ZJ -4010D

TENSION CONTROLLER

MODEL LD-30FTA
INSTRUCTION MANUAL

LD-30FT
TENSION CONTROLLER
A
設定登録 1 2 3 4 5 6 7 8 SPA
ＭＥＮＵ
φ
%
材料厚
設定切替
THICKNESS
μｍ
PALAM

φ
巻径 出力／ＯＵＴＰＵＴ
%
ＳＥＣ REEL DIA

巻径初期化
Ｄ．ＲＥＳＥＴ 手動／ＭＡＮＵＡＬ 自動／ＡＵＴＯ

張力設定／ＴＥＮＳＩＯＮ ＳＥＴ F
5
ＯＮ

ＯＦＦ ー ＋
0 10
 Cautions on Safety
(Make sure to read this page before using the unit .)

To assure safety When the unit is handled incorrectly , a

DANGER: dangerous situation may occur and the
• Make sure the user thoroughly read this instruction manual possibility of death or serious injury is
before using the unit , and pay attention in assuring safety expected.
while using the unit.

• The unit is manufactured under the severe quality control . CAUTION: When the unit is handled incorrectly , a
When a severe accident or loss is expected in the dangerous situation may occur and the
equipment used due to failure of the unit , provide a backup possibility of medium or slight injury is
function or the fail -safe function in the system . expected or property damage exclusively
is expected.
In this manual , cautions of safety are classified into "DANGER"
and "CAUTION". Even an item is classified as " CAUTION", its contents are
important and it may lead to a serious result depending on the
situation. Make sure to observe every item .

Turn off all the phases of the external power Design the installation plan using the wire
DANGER supply before starting installation and wiring . DANGER size suitable to the current capacity .
Otherwise, electrical shock or damage in the unit may Use the wire size suitable to the current capacity to
occur. Make sure to turn off all the phases of the supply the power to the load . If a wire having smaller
external power supply before starting installation and current capacity is used,the insulation sheath will be
wiring. melted and insulation will become defective . In this
situation, electrical shock or a short-circuit may occur,
and fire may occur .

Perform grounding ( grounding registance

DANGER 100Ω or less).
Set up the emergency stop circuit
DANGER independently of the product .
Otherwise, electrical shock may occur. Perform
grounding ( grounding registance 100Ω or less) to the Otherwise, the unit may become out of order and an
unit using a wire of 2 mm2 or more, otherwise, electrical accident may occur when malfunction occurs in the
shock may occur. Never share the grounding with a tension controller . Make sure to assemble the
strong electric system. emergency stop circuit outside the tension controller .

Never open the covers while the power is

DANGER supplied to the unit or when the unit is DANGER Never use the unit in an atmosphere where
inflammation or explosion can occur .
operating.
Never supply the power to the unit nor operate the unit Otherwise, inflammation or explosion may occur .
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 . Separate the wiring of the strong electric
CAUTION system from the wiring of the weak electric
system.
Separate the wiring of the strong electric system from the
DANGER Never touch a switch with a wet hand . wiring of the weak electric system, and make sure that
noises are not superimposed on the wiring of the weak
Never touch a switch with a wet hand , otherwise, electric system. Otherwise, the unit may not operate
electrical shock may occur. correctly.

Never drop cutting chips and wire chips CAUTION Confirm the ambient enviroments .
DANGER while screw holes are tapped and wiring
work is performed. Never install the unit with an enviroment where dusts , soot,
Damage , fume, fire, malfunction or others may be conductive dusts or corrosive gas is present or a place
caused in the unit . exposed to high temperature , condensation or wind and
rain. Otherwise, the unit may be damaged , malfunction or
be deteriorated .

DANGER Never modify nor disassemble the unit Do not use any unused terminals for any
CAUTION external lines.
Never modify nor disassemble the unit . Otherwise, the
unit may become defective or an accident such as fire , Correctly connect the AC power cable to the specified
damage , etc. may occur. terminal, and do not use any unused terminals for any
external lines. Improper connection may seriously
damage the product .

