Mitsubishi LE-40MTA-E Instruction Manual Download Page 1 | Manualshive

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TENSION CONTROLLER

MODEL

LE-40MTA-E

INSTRUCTION MANUAL

ZJ - 4015E

Introduction:

•

This instruction manual describes the minimum necessary operations and functions for the
optimum adjustment of machines by using the LE-40MTA-E tension controller in Sections
1 through 5 taking "One-reel unwinding powder" shown below as an example.
Before start setting any systems, thoroughly read these five sections first.

•

When mechanism other than "One-reel unwinding powder" is used, read Section 6 "Mech-

anism other than one-reel unwinding powder" for setting. For the basic items such as the
initialization, wiring as well as zero and span adjustment, read Sections 1 through 5.

•

When using functions other than the above, read Section 7 "Use of extensive functions"

and after.

•

Note that this instruction manual is applicable to

system ROM version 3.00 or later.

Tension detector

Tension controller

Powder brake

Example of "One-reel unwinding powder "

Z990D30601E

1
2
3
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Summary of Contents for LE-40MTA-E

Page 1: ...ughly read these five sections first When mechanism other than One reel unwinding powder is used read Section 6 Mech anism other than one reel unwinding powder for setting For the basic items such as the initialization wiring as well as zero and span adjustment read Sections 1 through 5 When using functions other than the above read Section 7 Use of extensive functions and after Note that this ins...

Page 2: ......

Page 3: ...Otherwise the unit may be damaged malfunction or be deteriorated Never open the covers while the power is supplied to the unit or when the unit is operating Never supply the power to the unit nor operate the unit while the main body cover and the terminal cover are open When the covers are open a high voltage area may be exposed and electrical shock may occur Turn off all the phases of the externa...

Page 4: ......

Page 5: ...sive sag or tension in material during acceleration and deceleration 27 7 3 Control of excessive winding tension Internal reel diam eter taper control 28 7 4 External reel diameter taper control 30 7 5 Change of control gains 32 7 6 Output of contact when running out of material 34 7 7 Use for machines with frequent inching operation 34 7 8 Externally turns on or off control output 35 7 9 Setting ...

Page 6: ...ion for automatic adjustment are offered The operation data can be read and written using the memory cassette FX EEPROM 4 or 8 sold sep arately The above external devices may be connected to the input output terminals of the tension controller The tension detector actuator and some of the command input switches those indicated with white let ters on a black background are mandatory Other devices a...

Page 7: ...0 The full scale tension is set in the initial setting When the taper tension is controlled in accordance with the reel diam eter the tension set value subtracted by the taper tension is regarded as actual target tension and used during automatic control When the MANUAL switch is pressed manual operation is available The control output of 0 100 can be obtained with the scale of the manual torque s...

Page 8: ...not be caused Perform Class 3 grounding to the analog I O cables and the winding shaft pulse input cable with shielded cables on the signal receive side Never let the I O cables pass through a duct together with other power cables Never bind the I O cables together with other power cables Generally the allowable wiring length shall be 10 m or less to assure safety against noise General description...

Page 9: ...er supply to the terminals PSL and PSN as shown in the figure above If the AC power supply is connected to the I O terminal or DC supply terminal the tension controller will be burn out Do not use the spare terminal for an external device Otherwise the unit may be damaged Perform the solid grounding to the ground terminal and FG using a wire of 2mm2 or more Never perform grounding together with th...

Page 10: ...etting TENSION SET and manual setting MANUAL SET using the trimmer provided on the panel Entering of a numeric directly is not possible The set value is modified even if the value is not displayed on the screen Increase or decrease the displayed value using the numeric input keys then press the ENTER key for determination Tension setting and manual setting are set by the trimmer but cannot set by ...

Page 11: ... monitor 2 Diameter monito Password screen MANUAL switch Initial setting Pass word Full scale setting Zero Span adjustment Confirm setting Initial setting screens Operator screens usual operation Switch Unit Control reels Number of reels Taper Actuator Stall AI2 AI3 MC5 MC6 Tension Filter Display Filter Output ZT Zero adjustment Span adjustment Full scale Start and stop Start T Stop T Stop G Stop ...

