Mitsubishi LE-40MTB-E Instruction Manual
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Mitsubishi LE-40MTB-E Instruction Manual

Mitsubishi LE-40MTB-E Instruction Manual

Tension controller
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TENSION CONTROLLER
LE-40MTB-E
MODEL
INSTRUCTION MANUAL
Introduction:
• This instruction manual describes the minimum necessary operations and functions for the
optimum adjustment of machines by using the LE-40MTB 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 5.00 or later.
Example of "One-reel unwinding powder "
Powder brake
Tension detector
Tension controller
ZJ - 4017F

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Summary of Contents for Mitsubishi LE-40MTB-E

  • Page 1 ZJ - 4017F TENSION CONTROLLER LE-40MTB-E MODEL INSTRUCTION MANUAL Introduction: • This instruction manual describes the minimum necessary operations and functions for the optimum adjustment of machines by using the LE-40MTB tension controller in Sections 1 through 5 taking "One-reel unwinding powder" shown below as an example.
  • Page 3 • We shall not be responsible for any damage caused by repair , disassembly, modification, etc. performed CAUTION by a third party other than MITSUBISHI or a company specified by MITSUBISHI . • The cautions on safety and the specifications described in the instruction manual are subject to change...

  • Page 5: Table Of Contents

    Table of Contents 1. Outline 7. Use of extensive functions Outline of unit -------------------------------- 2 7.1 Control of excessive sag or tension in Panel configuration ------------------------- 3 material during start and stop--------- 26 7.2 Control of excessive sag or tension in material during acceleration and 2.

  • Page 6: Outline

    1. Outline 1.1 Outline of unit The tension controller LE-40MTB-E automatically controls the tension of a long material during unwinding, use of the feed reel and winding, and is used together with the fine displacement tension detector. The applicable actuators are powder clutch/brake, hysteresis clutch/brake, servo motor (torque mode), and air clutch/brake.

  • Page 7: Panel Configuration

    1.2 Panel configuration The figure below shows the configuration of the panel of the tension controller LE-40MTB-E. (1) : POWER switch (11) : Door open screw (2) : Power LED (12) : MANUAL mode switch (3) : Output ON/OFF switch...

  • Page 8: Mounting And Wiring (Basics)

    2. Mounting,connection and wiring 2.1 Caution on mounting DANGER • Never drop cutting chips and wire chips while screw holes are tapped and wiring work is performed. Otherwise, damage, fume, fire, malfunction or others may be caused in the unit. •...

  • Page 9: Wiring

    SA and SN. If it is an electric-pneumatic regulator of 4- 20mA, connect it between terminals EAP and EAN. 5. Connect the Run/stop signals to the terminal MC1. When using other functions, refer to Section 6 and after. LE-40MTB-E Power supply AC100~240V 50~60Hz...

  • Page 10: Operation

    3. Operation 3.1 Setting and change of settings 1. Selection of item on screen When two or more items are displayed on the screen, one of them can be selected using the following pro- cedure. The selected item is marked with " ", and held in the memory even while the power is interrupted.

  • Page 11: Overall Flow Of Screen

    3.2 Overall flow of screen The figure below shows the overall configuration of screen displays. The data can be read in turn using the keys. Four major screens are available. Those are the initial setting screen, operator screen of usual operation, engineer screen for system setting and memory cassette data transfer screen.

  • Page 12: Basics Of Adjustment And Operation

    4. Basics of adjustment and operation 4.1 Adjustment flow for trial operation Carry out the following start-up adjustment as the preparatory step for the automatic operation. Controller Check the driving Controller * Initial setting system in manual installation and * Adjust tension detectors operation mode wiring See pages 8 through 10.
  • Page 13 T L . P A R T S E L E C T R E E L R O L L U N W I N D W I N D F E E D • When using the NRO N U M .

  • Page 14: Adjustment Of Zero And Span For Tension Detector

    4.3 Adjustment of zero and span for tension detector • This is to set the full - scale S C A L E S E T T E N S I O N F U L L S C A L E tension (maximum →...