CAUTION • We shall not be responsible for any damage caused by repair , disassembly, modification, etc. performed
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
without notice .
 Table of Contents
1. Outline
1.1 Functions and features - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2
1.2 Panel Configuration - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4
1.3 DIP switch functions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4
1.4 Operating / Setting Procedure - - - - - - - - - - - - - - - - - - - - - - - 5

2. Installation and Wiring

2.1 Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6
2.2 Mounting the type LD-30FTA-1AD optional card - - - - - - - - - - 7
2.3 Wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7

3. Specifications
3.1 External wiring diagram and terminal arrangement - - - - - - - - 8
3.2 Input/output specifications - - - - - - - - - - - - - - - - - - - - - - - - - - 9
3.3 Environmental specifications - - - - - - - - - - - - - - - - - - - - - - - - 9
3.4 I/O operation(Example of unwinding control) - - - - - - - - - - - - - 10

4. Set Parameters
4.1 Set items and Types - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 11
4.2 Adjustment Procedure- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 12
4.3 Details of set items - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 13

5. Inspection, Trial Run and Adjustment

5.1 Initial Inspection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15
5.2 Parameter Setting- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15
5.3 Trial Run - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15
5.4 Automatic Operation Confirmation - - - - - - - - - - - - - - - - - - - - 15
5.5 Abnormality Inspection - - - - - - - - - - - - - - - - - - - - - - - - - - - - 16
5.6 Maintenance / Inspection- - - - - - - - - - - - - - - - - - - - - - - - - - - 16

6. Setting Examples
6.1 Application example : Proximity switch - - - - - - - - - - - - - - - - - 17
6.2 Application example : Ultrasonic sensor - - - - - - - - - - - - - - - - 18

7. Supplements on Operating Procedure

7.1 Manual torque adjustment and the role of the pulser dial - - - - 19
7.2 Relationship between the tension setting
and the maximum tension - - - - - - - - - - - - - - - - - - - - - - - - - 19
7.3 Role of the keyin inhibit key - - - - - - - - - - - - - - - - - - - - - - - - 19
7.4 How to use the menu selection function- - - - - - - - - - - - - - - - 19
7.5 Flickering of indicator lamps and its meaning - - - - - - - - - - - - 20
7.6 Taper ratio setting and output characteristics - - - - - - - - - - - - 20
7.7 Non-linearity compensation function - - - - - - - - - - - - - - - - - - 20
7.8 Guideline of allowable minimum tension - - - - - - - - - - - - - - - 21
7.9 Major differences from the type LD-FB type
tension control unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 21
7.10 Output remote input and the output ON/OFF key
provided on the panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - 21
7.11 Relationship between the acceleration/deceleration gain
and the winding / unwinding/backward rotation input- - - - - - - 22
7.12 Attachment of the reel diameter input - - - - - - - - - - - - - - - - - 22
7.13 Non-linear compensation number table - - - - - - - - - - - - - - - - 23

1
 1. Outline

1.1 Functions and features

the type LD-30FTA tension control unit is an open loop type semi-automatic tension control unit adopting
the reel diameter calculation control called "integrated thickness detection method".
In the integrated thickness detection method, the initial diameter and the material thickness are preliminarily
set in the control unit, and the current reel diameter is calculated by subtracting (for unwinding) or adding
(for winding) the material thickness multiplied by the number of rotations of the reel bobbin shaft from/to the
initial diameter. (A proximity sensor is provided in the reel shaft so that the number of rotations can be de-
tected.)
The calculation result is used to generate the voltage output of 0 to 24 V for a powder clutch/brake or hys-
teresis clutch/brake functioning as an actuator or generate the command voltage of 0 to 5 V for an amplifier
for a servo motor.

The tension control is possible by an easy adjustment and the operation.

・Automatic control is possible only by the tension setting and setting a thickness of the material and an
initial diameter.
・The input power supply is wide range of 100 to 240VAC.
・A material thickness and an initial diameter can be widely set.
・The reel diameter can be memorized even if the power supply is turned off.
・Many kinds of actuator which is the AC servo etc.

Advanced mode which supports various situations.

・Taper tension control.
・Inertia compensation function at accelerating and decelerating mode.
・Compensation function for non-linear torque of powder clutch/brake.
・Mechanical loss compensation function .

The ease of use was pursued.

・English/Japanese display and pictograph display
・Numeric setting by dial operation
・Advanced/easy mode switch
・Pleasant operativeness by eight kinds of material memories
・The drive constant (thickness of the material, initial diameter, and taper rate, etc.) can be memorized
up to eight kinds.
・Adoption of locking key to prohibit miss-operation prevention and display of invalid function.

Unwinding bobbin

Following switches can be also connected .

Initial diameter preset command
Control output ON/OFF command
Backward rotation/forward rotation status signal
Run/stop signal (advanced function m ode)
Acceleration signal (advanced function mode)
Deceleration signal (advanced function mode)

Proximity Wide range power supply Externally

switch 100 to 240 VAC Series installed switch
Powder
Type LD-30FTA
Tension control unit

Tension setting, initial diameter setting , material thickness setting

2
The ultrasonic sensor and the touch lever can be used.
The use of the ultrasonic sensor and the touch lever becomes possible by installing analog input board
(LD-30FTA-1AD) of the option.
As a result, the operator becomes possible the automatic operative method only because of the tension
setting according to an analog volume.