Page 12: ...stment as necessary See page 26 and after Completion of adjustment Check for abnormalities when error occurs See pages 43 through 45 See pages 8 through 10 W X T S T S Power ON L 4 0 M T A T e n s i o n C o n t r o l l e r E V e r V C o p y r i g h t M I T S U B I S H I E L E C T R I C C O R P E P S S W E N T S E T E N T E R P A S S W O R D A T S N U N I T S E L E C T T E N T I O N U N I T 10 N N ...

Page 13: ...rmally the taper control is not used for unwinding control This is to select whether to use the internal signals of the tension controller or to receive the external reel data to calculate the reel diameter for the taper control Receiving the external reel diameter results in better taper control accuracy See page 28 for details T R D I A S E L E C T T A P E R S I G N A L I N T E X T P T P E R M D...

Page 14: ...se the following screen to select one or two tension detectors ENTER CANCEL Stand by for approximately 10sec S T E R O T U Z Z R O T U N E E N I N G E R R O R T H E D E T E C T I O N R O L L E R I S T O O H Z R O T U N E C M P L E T E O E Finished Error ENTER CANCEL Suspend weight W N The weight should be a static load as close to the full scale tension value as possible Should be between 1 to 1 3...

Page 15: ...em check in manual operation mode perform operational check by the automatic operation in step 4 following the procedure below Set the tension controller See page 18 for the operator screen Press the automatic mode switch to enter automatic mode Turn on the MC1 contact input to start automatic operation This completes the basic adjustment for operation Where a different mechanism or other function...

Page 16: ...p gain and the stop bias become valid until the stop timer times up After that the stall values become valid The start timer and stop timer will be discussed later See the next page for more about the stall The lighting conditions of the auto matic mode switch start stop in put MC1 and the state of the automatic mode indicator are as the figure on the right Use a micro signal switch commensurate w...

Page 17: ...lly turned on when the reel is changed When the initial setting MC4 OUT SW at the STALL RESET screen is selected see page 9 the control output is switched from ON to OFF by the output on off switch on the panel at the time of changing the material The stall memory value will be preset to the stall setting value When MC4 is kept on for approximately 0 5 second or longer the stall memory value is pr...

Page 18: ...STALL MD screen with SWITCH on the initial setting screen or the engineer screen To enter the stall setting value by key input on the operator screen use the STALL SET screen To change the stall setting value input by the external analog input setting refer to page 40 A special use of stall function The system can be set so as to reset the stall memory value only by the MC4 contacts without using ...

Page 19: ... R G A I N S T T I N G S E L E C T M E N U B Y C U R S O R E R E E L C H G The control output by the manual torque and the stall setting are set by the following standard Dmax Maximum diameter D Diameter F Control tension D0 Initial diameter F Average drive tension Feed control Feed control Manual torque Stall New reel preset F N 100 F max F N 100 F max D 0 F0 N 100 D max F max D F N 100 D max F m...

Page 20: ...epending on the parameter setting Stall set When new reel and taper functions are in use Manual setting Total tension monitor Tension monitor left and right O U T P U T M N U S E T S E T A T N S N 10 N M N U S E T S E T A T N S N N M N U S E T S E T A S T T S N M N T T A R G E T 10 N N T S N M N T T A R G E T N N T S N M N T L E F T 10 N R I G H T 10 N N T A R G E T 10 N T S N M N T L E F T N R I ...

Page 21: ...xternal setting is effective EXT is displayed on the screen O U T P U T N W R S E T S E T E O U T P U T T P E R S E T S E T A C N R 2 m m φ T P E R S E T C N R 1 m m φ T P R 1 A T P E R S E T C N R 4 m m φ T P R 4 A T P R 3 New reel set When multi shaft mode is selected T N S N N N W R S E T S E T E S T Linear taper set When taper is selected T N S N N T P E R S E T S E T A Nonlinear taper set Whe...

Page 22: ...orque command EMG stop Normal opelation Torque input Upper Limit SA SN 2 Setting A T U A T O R S E L E C T A C T U A T O R P O W D E R A C S E R V O M O T O R C Select AC SERVO MOTOR Setting and changing servo amplifier parameters With the servo on input terminal turned off turn on the servo amplifier power supply Change the settings of the following parameters Put the servo loop in torque mode Se...