  • Page 15: Automatic Operation

    4.4 Automatic operation Having completed the steps described up to the preceding pages, the minimum necessary processes shown in (1) and (2) below would be finished as the system controls the tension. (1) Controller installation and wiring (2) Initial setting (zero span adjustment of the tension detectors in particular) Now, check the drive system in manual operation mode in step (3).

  • Page 16: Basic Knowledge For Operation

    5. Basic knowledge for operation 5.1 Entering Run / stop signals (use of MC1) The minimum necessary preparation for tension control is described in "Adjustment flow for trial operation" on page 10. This section explains the use of start/stop (MC1) contacts essential to the step (4) operational check in au- tomatic mode.

  • Page 17: Use Of Stall Setting (Output When Operation Is Stopped)

    5.2 Use of stall setting (output when operation is stopped) Stall output is a constant torque given during the automatic control to the machine while it is stationary. At this stage, the feedback control does not take place. This torque is the initial torque for the machine to start with in the automatic control.
  • Page 18 2. Resetting stall memory value • Two methods are available to reset the stall memory value as follows: Operation input MC1 Stall memory • An output on/off switch is used to re- the stall memory value. Main reel speed • Stall memory reset input MC4 con- tacts are used for reset.

  • Page 19: Calling Up Engineer Screen

    5.3 Calling up engineer screen • Follow this operation to make changes from the state of initial setting. • Enter the password on the password screen. Press the enter key to enter the engineer screen. Reel diameter Complete monitor or tension initial setting monitor screen.

  • Page 20: Display Of Operator Screen

    5.4 Display of operator screen The usual operations (setting operations) are performed on the following screen. Automatic • The bar graph in the upper right corner always Operation Mode selected indicates the detected tension (%). The "100%" indication corresponds to the full -scale tension. Tension set •...
  • Page 21 × • The unit of tension (N or 10N) and the decimal point position are determined by setting the parameter. • The DISPLAY SELECTOR (TENSION /OUTPUT) switches over the tension display and output display. • On the screen of Tension set, Stall set, New reel set, Taper ratio, the internal setting or the external setting which is effective is displayed on the screen.

  • Page 22: Use Of Ac Servo Motor

    Emergency stop : Set the speed limit input to zero. Upper Limit Torque Limit Servo amplifier Upper Limit Speed Limit LE-40MTB-E Torque command Torque input EMG.stop Speed Limit input Normal opelation 2. Setting • For the setting, use the "ACTUATOR" screen within "SWITCH" on the initial setting screen or the engi- neer screen.

  • Page 23: Use Of E/P Regulator

    6.2 Use of E/P regulator When using an air clutch/brake instead of the powder clutch/brake or the hysteresis clutch/brake, the control out- put of 4 to 20 mA (load resistance to be 470Ω or less) can be supplied to the electric-pneumatic regulator. The control output of 0 to 100% at this stage corresponds to 4 to 20 mA.

  • Page 24: Use For Winding Operation

    When the LE-40MD is not used, there will be no functional differences between the selection of “UNWIND” (unwinding) and “WIND”(wining) in the LE-40MTB-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.

  • Page 25: Feed Reel Control

    6.5 Feed reel control The basic settings and connection are the same as those described up to section 5. Items particular to the feed reel control are described below. When using an auxiliary brake/clutch for the feed reel, it is convenient to adjust the output manually using the new reel preset output NRO.

  • Page 26: Simultaneous Multi-Reel Control

    6.6 Simultaneous multi-reel control When controlling multiple reels by the tension detection from one-reel, the basic setting and connection are the same as those described up to section 5. This section therefore describes the connection related only. This example is applicable to : •...

  • Page 27: Powder Unwinding, Two-Reel Switching

    6.7 Powder unwinding, two-reel switching In the two-reel operation, the contacts inter- MC2 input A reel A reel B reel locking with the reel change are connected to Reel exchange MC2. When this contact input changes from ON to OFF or OFF to ON, the control output Preset timer is preset to the new reel preset value.