It is the best for such a control.

・Machine which does not need tension accuracy so much.
・Machine which moves slightly though the material is not heavy.
・Machine without place where tension detector is applied.
・Machine with serious manual adjustment of tension.
・Machine on which cost is not put so much.

Converting machinery
・Print machine and screen printing machine
・Slitting . cutting and laminating machine
・Paste putting machine and coating machine
・Washing machine and drying machine
・Cutting machine and punching machine
・Reel machine and inspection machine
・Wrapping machine and filling machine
・Surface processing machine
・Stranded wire machine
・Textile machine, needlework, and dye machine
・Rolling mill and wire drawing machine

Winding bobbin

Feed roller

Ｓ Feed motor Ultrasonic sensor

Ｍ (or touch lever)

Servo motor
Ｓ
Ｍ
Following parameters can be also set .
Tension setting
•Minimum/maximum winding diameter
•Taper ratio (advanced function mode)
•Five items related to inertia compensation Optional card Servo
(advanced function mode) amplifier
Type LD-30FTA
•Mechanical loss (advanced function mode) Tension control unit
•Weak excitation (advanced function mode)
•Winding shaft pulse (advanced function mode)
•Compensation for non-linear torque
characteristic (advanced function mode)

3
 Panel Configuration
1.2 Panel Configuration
(7)Materal (8)Parameter setting (9)Menu selector keys (11)Output display and
thickness set key selector key and indicator lamp diameter monitor display
(6)Initial (10)Pulse monitor
diameter set key indicator lamp
(5)Material thickness
and parameter item
display TENSION CONTROLLER LD-30FTA
設定登録 1 2 3 4 5 6 7 8 SPA
(4)Reel diameter and ＭＥＮＵ
φ (12)Display selector key
parameter data display 材料厚
設定切替
%

THICKNESS
μｍ
PALAM

φ
(3)Reel diameter %
ＳＥＣ
巻径
REEL DIA
出力／ＯＵＴＰＵＴ

reset key
巻径初期化
Ｄ．ＲＥＳＥＴ 手動／ＭＡＮＵＡＬ
(13)Output ON/ OFF key
自動／ＡＵＴＯ

張力設定／ＴＥＮＳＩＯＮ　ＳＥＴ F
(2)Keyin inhibit key and ＯＮ
5

indicator lamp
ＯＦＦ
0 10
(14)Automatic control mode
keys and indicator lamp

(1)Power switch and (17)Manual control mode (16)Parameter setting

indicator lamp keys and indicator lamp pulser dial (15)Tension set trimmer

1.3 DIP switch functions

When the door on the panel is open, eight-bit DIP switch can be seen on the rear face of the door.
When the power is turned off and turned on again, the setting status of the DIP switch is read.

1 Controlled shaft : Specifies unwindingl or winding.

2 Thickness unit : Specifies 1 µm or 0.1 µm.
3 Diameter analog input : Specifies whether or not a mounted optional card is used.
4 Output remote : Specifies whether or not the output ON/OFF switch is connected ex-
ternally.
5 No function : This switch is not defined yet.
6 Memory initialization : Returns diversified parameter data to the initial values selected when
the tension control unit is shipped.
7 Function mode : Specifies the easy mode or the advanced function mode.
8 Operation mode : Specifies the operation mode or the tunning mode.

1 2 3 4 5 6 7 8
Unwinding ×1 Unused Unused Always Normal Easy Operation

ON

diameter Make sure to turn off the

Controlled Thickness Output No Memory Function Operation
analog power at first, then change
shaft unit remote function initialization mode mode
input the setting.

OFF
Advanced
Winding ×0.1 Used Used Initialization function Tunning
All the bits of the DIP switch are
set to ON when the tension
control unit is shipped from the
works.

4
1.4 Operating / Setting Procedure
Switch manipulation
Normal
operation ・When the power switch 1 is set to ON, the power indicator lamp is lit and the version of the
tension control unit flickers on the monitor display 11 for approximately 2 seconds.
Refer to P.19 ・Every time the output ON/OFF key 13 is pressed, the control output is toggled between ON
and OFF. While the output is set to ON, the output indicator lamp is lit.
When the DIP switch is set so that the remote output can be used, the output can be also set
to ON or OFF by that input.