Page 23: ...ut of 0 to 100 When using an electric pneumatic regulator of 4 to 20 mA input current type connect it as per the fig ure shown on the right When using an electric pneumatic regulator of 0 to 5V voltage input type connect it between termi nals SA and SN Use the ACTUATOR screen within SWITCH on the initial setting screen or the engineer screen to set or change the settings Use this output in powder ...

Page 24: ... the engineer screen to set or change settings 6 4 Use for both winding and unwinding operation There will be no functional differences between the selection of Unwinding and Winding in the LE 40MTA E Therefore for the switch over type that functions both as the winder and unwinder there will be no problem in the winding or unwinding operation However observe the following The taper control to pre...

Page 25: ...surrection and power running sides the control may be come unstable near zero In such case use an auxiliary clutch or brake for the feed reel so that the control output is used either for the resurrection side only or power run ning side only For the feed reel control use the CONTL PART screen within SWITCH on the initial setting screen or the engineer screen to set as follows When the NRO is used...

Page 26: ...es brakes connect them in the manner that the total of the rat ed current will be 4A or less Note however that torque variation occurs between the powder clutch and brake When the P N output is insufficient up to 10 pcs power amplifiers for powder clutches and brakes can be connected to terminals SA SN Two or more servo amplifier can also be connected Note however that the load resistance should b...

Page 27: ...r controller setting on page 15 to determine the settings Use the PRESET T screen within REEL CHANGE on the engineer screen to set or change the pre set time Include a margin in the preset value so that the tension feedback will not take place while the tension is unstable after switching the reels A reel A reel B reel New reel preset MC2 input Reel exchange P N control output Auxiliary power outp...

Page 28: ... set to the reel A becomes valid When it is ON the mechani cal loss cancel value set to the reel B is valid This is effective when the mechanical loss of the reel A differs greatly from that of reel B See page 35 For setting the new reel preset value and preset time refer to Section 6 7 Powder unwinding two reels switching on the previous page A reel A reel B reel New reel preset MC2 input Reel ex...

Page 29: ... the REEL NUM Number of reels screen within SWITCH in the initial setting screen or the engineer screen to set reel switch over or change the setting Select REELS multiple reels Use the NEW R SET new reel set screen on the operator screen to set or change the new reel preset value Refer to the guideline for controller setting on page 15 to determine the settings Use the PRESET T screen within REEL...

Page 30: ...ntrol is selected at the time of shipping from the factory 1 The feedback control takes place while the stop timer is in operation This is selected when non abrupt stop 2 The output is fixed while the stop timer is in operation This is selected when the tension during the stop in 1 above is zero Select Feedback or Fixed on the Stop T set screen to select 1 or 2 respectively Set the start timer Sel...

Page 31: ...described above As an example gain 1 may be used during acceleration and gain 2 during deceleration Use the micro signal switch commensurate with DC8V 4mA as the input contacts Connect the gain 1 contact signal to MC3 Connect the gain 2 contact signal to MC5 or MC6 whichever is used Use the OUT GAIN screen within START STOP on the engineer screen to change the setting val ue of gain 1 and gain 2 U...

Page 32: ...essary to enter the reel diameter the accuracy is not very high Two methods are available to set the taper ratio as follows 1 By setting the taper ratio key entry internally 2 By entering the taper ratio externally through analog voltage Two methods are available to enter the taper curves as follows 1 Linear line taper control 2 Non linear line taper control 1 Outline of taper control Calculation ...

Page 33: ...hen select INT internal on the TPR DIA taper reel diameter screen Two methods are available to set the taper ratio as follows Setting by key entry on the operator screen standard Setting by external analog input see page 39 Use the TAPER SET screen on the operator screen to set the taper ratio by key entry The Target value in which the taper ratio is taken can be confirmed on the TNSN MNT tension ...

Page 34: ...meter screen Select which taper to use the linear line taper or non linear taper See the next page To change the reel diameter input values by the external analog input change the data on the AI2 or AI3 setting screen within SWITCH on the initial setting screen or the engineer screen To change the maximum or minimum value of the reel diameter change the data on the DIA SET screen within REEL on th...