  • Page 28: Powder Winding, Two-Reel Switching

    6.8 Powder winding, two-reel switching In the two-reel operation, the contacts inter- MC2 input locking with reel change are connected to A reel A reel B reel Reel exchange MC2. When this contact input changes from ON to OFF or OFF to ON, the control output Preset timer is preset to the new reel preset value.

  • Page 29: Servo Winding And Unwinding, Two-Reel Switching

    6.9 Servo winding and unwinding, two-reel switching The control output from the terminal SA is input to the TLAP of the reel A or reel B servo amplifier through the reel change, and controls the servo motor torque. To stop the previous reel, set the speed limit command to 0 and give another torque limit input separately as described on page 18.

  • Page 30: Use Of Extensive Functions

    7. Use of extensive functions 7.1 Control of excessive sag or tension in material during start and stop The following control is possible to limit the tension variation due to material inertia during machine start and stop. 1. Outline • The start timer is used to reduce the tension varia- tion by shock at the time of starting.

  • Page 31: Control Of Excessive Sag Or Tension In Material During Acceleration And Deceleration

    7.2 Control of excessive sag or tension in material during acceleration and deceleration The following control is possible to limit the tension variation by material inertia during abrupt acceleration or deceleration of the machine. 1. Setting Deceleration Acceleration Terminal Stop Time Start/stop Gain 1...

  • Page 32: Control Of Excessive Winding Tension

    7.3 Control of excessive winding tension 1. Outline of taper control Such control as to increase/decrease the working tension, depending on the change in winding diameter is called "Taper tension control", in which the tension is controlled in accordance with the preset pattern, to suit the change in winding diameter.
  • Page 33 Internal reel diameter taper control The figure on the right shows the tension characteris- Taper ratio τ=0% tics in the taper control by calculating internal reel diam- eter. This figure assumes that the actuator torque is proportional to the control output. τ=25% When calculating the internal reel diameter, the calcu- lation is based only on the torque control output.

  • Page 34: External Reel Diameter Taper Control

    7.4 External reel diameter taper control Entering the reel diameter externally results in high precision taper When touch lever is used tension control. Two methods are available to set the taper ratio as follows: Touch lever (1) Setting the taper ratio by pulser dial entry (see page 29). (2) Setting the taper ratio externally through analog voltage.
  • Page 35 3. Linear line taper • When the non-linear taper "LINEAR" is selected, the sys- Setting tension tem enters in the linear line taper mode. The control takes place according to the taper ratio on the panel or to the Portion of taper ratio determined by the external controller, whichev- decrease due er is larger.

  • Page 36: Change Of Control Gains

    7.5 Change of control gains The gains can be adjusted during operation. Adjust the auto-gain in the manual operation or automatic op- eration. To perform fine adjustment, adjust the manual gain. No need to change the gain if the tension is stable.
  • Page 37 1. Manual gain adjustment • When fine adjustment of the gain is required, first set the integral time, then adjust the proportional gain according to the following procedure. • The dead zone gain and dead zone width are not required to be changed in normal cases. However, adjust these values if it takes too long time to reach the target tension when starting the system, switch- ing to a new reel, changing the tension settings.

  • Page 38: Output Of Contact When Running Out Of Material

    7.6 Output of contact when running out of materials This contact output can be used to detect an abnormality There is hysteresis of such as material running out. about 3% of tension The contact output will be turned on when the detected fullscale between ON tension is smaller than the set parameter.

  • Page 39: Externally Turns On Or Off Control Output

    7.8 Externally turns ON or OFF control output Turning ON or OFF this input allows remote control of the control output. This takes precedence over the output on/off switch OUTPUT ON/OFF Switch on the panel. Control output 1. Connection • Use a micro signal switch commensurate with DC8V 4 mA as Photo coupler Out remote the input contacts.

  • Page 40: Use Of Cut Torque

    7.10 Use of cut torque In the automatic paper-jointing control, this func- tion facilitates the material cutting while the cut- Fixed control output ter is in operation by fixing material tension at a (during this period) greater value. When the MC5 or MC6 contact input is ON, the control output is fixed and maintained at a con- Cut torque setting value Cut torque...