(Note) Use the Output ON/OFF key 13 or [REM] input without using the
Power switch 1 when the output is turned on and off.
・Allowable power switch life cycles : 20,000 times

Manual control mode

・When the control mode key 17 is pressed, the manual mode is selected and the operation
mode indicator lamp is lit.
In the manual mode, the control output of 0 to the maximum value is generated in accordance
with the setting of the pulser dial 16 , and the control output value is displayed as 0 to 100% on
the manual output display 11 .
Automatic control mode
・When the Automatic control mode key 14 is pressed, the automatic mode is selected and the
operation mode indicator lamp is lit.
In the automatic mode, the tension can be set within the range of 0 to 100% by manipulating
the tension set trimmer 15.
The 100% tension indicates the rated torque of the actuator converted for the reel shaft divided
by a half of the maximum reel diameter (which is the maximum radius) set by the parameter.
Monitor display
・The contents displayed on the monitor display 11 can be changed over by manipulating the
display selector key 12. The selected contents are indicated by the unit indicator lamp (reel
diameter/output).
・The reel shaft pulse monitor indicator lamp 10 flickers by ON/OFF of the proximity switch.
・When the material thickness set key 7 is pressed, the thickness currently set is displayed as
Material a numeric on the material thickness display 5 . (The decimal point position is determined by
thickness the parameter.)
/initial ・When the pulser dial 16 is turned clockwise or counterclockwise, a value displayed is in-
diameter creased or decreased so that the set value of thickness can be changed.
setting ・When the initial diameter set key 6 is pressed, the initial diameter already set is displayed as
Where the reel a numeric on the reel diameter display 4 .
diameter input ・When the pulser dial 16 is turned clockwise or counterclockwise, a value displayed is in-
is not used
Refer to creased or decreased so that the set value of initial diameter can be changed.
P.11~14 ・When the material thickness set key 7 is pressed, the material thickness unit indicator lamp
"μm" flickers. When the initial diameter set key 6 is pressed, the reel diameter unit indicator
lamp "φ" flickers. When the corresponding set key 6 or 11 is pressed, the flickering symbol
stops flickering and is lit.
Where the reel
・When the reel diameter reset key 3 is pressed and held for 1 sec or more, the current diameter
diameter input being calculated is reset to the initial diameter set as described above.
is used ・When the diameter analog input is used, the material thickness and the initial diameter are not
required to be set. They are not displayed, and the key operations related to them are not ac-
cepted. → Refer to p. 15
・When the parameter setting selector (PALAM) key 8 is pressed, the parameter item is dis-
Parameter played on the display in upper left 5 and the parameter data is displayed on the display in
setting lower left 4. (Among the material thickness set key 7 , the initial diameter set key 6 , the pa-
Refer to rameter setting selector key 8 and the manual control key 17 , the one pressed at last becomes
P.11~14 valid, and the contents displayed on the displays 4 , 5 are changed in accordance with the valid
key.)
・Every time the parameter setting selector key 8 is pressed, the parameter items are read and
displayed one by one in turn.
・The set value of the displayed parameter item can be increased or decreased by turning the
pulser dial 16 , and a new value becomes valid.
・When the keyin inhibit key 2 is pressed and held for 5 seconds or more, the keyin inhibit in-
dicator lamp is lit. When the key 3 is pressed and held for 5 seconds or more again, the indi-
cator lamp 4 is extinguished. By setting the keyin inhibit function, display of unused
parameters can be prevented and change of the material thickness and the initial diameter by
mistake during operation can be prohibited.
Menu ・By manipulating the menu selector keys 9 , the menu selection indicator lamp can be changed
selection over from 1 to 8 .
Refer to P.19
・When diversified parameters are set to these menu numbers , the operator can select the op-
eration constant in accordance with the material.
5
 2. Installation and Wiring

2.1 Installation
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.
• Make sure to turn off all the phases of the power supplies outside before starting
installation and wiring.
• Make sure to attach the terminal block cover offered as an accessory to the unit
to prevent electrical shock before supplying the power after the wiring work.

CAUTION • Never install the unit in a place with dusts, soot, conductive dusts or corrosive gas
or a place exposed to high temperature, condensation, wind or rain. Never install
the unit directly in a place in which vibration or impact is applied.
Otherwise, damage, malfunction or deterioration may be caused.

The tension controller can be installed on the floor, wall or panel surface.

