DLCA-CAT+ Tension Signal Amplifier

Precision Tension Measurement for High-Speed Web Processing

In continuous web processing, accurate tension measurement protects material quality, reduces waste, and keeps lines running at speed. The DLCA-CAT+ works in conjunction with load cells to capture and output real-time web tension data, making it the critical link between your tension sensors and your control system.

Whether you’re integrating with MAGPOWR tension controllers, a third-party PLC, or a motor driver, the DLCA-CAT+ delivers calibrated tension values locally and over your preferred industrial network without the need for additional conversion modules or supplemental hardware.

Key Benefits

• Faster Response Time: A 1 ms (1000 Hz) sampling rate provides quicker access to actual tension values, reducing the lag between real-world conditions and control system response.
• Improved Measurement Accuracy: 4-digit display resolution and display linearity of 0.05%-0.10% deliver more precise tension value acquisition compared to previous-generation amplifiers.
• Broad Network Compatibility: Five industrial Ethernet protocols (Modbus TCP, EtherNet/IP, CC-Link IEF Basic, EtherCAT, and PROFINET) are supported without requiring external conversion modules, enabling seamless integration with virtually any PLC environment.
• Single and Dual Tension Zone Flexibility: Operator-configurable single- or dual-tension zone modes allow the DLCA-CAT+ to adapt to your line configuration. Single-zone mode supports monitoring on either side of the web; dual-zone mode enables independent measurement across two load cells, reducing hardware costs compared to running two separate single-zone setups.
• Touchscreen Ease of Use: The DLCA-CAT+’s 5-inch touchscreen interface simplifies setup, calibration, and day-to-day operation, with multi-language support for global deployments.
• Broad I/O Compatibility: Standard analog and digital interfaces, including 3 analog outputs (0-10 VDC / 0-20 mA), 3 digital outputs, and 2 digital inputs, provide flexible connectivity to drives, controllers, and monitoring systems.

How It Works

The DLCA-CAT+ connects directly to MAGPOWR load cells or compatible third-party bridge sensors to measure the mechanical force applied to tension rollers or sensing rollers in real time. That tension signal is amplified and processed, yielding a calibrated value displayed on the touchscreen, transmitted over your industrial network, or delivered via analog/digital outputs to downstream control equipment.

The system supports three operating modes, configurable at the operator level:

• Single tension zone, single sensor: One load cell monitors tension on a single side of the web
• Single tension zone, dual sensors: Two load cells combined to measure tension across the full web width
• Dual tension zones: Two individual load cells monitor independent zones simultaneously

DLCA-CAT+ Configurations

The DLCA-CAT+ series is available in two models to suit different installation environments and panel architectures. Both share the same core measurement capabilities, I/O configuration, and fieldbus protocol support.

DLCA-CAT+ (Panel Mount)

The DLCA-CAT+ is a panel-mount amplifier featuring a 5-inch touchscreen for direct operator interaction and local tension display. Designed for machine-side or control panel installation, it provides full standalone operation alongside remote network control capability.

DLCA-CAT+ Highlights

• 5-inch touchscreen with web server and remote network control
• Optional remote standalone operator interface
• Panel mount installation
• Front panel IP54 protection rating
• Operating range: 0-60°C (32-140°F)
• Power: 18-30 VDC

DLCASLIM-CAT+ (DIN Rail Mount)

The DLCASLIM-CAT+ delivers the same tension-measurement performance as the DLCA-CAT+ in a compact DIN rail form factor, ideal for panel-efficient installations and systems where space is at a premium. It operates via remote network control, making it well-suited for multi-zone machine architectures managed from a centralized interface.

DLCASLIM-CAT+ Highlights

• Slim DIN rail design minimizes panel footprint
• DIN rail mount installation
• IP20 enclosure rating
• Remote network control operation
• Same fieldbus protocol support as DLCA-CAT+
• Operating range: 0-60°C (32-140°F)

Network Connectivity

The DLCA-CAT+ series supports five industrial Ethernet protocols as standard, with no additional conversion modules required. Three dedicated network ports handle protocol routing:

• ETH port: Modbus TCP, EtherNet/IP, CC-Link IEF Basic
• EN1 / EN2 ports: EtherCAT or PROFINET (depending on model variant)

This multi-protocol architecture is available in three model variants per configuration, allowing you to specify only the protocols your system requires.

DLCA-CAT+ Applications

The DLCA-CAT+ is engineered for web tension measurement in continuous processing lines across industries, including:

• Battery and capacitor manufacturing
• Film and wire processing
• Printing and flexible packaging
• Rubber tire manufacturing
• Roll pressing, coating, and laminating
• Die-cutting, winding, and rewinding

Note: The DLCA-CAT+ is not suitable for explosion-proof or intrinsically safe environments. For hazardous location applications, see the MAGPOWR IS-2.