  • Page 41: Use Of External Analog Signals

    8. Use of external analog signals When entering settings externally by analog voltage, prohibit the settings change from the panel. This makes the setting value change only by the external analog input (controller installed externally) valid. Notes Regarding the tension setting , stall setting, new reel presetting and taper ratio setting , the setting through the panel or the setting by external analog input , whichever is greater , takes precedence in shipping -setting condition .

  • Page 42: Varies Stall

    8.3 Varies stall 1. Connection • Given 0 to 5V input, the stall setting value becomes 0 to 100% output. Connect this signal to the terminal A12 or A13. • When the stall memory reset input [ MC4 ] is turned ON or the output on/off switch on the panel changes from ON to OFF, this Stall value is preset in the stall memory value.

  • Page 43: Varies New Reel Torque

    40MTB-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.

  • Page 44: Other Functions

    9. Other functions 9.1 Records tension data Corresponding to the tension detection from zero to full scale, 0~5V the output from 0 to 5V is generated. The full scale tension Tension meter is set by the parameter. recorder Load resistance 1.

  • Page 45: Returns All Settings To Initial Factory Settings

    9.3 Returns all settings to the initial factory settings To reset all the settings to the factory settings, use the "MEMORY INIT." screen within "OTHERS" on the engineer screen. Note that the data having been established will disappear. M O R Y I N I T .

  • Page 46: Copies Data Settings To Other Controller

    9.4 Copies data settings to other controller • All the set data saved in the tension controller except the Memory external input from the trimmer or others and internal mon- cassette. itor values can be written, read and compared between the memory cassette FX-EEPROM - 4 (or FX-EEPROM-8).

  • Page 47: Model Le-40Md Reel Diameter Calculation Unit

    9.5 Model LE-40Md reel diameter calculation unit Used with the LE-40MTB-E tension controller, the LE-40MD reel diameter calculation unit enhances the functions during the reel shaft control. The LE-40MD reel diameter calculation unit, using the rate calculation method based on the reel shaft pulse and the measure roll pulse, detects the reel diameter without contacting mechanically.

  • Page 48: Use Of Materials With Different Settings

    9.6 Use of materials with different setting When using materials with different settings, the menu function is recommended to use. Eight data set values can be stored in the memory for the items marked with “MENU #” ( pointed out by * in the figue below ) on the screen.
  • Page 49 3. Menu copy Data can be copied between menu 0 and menu 1 through menu 7. [1] Copy the menu on the “MENU COPY” screen in the “MENU” of the engineer screen. [2] Select the screen to be copied with the keys.

  • Page 50: Execution Of Fx Programmable Controller Link

    • The tension controller LE-40MTB-E can perform the parallel wire link with the Mitsubishi MELSEC-F (FX2N) series programmable controller. • When the tension controller LE-40MTB-E is linked to the programmable controller, the data setting can be performed from the programmable controller to the tension controller,and the control status of the tension controller can be monitored in the programmable controller.
  • Page 51 LE-40MTB-E -485-BD Grounding resistance 100Ω or less 5. Setting To execute parallel link with the LE-40MTB-E, use the " PC-link " screen in " Other " on the engineer screen for setting. Reel diameter Complete monitor or tension initial setting monitor screen.
  • Page 52 • From the LE-40MTB-E to the programmable controller By monitoring the internal contacts M900 to M906 on the programmable controller side, the I /O status of the contacts in the LE-40MTB-E can be monitored. The M907 is used to transfer the data devices.
  • Page 53 Ten points of 16 bits, D490 to D499, can be transferred from the programmable controller to the LE-40MTB-E. It means that when the number of data to be sent to the LE-40MTB-E becomes 11 or more, data transfer is impossible. To solve this problem, a set value No. is assigned to a data device having an even number, and the contents of the data is assigned to a data device having an odd number.
  • Page 54 Set value Variable System Set item setting setting Tension setting Stall value setting Initial diameter setting New reel preset value setting Taper ratio setting Corner 1 setting Taper 1 setting Corner 2 setting Taper 2 setting Corner 3 setting Taper 3 setting Corner 4 setting Taper 4 setting Manual setting...
  • Page 55 Set value Variable System Set item setting setting Memory switch setting 1 BIT0 Unit of tension ( N / ×10N ) BIT1 Control reel ( winding / unwinding ) BIT2 ( intremediate reel / winding reel ) BIT3 Number of reels (multiple reels / one reel ) BIT4 Taper control ( used / unused ) BIT5...
  • Page 56 Set value Variable System Set item setting setting Zero tension setting Maximum diameter setting Minimum diameter setting Reel pulse number REEL.PLS. setting Reel daimeter calculate cycle D CYCLE setting Maximum reel rotation velocity R MAX setting Switch-over menu No. * : ON /OFF = 1 / 0 ** : Valid when the diameter caluculation unit LE-40MD is used.
  • Page 57 7. Example of program After the data processing is completed in the LE-40MTB-E, the X0 is turned on while the M907 is turned off, then all set value are transferred at a time to the temporary buffers for link. After the data processing is completed in the LE-40MTB-E, the X1 is turned on while the M907 is turned off, then the set values other than X1=ON are transferred to the temporary buffers for link.