TENSION CONTROLLER LD-30FTA

設定登録 1 2 3 4 5 6 7 8
ＭＥＮＵ

φ
%
材料厚
設定切替
THICKNESS
μｍ
PALAM

φ
巻径 出力／ＯＵＴＰＵＴ
%
REEL DIA
168

巻径初期化
Ｄ．ＲＥＳＥＴ 手動／ＭＡＮＵＡＬ 自動／ＡＵＴＯ

張力設定／ＴＥＮＳＩＯＮ ＳＥＴ F
5
ＯＮ

ＯＦＦ

0 10

22 or less
172.5
256
Installed on floor surface Installed on wall surface

Perform pressure
welding from the rear
face with fixing
screws.
Screw hole dimensions when installed on floor or wall Mounting screw
4-M4×12
Screw 4ーM4
80±0.5

＋3
244 ー0.5

Panel cut dimensions when installed on panel

4 or less ※Sheet metal
38.5 or less 140

Installed on panel surface

Perform Class D grounding (100Ω or less ) in either posi-
150±0.5

tion marked with ※ in which the main body mounting plate

is not fixed.

232±0.5

• When installing the tension control unit on the floor surface or wall surface, use the
CAUTION screws offered as accessories to fix the main body and the mounting legs.
Screws whose length is not less than 10 mm cannot be used because such screws
may be in contact inside the main body.
• Perform ClassD grounding ( 100Ω or less )for the casing on sheet metal using a
screw hole on the side on which the main body mounting plate is not fixed.

6
 When the front door is open, the terminal block for exter-
nal connection can be seen inside the box.
Pull out the cables to the outside from the cable outlet
slots provided in the lower portion of the box.
Flat cable

Plate
DIP switch
Terminal cover
2.2 Mounting the type LD-30FTA-1AD Optional card

optional card
(When you used the option function) Lead wire
Plate stud
Terminal block
Make sure to shut down all the phases of the external
power supply.Then, open the front door. Disconnect the Cable outlet slot
flat cable . Remove the plate inside the box (by holding
Connector
the tip of the studs at the four corners and pulling out the
plate). Insert an optional card into the connector. Attach
the plate again.

2.3 Wiring
• Perform the wiring refering to the wiring diagram and terminal arrangement
as shown in Section 3.1.

7 .8 or less
• Use crimp-style terminals whose dimensions are as shown in the figure on
the right.
• The terminal tightening torque shall be 0.5 to 0.8 N•m. Tighten the terminals M3.5

7 .8 or less
securely so that malfunction will not be caused.
• Perform Class D grounding ( 100Ω or less ) 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.

DANGER • Make sure to shut down all the phases of the external power supply. Then, start the
installation/wiring work.
• If all the phases are not shut down, you may get electric shock or the tension control
unit may be damaged.
Perform Class D grounding ( 100Ω or less ) to the ground terminal and the sheet met-
al of the casing of the tension control unit with electric wires of 2mm2 or more. If Class
D grounding ( 100Ω or less ) is not performed, electric shock may be caused.
• When supplying the power to a load, use an electric wire in accordance with the cur-
rent capacity. If the electric wire is thinner than necessity, the insulating sheath may
be melt and imperfect insulation may be caused. As the result, electric shock, short-
circuit or fire may occur.

CAUTION • Connect the AC power supply correctly to specified terminals. Never use unused ter-
minals for the outside.
• If the AC power supply is not correctly connected or unused terminals are used, the
tension control unit may be damaged.
• Separate the strong electric system from the weak electric system. Never perform
common grounding for them. If common grounding is performed, noise may be su-
perimposed on the weak electric system wiring and malfunction may be caused.
• Please do not leave the line in the controller case so much for the malfunction preven-
tion when wiring is too long and tne line is generated too much.
• Please do not birng tne AC power supply cable close to the panel side for the mal-
function prevention.

Note
This product is an electronic equipment in which a micro computer (CPU) is built in. If the CPU has become
out of order caused by insertion of conductive foreign objects or abnormal noise into the main body, the output
of this product is fixed. When disorder of the CPU is caused by noise, the product can be recovered to the
normal status by turning off the power and turning it on again.
7
 3. Specifications

3.1 External wiring diagram and terminal arrangement

250V 8A LD-30FTA
Fuse
5V +5V
L
Power supply AIC
AC100 to 240V
50 / 60Hz 12V +12V
N
SIC
Class D grounding
( 100Ω or less )

Metal plate 1.6kΩ×7

Run / Stop RUN

Out remote REM Control output

PP
for cluch / brake
Reel diameter preset RSD
0.1Ω DC24V 3A or less
PN (load resistance : 8Ω or more )
Acceleratin gain ACC
Backward rotation Control output
BWD TOUT DC 0 to 5V
/ forward rotation +
5 mA or less
Deceleration gain DCC – AOC (load resistance : 1kΩ or more )
MCC

