumTension Alarm activation type 3 Alarm output is the complement of alarm activation type 2 www maxcessintl com MAGPOWR DLCA MI 850A348 1A 5 3 PARAMETERS Digital input threshold Parameter Description Default Range P 12 Sets the digital input threshold for either 5V or 24V operation When set for 5V the threshold between on and off is 2 5 volts with 2096 hysteresis When set for 24V the threshold between on and off is 12 volts with 2096 hysteresis 24 volts n a Calibrate the analog outputs not normally changed CALO These parameters set the offset and gain for the outputs to calibrate the outputs to real volts or real current The parameters compensate for component tolerances on each DLCA These parameters are calibrated at the factory and are not reset by the power up function reset parameters to default If these ne
17. ed for maximum tension and the selection of the decimal point position The DLCA displays tension with three significant digits Example 1 Using two GTSD 15000M load cells The rated load is 30000 kg The application s maximum tension is 15000 kg Enter decimal point position as 000 0 Enter Maximum tension as 15 0 The DLCA now displays tension with units of 1000 kg The display will increment in 100 kg steps Same application but desired units are Newtons The load cell s rated load is 294 kN The application s maximum tension is 147 kN Enter decimal point position as 0000 Enter Maximum tension as 147 The DLCA now displays tension with units of 1 kN The display will increment in 1 kN steps Same application but desired units are Pounds www maxcessintl com The load cell s rated load is 66 1 kPounds The application s maximum tension is 33 0 kPounds Enter decimal point position as 000 0 Enter maximum tension as 33 0 The DLCA will now display tension with units of kPound The display will increment in 0 1 kPound steps MAGPOWR DLCA MI 8504348 1 A 4 13 OPERATION Entering maximum tension continued Example 2 Using two GTSB 2200 load cells The rated load is 4400 lbs The application s maximum tension is 2000 Ibs Enter decimal point position as 00 00 Enter Maximum tension as 2 00 The DLCA now displays tension with units of 1000 lbs The display will increment in 10 Ib steps Alterna
18. ed to be changed connect a volt meter or current meter as appropriate to the output that is being calibrated Parameter Z Description Range CO 1 Sets the O to 10V output to 0 0 9999 Change the value until the meter reads 0 00 volts C0 2 Sets the O to 10V output to 100 0 9999 Change the value until the meter reads 10 00 volts C0 3 Sets the 4 to 20mA output to 0 999 9999 Change the value until the meter reads 0 00 milliamps C0 4 Sets the 4 to 20mA output to 100 0 9999 Change the value until the meter reads 20 00 milliamps C0 5 Sets the 0 to ImA output to 0 0 9999 Change the value until the meter reads 0 00 volts or 0 00 milliamps C0 6 Sets the 0 to ImA output to 100 0 9999 Change the value until the meter reads 10 00 volts or 1 00 milliamps www maxcessintl com MAGPOWR DLCA MI 8504348 1 A 5 4 PARAMETERS Password Parameter Description Range P 00 Password 0 9999 When the DLCA is locked the display will show for this parameter until the or button is pressed Enter in the password to unlock the parameters When the DLCA is not locked the display will show 0000 for this parameter Enter in a new password to lock the parameters When the DLCA is locked all parameters will be viewable but cannot be changed and no calibrations will be performed Miscellaneous Parameter Description Defau
19. er the passing or error screen press to return to displaying tension See the calibration errors in Table 3 on page 4 11 If the displayed tension reads negative when force is applied to the load cell change parameter P 20 Tension Polarity to 1 The displayed tension will now read positive when force is applied www maxcessintl com MAGPOWR DLCA MI 8504348 1 A 4 11 OPERATION Tension calibration errors Display Error description PASS Calibration was successful No Errors found Signal read by the amplifier is too large when maximum tension is applied Er 1 This is caused by maximum tension being too large Reduce maximum tension Signal read by the amplifier is too small Too little of the load cell range is Er 2 being used thus the gain is greater than 32 1 Use more of the load cell range or set maximum tension higher Er 3 Roller weight too large Roller weight exceeds 9096 of the load cell rating Make roller weight smaller Er 4 Calibration tension is greater than Maximum tension Make Maximum tension larger than Calibration tension Er 5 Maximum tension exceeds the load cell rating Lower wrap angle make roll weight smaller or get higher rated load cells Table 3 Load cell calibration errors www maxcessintl com MAGPOWR DLCA MI 8504348 1 A 4 12 OPERATION Entering maximum tension Examples The following are examples of displaying tension that results from the value enter
20. h 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 58 9 2 32 35 0 1 38 D MEM ee feetadg i 70 0 2 76 GE i 13 14 15 18 17 18 48 20 21 22 23 24 DIGITAL LOAD CELL AMPLIFIER 86 0 3 39 TEN DLCA M XBS o O C g Qo OY Bras ue BG 123 4 5 6 7 8 8 10 11 12 712 6217217212 6216216212 IC Figure 1 DLCA dimensions www maxcessintl com MAGPOWR DLCA MI 850A348 1 A 3 2 INSTALLATION 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 80 C The wire size must be at least 0 34 mm 22 AWG
21. ifier is being installed MAGPOWR DLCA MI 8504348 1 A 2 4 SAFETY INSTRUCTIONS Basic safety information Continued Operation None as tasks from the operator are generally not required Maintenance and repair A 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 www maxcessintl com MAGPOWR DLCA MI 8504348 1 A 3 1 INSTALLATION Mechanical installation A AN 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 whic