  • Page 58: Execution Of Cc-Link

    9.8 Execution of CC-Link 1. Outline • When the tension controller LE-40MTB-E is linked to the CC-Link network, the data for the tension con- troller can be set on the master programmable controller and the control status of the tension controller can be monitored on the master programmable controller.
  • Page 59 32CCL. This number can be set to one to four for the FX2N-32CCL. However, the number of data de- vices to be linked to the LE-40MTB-E is limited to ten because of the specifications of the relation with other programmable controller link. Four devices per station can be linked in the FX2N-32CCL, there- fore, set the occupied station number to three when connecting with the LE-40MTB-E.
  • Page 60 Select " CC-Link " 5. Handling the link data • When the link data is written into the LE-40MTB-E, the data whose data are for Menu 0 and for system data ( items marked with in the system column of the table on page 81 and 82 ) exclusively are saved.
  • Page 61 #745(2E9H) in the master unit. • The data is sent to the LE-40MTB-E by writing data in the remote register #0 to #9 of the FX2N-32CCL. Because the LE-40MTB-E can process up to five data ( up to ten devices) at a time, the data should be written in combination with two operations by the two contact devices, such as the numeric data transmission completion flag and receipt completion flag.
  • Page 62 LE-40MTB-E writes the data into the specified setting value. For example, the host number of the FX2N-32CCL is set to 1, the data to the LE-40MTB-E will be writ- ten into the buffer memories #480 (1EOH) to #489(1E9H) of the master unit.
  • Page 63 • From the master programmable controller to LE-40MTB Set value Variable System Set item setting setting Tension setting Stall value setting Initial diameter setting New reel preset value setting Taper ratio setting Corner 1 setting Taper 1 setting Corner 2 setting Taper 2 setting Corner 3 setting Taper 3 setting...
  • Page 64 Set value Variable System Set item setting setting Memory switch setting 1 BIT0 Unit of tension ( N / ×10N ) BIT1 Control reel ( winding / unwinding ) BIT2 ( intremediate reel / winding reel ) BIT3 Number of reels (multiple reels / one reel ) BIT4 Taper control ( used / unused ) BIT5...
  • Page 65 Set value Variable System Set item setting setting Zero tension setting Maximum diameter setting Minimum diameter setting Reel pulse number REEL.PLS. setting Reel daimeter calculate cycle D CYCLE setting Maximum reel rotation velocity R MAX setting Switch-over menu No. * : ON /OFF = 1 / 0 ** : Valid when the diameter caluculation unit LE-40MD is used.
  • Page 66 8. Example of program X0021 M907 CC-Link parameter setting M300 Unit error Unit ready M300 M301 M301 Number of connected device Number of retries Number of automatic return Writing into buffer memory Operation command when CPU goes down (Stop) Writing into buffer memory M301 Station data H1301...
  • Page 67 Start timer setting D306 D307 5.0 s D308 Gain 1 setting 120％ K120 D309 M807 Transmission of numeric data to LE-40MTB-E Numeric data Numeric data transmission completed transmission command M907 H1E0 D300 Writing data device Numeric data Starting data device...