+12V Class D grounding

( 100Ω or less )
Proximity
switch for reel SPA
sensor
12V
SIC
Class D grounding
( 100Ω or less )
Optional card LD-30FTA-1AD
+12V
External winding 100kΩ×3
diameter input AID
A/D conversion of 12 bits
AIC
Class D grounding
( 100Ω or less )

L ・ N ・ ・ ・ PP RUN RSD BWD

・ ・ ・ ・ PN MCC REM ACC DCC

・ +12V SPA +5V ・ ・ TOUT ・ LSA LSB

・ SIC ・ AIC AID ・ AOC ・ LSG ・

Not for use

Input terminals indicated with white letters on a black background

:Valid when the DIP switch is set to select the advanced function mode

Recommended sensors
Proximity switch- - - - - - - - - - - Manufactured by SUNX
Type GX-N12M proximity switch
Type GX-N18M proximity switch
Pptentiometer for touch level - Manufactured by MIDORI SOKKI
Type CPP-45 potentiometer (2kW type
Free rotation type with effective angle of 300 degrees
(Left and right stoppers are not provided.)
Ultrasonic sensor - - - - - - - - - - Manufactured by BAUMER ELECTRIC
Type UNAM30U9103 (maximum detection distance : 100 to 600mm)

8
3.2 Input/output specifications
Items Terminal Specifications
L • 100 to 240 VAC (-15% to +10%) , 50/60 Hz • Power fuse : 250 V, 8 A built in
Input
N • Power consumption: 300 VA (at 24 VDC, 3A)
Power supply

+12V
• Power supply for proximity switch
SIC
DC12V, 100mA or less
+12V
Out pnt • Power supply for analog signal
AIC
+5V
• Power supply for analog signal DC5V,50mA or less
AIC
• Run/stop
RUN ON = Run,
OFF = StopDuring OFF, stop gain operation is performed.
• Output remote (varid when the DIP switch is set to select the output remote )
REM ON = Output generated
OFF = Output stopped
(The output ON/OFF switch provided on the panel is valid.)
• Reel diameter preset (parallel to reel diameter preset switch provided on
RSD the panel )
Contact During ON,the initial diameter is set as the current reel diameter.
input • Acceleration gain
ACC
The acceleration gain is valid while the input is ON. 12V DC,
• Backward rotation / foward rotation 7mA / terminal
Input signals

ON = Backward rotationOFF = Forward rotation

BWD (Addition and subtraction of the reel shaft pulse is changed over.)
The change of this terminal is valid only to the state of RUN=OFF at the
high function mode.
DCC
• Deceleration gain
he deceleration gain is valid while the input is ON.
MCC • Contact input common terminal
Proximity 0.25 msec or more is required respectively for ON width and OFF width.
SPA One rotation of the reel shaft can be set to 1, 2, 4 or 8 pulses by the pa-
switch for
rameter.
reel shaft (valid when the DIP switch is set so that of the diameter analog input is
SIC
sensor not used)
The diameter analog input of 0 to 10 V is supplied from a potentiometer for touch lever or
External AID an ultrasonic sensor to a point between the AID and AIC terminals. Make sure that the
winding variation of the input voltage becomes as large as possible (at least 1 V or more) within
the range of the minimum diameter to the maximum diameter.
diameter However, the input voltage shall be adjusted within the range of 1 to 10 V (from the mini-
input AIC mum diameter to the maximum diameter).
(valid when the DIP switch is set so that the diameter analog input is used)
PP • Control output for brake / clutch
0 to 24 VDC, 3 A or less (load resistance: 8 Ω or more)
PN Applicable to powder type or hysteresis type clutch and brake.
Out put TOUT • Control output
0 to 5 V, 5 mA or less (load resistance: 1 kΩ or more)
Connected to power amplifier or servo amplifier for clutch and brake.
AOC Power amplifier shall be used when the current capacity of the control output of the PP/
PN terminal is insufficient.
• Use a contact input switch suitable to very weak current of 12 VDC, 7 mA.