22. ld for two seconds until the display starts flashing to store the changes Use the and or buttons to go to CAL2 Press to enter the CAL2 sub menu Display now shows C2 1 Unload the load cell roller and press 2 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 Display now shows C2 2 Press 2 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 Range 0000 0000 000 0 00 00 0 000 Display now shows C2 3 Press 2 and enter the load cell sensitivity in mV V units MAGPOWR load cells have a sensitivity of 2 1 mV V Consult the manual of competitor s load cells if using non MAGPOWR load cells Press and hold for two seconds until the display starts flashing to store the parameter Range 000 1 100 0 continued www maxcessintl com MAGPOWR DLCA MI 8504348 1 A 4 9 OPERATION Tension calibration Weightless calibration continued Display now shows C2 4 Press 2 and enter the combined load cell rating Press and hold for two seconds until the display starts flashing to store the parameter Range 0 9990 Display will now show C2 5 Press and enter the maximum tension Press and hold for two seconds until the display starts flashing to store the parameter This v
23. llowed 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 www maxcessintl com MAGPOWR DLCA MI 850A348 1 A SAFETY INSTRUCTIONS Instructions for use Safety symbols Information about safety symbols A www maxcessintl com 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 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 Avoidi
24. lt P 19 Tension number format 0 Tells whether tension display is 3 digit with no fixed right hand zero or 3 digit with fixed right hand zero 0 Auto Select between formats Based on value in Maximum Tension C1 3 or C2 5 1 2 3 digit with no fixed right hand zero 2 3 digit with fixed right hand zero P 20 Tension polarity 1 Set to 1 to show positive tension when the force is acting in the direction opposite the force direction arrow on the load cells Set automatically by Precision calibration P 21 DP position 0 Set the decimal point position to show when displaying tension 0 0000 1 0000 2 000 0 3 00 00 4 0 000 P 22 Firmware Version Displays the firmware version P 23 Exit from menu and return to displaying tension www maxcessintl com MAGPOWR DLCA MI 8504348 1 A 6 1 MAINTENANCE Maintenance No regular maintenance is required on the DLCA Fuse Replacement The fuse may be accessed by opening the enclosure Insert a flat blade screwdriver under one of the retaining tabs in the base and lift the cover See Figure 7 Figure 7 Enclosure top removal www maxcessintl com MAGPOWR DLCA MI 850A348 1 A 7 1 TROUBLESHOOTING Fault Description Probable Cause Solution Reference Er 10 at power up Er 11 at powr up Er 12 at power up Er 13 at power up Display not lighted Analog outputs not changing with the displayed tension Alarm output not working Remote
25. menn nnne 4 9 Figure 7 Enclosure top removal nennen nennen nnne nnns nnne nnne nnns 6 1 TABLES Table 1 Convert wiring from an LCA to the DC 3 5 Table 2 Load cell diagnostic errors a nennen enne nnn nnne 4 1 Table 3 Load cell calibration errors occcooncnccocncnonnnonocncnnnnnonacncnnnncnnnnnonnrncnnnnnonarnnnananenannos 4 11 www maxcessintl com MAGPOWR DLCA MI 850A348 1 A 1 1 INTRODUCTION 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
26. ng 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 MAGPOWR DLCA MI 8504348 1 A 2 2 SAFETY INSTRUCTIONS 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 P P P bP P www maxcessintl com MAGPOWR DLCA MI 850A348 1 A 2 3 Basic safety information www maxcessintl com SAFETY INSTRUCTIONS 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 techni
27. r 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 www maxcessintl com MAGPOWR DLCA MI 8504348 1 A 4 2 OPERATION 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 displaying tension and not if in the parameter menu or during calibration Reset parameters to defaults Press and hold and 2 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 output parameters C0 1 through CO 6 These parameters are calibrated at the factory for the component tole
28. rances 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 www maxcessintl com MAGPOWR DLCA MI 8504348 1 A 4 3 OPERATION Programming mode Enter the programming menu Press and hold and for two seconds Exit the programming menu Press and hold and for two seconds Also While showing parameter P 23 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 2 and release to cancel the data change and return to the menu Press 2 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 CALI and CAL2 menus a
29. re 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 www maxcessintl com MAGPOWR DLCA MI 8504348 1 A 4 4 OPERATION 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 www maxcessintl com MAGPOWR DLCA MI 850A348 1 A 4 5 OPERATION 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 an
30. tively www maxcessintl com Enter decimal point position as 0000 Enter maximum tension as 2000 The DLCA will now display tension with units of 1 lbs The display will increment in 10 lb steps Note that the right most zero is fixed and does not change MAGPOWR DLCA MI 8504348 1 A 5 PARAMETERS Parameters Filtering The tension display and all 3 analog outputs have a separate low pass filter The filter response can be set from 100 Hz to 0 01 Hz Parameter 7 Description Units Default Range P 02 Tension display filter frequency Hertz 3 100 01 99 99 P 03 O to 10V output filter frequency Hertz 40 100 01 99 99 P 04 4 to 20mA output filter frequency Hertz 40 100 01 99 99 P 05 0 tol mA output filter frequency Hertz 40 100 01 99 99 Analog output scaling Each analog output s output values for zero tension and maximum tension can be set by the following parameters Parameter 7 Description Units Default Range P 06 Sets the O to 10V output voltage volts 0 100 00 10 00 when the tension is 0 P 07 Sets the O to 10V output voltage volts 10 100 00 10 00 when the tension is equal to maximum tension P 08 Sets the 4 to 20mA output current milliamps 4 100 00 20 00 when the tension is 0 Allows changing to a O to 20 mA output P 09 Sets the 4 to 20mA output current milliamps 20 100 00 20 00 when the tension is equal to maximum tension P 10 Sets the O to

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