Page 35: ...ne taper is given from corner 1 set the taper as shown in the right figure Corner 1 Taper 1 Cor ner 2 Taper 2 The linear line taper control may take place from corner 1 to corner 2 Set the data as follows corner 1 Dmin corner 2 Dmax Not necessary to set data to corners 3 and 4 The TARGET value in which the taper ratio is taken can be confirmed on the TNSN MNT tension monitor screen of the operator...

Page 36: ...the premises it does not adversely affect the material Press the enter key to set the value When adjusting the automatic gain the output increases instantaneously When handling the material easily elongated or ruptured set the additive output to a small value for adjustment When errors generated during the automatic gain adjustment add as large a torque as possible An error will also be generated ...

Page 37: ... Initial set value 50 The proportional gain corrects the output in proportion to the deviation between the target tension val ue and the operating tension value When a large value is set the target tension is reached faster but hunting easily occurs Set a value with which overshoot slightly remains when the target tension is changed The dead zone gain and the dead zone width are not required to be...

Page 38: ...hines with frequent inching operation This function is used to control the loss of tension by machine inching When this input is ON the control output will not be smaller than the stall memory value Use a micro signal switch commensurate with DC8V 4 mAas the input contact Connect the inching signals to the terminal MC5 or MC6 set as follows To set the inching function use the MC5 or MC6 setting sc...

Page 39: ...lus me chanical loss will be generated In the two reel winding operation the system switches between mechanical loss correction torque MLA and MLB If off the mechanical loss cancel value for reel A setting is valid If on the mechanical loss cancel value for reel B setting is valid This setting is recommended in the case of the great mechanical loss in single reel winding To set the mechanical loss...

Page 40: ...acts Connect the cut torque to the terminal MC5 or MC6 set as follows Use the MC5 or MC6 setting screen within SWITCH on the initial setting screen or the engineer screen to set or change the cut torque setting 7 11 Reduction of variation in tension readout To reduce variation in the tension readout select Display filter within Tension on the engineer screen Increase the value to make the response...

Page 41: ...aper ratio setting the setting through the panel or the setting by external analog input whichever is greater takes precedence in shipping setting condition By prohibiting change of the setting value from the panel on the Setting prohibited screen only the external analog input controller installed externally is made valid If prohibited to change setting value from the panel the setting value from...

Page 42: ...This input is valid if it is greater than the taper ratio setting value by the key entry See the notes on the page 37 To change the stall setting value input to the setting by the external analog input use the A12 or A13 setting screen within SWITCH on the initial setting screen or the engineer screen 1 Connection AIC 100kΩ Stall 5V AI2 AI3 2 Setting A 2 S E L E C T A I 2 A N A L O G I N P U T D I...

Page 43: ...detector which is connected directly to the LE 40MTA E The automatic control is carried out using the greater value If Mitsubishi tension detector is not used carry out zero ad justment according to the instruction on page 10 In this case short circuit the terminals GRR and WHR and termi nals GHL and WHL To enter the external tension signal by the external analog input use the A12 or A13 setting s...

Page 44: ...the factory settings use the MEMORY INIT screen within OTHERS on the engineer screen Note that the data having been established will disappear TMO AOC Tension meter recorder Load resistance 1k Ω or more 0 5V 1 Connection 2 Setting T O F L T S E T T M O O U T P U T F I L T E R 1 4 s 1 2 s 1 s 2 s 4 s M C N T A C T S C O N T A C T S M O N I T O R M C 1 M C 2 M C 3 M C 4 M C 5 M C 6 Z T O M N I T O R...

Page 45: ...s turned on DATA ERROR message is displayed Completed is displayed After completion switching items by the or key is not possible W X Turn off the power Remove or replace the memory cassette When executing other operation after completing this process turn on the power supply again Power ON No control output will be generated while the memory cassette is loaded W X ENTER 2 Writing data on cassette...

Page 46: ...limit input of the motor to 0 when the material is cut Erroneous connection of the power terminal Pay attention to the phase order in the motor system al so contact of the DC I O cable with the power cable and short circuit of the output cable may cause serious damage Before turning on the power make sure that the power and ground are connected correctly and that the I O cable is wired correctly N...