3.3 Environmental specifications

Ambient temperature • 0 ~ 40°c during operation
Ambient humidity • 35 to 80% RH or less ( no condensation) during operation

Vibration resistance • In accordance with JIS C0040. 10 to 55 Hz, 0.5mm (4. 9m / s2 maximum),
2 hours in each of three axis directions .
Impact resistance • In accordance with JIS C0041. 98m / s2, 3 times in 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 and between the
Insulation resistance • 5MΩ or more by 500V DC megger ground terminal.
Grounding • Class D grounding (100Ωor less)
Operating atmosphere • No corrosive gas, flammable gas, conductive dust and excessive dust.
Power switch cycles • Less than 20,000 times
9
3.4 I/O operation - - - - - Example of unwinding control
( When the DIP switch is set to select the advanced function mode.)

Operation speed
( m/min)

Out remote ON
[REM]
OFF
ON
Run/Stop
[RUN] OFF

Acceleration gain ON
[ACC] OFF

Deceleration gain ON
[DCC] OFF
Winding diameter calculation is
ececuted from ON of RUN
input to timer of stop timer.
Control output
SPT
[PP] (%)
[TOUT] (V)

A1 D2
A2 D1 S2
MSL S1
LSC

Parameters A2/A1 = Acceleration gain

For the setting Can be set within the range of 0.05 to 4.0, but is limited by 100% output.
procedure, refer D2/D1 = Deceleration gain
to p.11 to p.14. Can be set within the range of 0.05 to 4.0, but is limited by 100% output.
S2 = S1 × SPG + SPB
Limited to 100% output or less.
SPG = Stop gain
Can be set within the range of 0.05 to 4.0.
SPB = Stop bias
Can be set within the range of 0 to 50% of the maximum control output.
SPT = Stop timer
Can be set within the range of 0 to 100 sec.
LSC = Little excitation
Can be set within the range of 0 to 50% of the maximum control output.
MLS = Mechanical loss
Used in unwinding, and can be set within the range of 0 to 50% of the max-
imum control output. This set value is always added to the control output.
• When the output remote input is set to ON, the control output is generated. When the output remote input
is set to OFF, the weak excitation output set by the parameter is generated.
• When the RUN input is set to ON in interlocking with start of operation of the machine, winding diameter
calculation is started.
• When the acceleration gain input at the time of start of the machine is set to ON, the control output in ac-
cordance with the acceleration gain set by the parameter is generated. (In unwinding, the setting should
be performed so that the output is decreased.)
• As to deceleration of the machine, when the deceleration gain input is set to ON, the control output in ac-
cordance with the deceleration gain set by the parameter is generated. (In unwinding, the setting should
be performed so that the output is decreased.)
• As to stop of the machine, when the RUN input is set to OFF, the control output in accordance with the
stop gain and the stop bias set by the parameters is generated. When the stop timer reaches timeout, the
control output is returned to a value which was valid immediately before the RUN input was set to OFF.
• The winding diameter is calculated after the RUN input is set to ON until the stop timer reaches timeout.
When the DIP switch is set so that the diameter analog input is used, the winding diameter is not calculated
but the control output in accordance with the signal voltage supplied to the external winding diameter input
terminal is generated. (Controls of other items including the acceleration gain, the deceleration gain and
the stop gain are performed in the same way as described above.)
10
 4. Set Parameters