  • Page 68: Inspection And Maintenance

    The actuator capacity is selected based on the line speed multiplied by the operating tension. A larger tension can be set in the LE-40MTB-E. However, in the case, the actuator may be burned out. Make sure that the operator is instructed appropriately as to the allowable maximum operating tension.

  • Page 69: Error Display

    If the output voltage is DC 12V, check the AUX.OUT.IS SHORT load (less 2A or not) and outer wiring. If the output voltage is not obtained, the LE-40MTB-E is defective. Check *2 and *3 of selection When completion of the ini- REEL ERROR item described in page 81.

  • Page 70: Unintended Operation

    • If fluctuations do not occur during manual operation, this is generally caused by high control gain set by the LE-40MTB-E tension controller. In this case, please adjust the control gain factor refer to Sec. 7.5. • Make sure that the OUTPUT ON/OFF switch is turned on.
  • Page 71 0 and the voltage measured when the material tension is set to full scale value is 30mV (150mVDC x 0.2) or more, the LE-40MTB-E is defective . • When the difference in voltage is less than 30mV, the tension load ap-...

  • Page 72: Input And Output Specifications

    11. Specifications 11.1 I / O Specifications Items Terminal Specifications 100 ~ 240V AC +10 ~ –15% 50/60 Hz 400VA Input Power fuse (250V 8A) built in Allowable instantaneous power interruption:10ms S1(+) Auxiliary power supply: 12 VDC, 2 A, Rating: 10 s Power S2(–) supplies...
  • Page 73 Items Terminal Specifications Diameter : Reel diameter signal for external taper control. 0 ~ 5 V corresponding to minimum value to maximum value. Stall : External stall setting signal. 0 ~ 5 V corresponding to 0 ~ 100% output torque. New reel : New reel preset 0 ~ 5 V corresponding to 0 ~ 100% output torque.

  • Page 74: External Connection Diagram

    11.2 I / O interface 250V 8A +10% Power supply for AC100~240V trimmers -15% 50/60 Hz Power supply for Power supply tension detector Class D grounding Shielded cable ( 100 Ω or less ) FG on metal plate DC24V 4A Powder clutch/brake Hysteresis clutch/brake...

  • Page 75: Various Setting Values

    11.3 Various settng values The items indicated with white letters on a black ground must be always set. Another items are set in ac- cordance with the functinon used. Set range Memory *1 Mainly Initial Setting Set items Set values Unit refer during...

  • Page 76: Select Items And Analog Data

    11.4 Selection item and analog data -------- The items cannot set during operation. 1. Selection item Memory *1 Mainly Setting Set item Description Initial set refer during page Menu System operation × Control while stop timer feed back / Fixed feed back ×10N / N ×...

  • Page 77: Outline Dimensions And Environmental Conditions

    11.5 Outside dimensions and general specification 1. Outside dimensions 16.5 LE-40MTB-E TENSION CONTROLLER X10N MONITOR SELECT OUTPUT ON/OFF MODE DISPLAY MENU TENSION AUTO MANUAL SHIFT POWER PAGE MENU6 MENU7 MANUAL ENTER MENU2 MENU3 CURSOR MENU4 MENU5 CANCEL MENU0 MENU1 12 MAX Accessories Weight : Approximately 3.5 kg...

  • Page 78: Supplement

    11.6 Supplement 1. Rough estimate of minimum drive tension The minimum drive tension which can be driven in torque controller can be requested by next outline type. When this is graphed, it is a right picture. De-and acceleration degree ⎯⎯⎯⎯ ≥ 8.5 ( ⎯⎯ ) W + 0.2 f : Minimum drive tension(‚m) w : Maximum reel weight (ton)
  • Page 80 TENSION CONTROLLER LE-40MTB-E MODEL JZ990D30801F...

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