Page 47: ... TUNING TARGET WEIGHT IS TOO LIGHT The weight at the span adjustment is too light in 1 3 or less of the tension full scales Make the weight heavy and execute the span adjustment again DETECTED LOAD IS TOO LIGHT The output voltage of the tension detector is too low Because the rated load of the tension detector is larger than that of the drive tension it is necessary to select the tension detector ...

Page 48: ...alts The MC1 input signal may not be turned OFF While the machine is stopped be sure to turn off the MC1 input signal After replacement of the material an extremely high or low tension is applied Check that the output set for the OFF status of the RUN input signal is optimum for the reel diameter of the replaced material Reset the stall memory Fluctuating tension control Check whether similar fluc...

Page 49: ...external wiring or tension de tector is defective Remove the wiring in the tension detector Short circuit the terminals WHR and GRR as well as the terminals WHL and GRL If zero adjustment is not possible still the LE 40MTA E is defective Connect the terminals RED and BLK exclusively to the tension de tec tor If the voltage between the white and green cables in the ten sion detec tor is 120 mVDC 15...

Page 50: ... Stall memory update is stopped OUT remote Control output is ON during ON Cut torque Lower output limit is effective during ON for cutter Each function is assigned by parameter MC6 Output ZT Zero tension detection output Set value 0 1999 N 199 9 kgf Output becomes ON when tension does not exceed set value Output is always OFF when 0 is set However output becomes ON regardless of set value and tens...

Page 51: ... to full scale tension Function is specified by parameter Internal resistance 100kΩ AI3 Output SA Control signal output Powder mode 0 5 VDC AC servo mode 0 5 VDC Load resistance 1 kΩ or more For power amplifier servo amplifier SN NRO New reel preset output Effective exclusively when REELS mode is selected 0 5 VDC Load resistance 1 kΩ or more AOC TMO Tension monitor output Filter can be adjusted by...

Page 52: ...ll preset output 0 5V DC12V 2A Rating 10s Auxiliary powe output Zero tension detection output 50 60 Hz Power supply FG on metal plate The function to be assigned 1 2 is specified by the parameter W u Tensino detector Left Tension detector Right 5V 100KΩ 100KΩ 100KΩ 5V 10KΩ External tension setting 1 1 2 Stall memory reset 2 Gain 1 input Reel exchange Operation stop 1 6KΩ Photo coupler AC100 240V 1...

Page 53: ...o tension detection value Zero tension N N 0 1999 0 c 36 Zero tension 10N 10N 0 199 9 0 0 c 36 Manual setting Manual set value 0 100 c c 18 Taper Linear taper Taper ratio int diameter 0 80 0 c c 31 Taper ratio ext diameter 0 100 0 c c 32 Non linear taper Corner 1 4 mmφ 0 2000 0 c c 33 Taper 1 4 0 100 0 c c 33 Start Stall Stall set value 0 100 20 c c 15 Timer Start timer s 0 0 10 0 4 0 c c 28 Outpu...

Page 54: ...into account Control output 0 100 Reel diameter input min diameter max diameter Set item Description Initial set Memory cassett transfer 1 Setting during operation Mainly refer page Selection item Control while stop timer feed back Fixed feed back c 28 Unit of tension 10N N N c 10 Control reel Unwinding Winding Feed Unwinding c 11 Number of reels One reel Multi reels One reel c 11 Taper control OF...

Page 55: ...z 0 5mm 4 9m s2 maximum 2 hours in each of three axis directions Impact resistance 98m s2 3 times each of three axis directions Supply noise resistance By noise simulator with 1 000 Vp p noise voltage 1 µs noise width and 30 to 100 Hz cycle Withstand voltage 1 500V AC 1 minute Entire terminals as a whole andbetween the ground terminal Insulation resistance 5MΩ or more by 500V DC megger Grounding S...

Page 56: ...t is determined automatically during operation The sliding timer is determined automatically in accordance with the following equation Sliding timer Tension detected during manual operation Target tension for automatic operation full scale tension 25 sec 1 Rough estimate of minimum drive tension 300 200 100 0 0 0 5 1 0 1 5 De and acceleration degree Maximum reel weight W ton Minimum drive tension ...

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Page 58: ...JZ990D30601E TENSION CONTROLLER MODEL LE 40MTA E ...

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