4.1 Set items and Types

Set item list
Set range Setting
Initial management Item
Set item value Unit No. Function mode
Minimum Maximum Menu System
value value
Tension setting 0 100 - % - - - Easy/advanced function
Material thickness setting 1/0.1 9,999/999.9 50 μm ○ × B Easy/advanced function
Initial diameter setting 1 2,000 500 mm ○ × C Easy/advanced function
Taper ratio setting 0 100 100 % ○ × 1 Advanced function
Stop timer setting 0.0 100.0 0.0 s ○ × 2 Advanced function
Stop gain setting 5 400 100 % ○ × 3 Advanced function
Stop bias setting 0 50 0 % ○ × 4 Advanced function
Deceleration gain setting 5 400 100 % ○ × 5 Advanced function
Acceleration gain setting 5 400 100 % ○ × 6 Advanced function
Mechanical loss setting 0 50 0 % × ○ 7 Advanced function
Little excitation setting 0 50 0 % × ○ 8 Advanced function
Winding shaft pulse
1,2,4,8 1 - × ○ 9 Advanced function
quantity setting
Non-linearity compensation ∗1 0 200 0 - × ○ A Advanced function
Minimum diameter setting ∗2 1 Maximum diameter 100 mm × ○ F Easy/advanced function
Maximum diameter setting Minimum diameter 2,000 500 mm × ○ 0 Easy/advanced function
Note
• An item for which the setting management "menu" column is set to " ○ " is a parameter handled as a setting
registration menu.
• An item for which the setting management "menu" column is set to " × " is not handled as a menu but can be
set in the adjustment mode exclusively. And the settiing value cannot be altered when the [RUN] input termi-
nal is turned ON in advanced mode.
• Parameters whose item No. is 1 to 9 are valid exclusively while the DIP switch is set to select the advanced
function mode.
• Parameters whose item No. is not (B) or (C) are read by the PALAM key. Parameters whose item No. is (B)
or (C) are read by the material thickness set/winding diameter set key.
∗1 • When the non-linearity compensasion is not used, be sure to set to zero.
∗2 • When diameter analog input is no use, Maximum diameter setting Minimum value is 1mmφ”.
Set value types
Batch change by Mode in which setting can
Set value Display/non-display in operation mode
menu changeover be changed
Material thickness/initial
Enabled Adjustment/operation mode Adjustment/operation mode
diameter setting
Menu setting Enabled Items 1 to 6 are set by lock key. Adjustment/operation mode
Setting is enabled in
System setting Disabled Always undisplayed in operation mode.
adjustment mode only.
Note
• When the keyin inhibit function is set to each of the items 1 to 6 of menu setting in the tunning mode, the
corresponding items are not displayed in the operation mode. Accordingly, the set value of such items can-
not be changed in the operation mode.
• In the initial status of the tunning mode, the keyin inhibiit function is set. Upon necessity, press and hold
the keyin inhibit key provided on the panel for 5 sec or more to extinguish the keyin inhibit indicator lamp.
• Each of the items 7 to A, F and 0 of system setting is displayed in the tunning mode exclusively. They can-
not be set in the operation mode.
• The setting of the material thickness and the initial diameter can be changed in both the tunning mode and
the operation mode.
• For the system setting items, the setting value cannot be altered when the [RUN] input termminal is turned
ON in advanced mode.
• As to the material thickness, the initial diameter and an item to which the keyin inhibit function is not set in
the tunning mode, when the keyin inhibit function is set in the operation mode, change of the setting with
the pulser dial are disabled.
• However, the manual output adjustment is valid without regard to the keyin inhibit function setting status.
• Menu selection is disabled while the RUN input terminal is set to ON in the advanced function mode.
In the easy mode,when the keyin inhibit is put in the operation mode, the setting of the thickness of the
material and the initial diameter with the pulser dial and the change of menu can not change.
Selecting an item and changing the setting
Press and hold the key lock key
Material Initial PALAM Manual for 5 sec to set or reset the key
thickness diameter lock function.

The key pressed at last is valid. The PALAM key Change the setting by turning
allows to select an item by repetitious operation. the pulser dial.

11
4.2 Adjustment Procedure
Set the DIP switch to select the adjustment mode. The setting of the DIP switch is read when the power is
Select the simple or advanced function mode. Select set from OFF to ON . For approximately 2 sec after the
use or non-use of the winding diameter input. Then, set power is set to ON, the version of the tension control unit
the power to ON. is displayed on the display in upper right of the panel.

Select the menu No. to be set Select a desired No , using the menu selector keys .

Easy mode Advanced function mode

Diameter analog Diameter analog Diameter analog Diameter analog

input is not used. input is used. input is not used. input is used.

0 :Maximum winding F :Minimum diameter setting 0 :Maximum diameter setting F :Minimum diameter setting
diameter setting
Tension setting monitor Minimum diameter teaching Minimum diameter teaching
0 :Maximum diameter setting 0 :Maximum diameter setting
Maximum diameter teaching Maximum diameter teaching
Tension setting monitor

Tension setting monitor Tension setting monitor

Press the PALAM 1 :Taper setting 1 :Taper setting
key, and select a 2 :Stop timer setting 2 :Stop timer setting
desired item.
3 :Stop gain setting 3 :Stop gain setting
After selecting the
item, set the data by 4 :Stop bias setting 4 :Stop bias setting
turning the pulser 5 :Deceleration gain setting 5 :Deceleration gain setting
dial.
6 :Acceleration gain setting 6 :Acceleration gain setting
7 :Mechanical loss setting 7 :Mechanical loss setting
8 :Little excitation setting 8 :Little excitation setting
9 :Winding shaft pulse
quantity setting
A :Non-linearity A :Non-linearity
compensation setting compensation setting

Material thickness setting Material thickness setting

Initial diameter setting Initial diameter setting

Setting is completed.
When setting/adjustment is finished or many menu items are to be set, change the menu No, and perform the setting
procedure again.

Items to which the key lock function is set in the

adjustment mode are not displayed and their setting
cannot be changed in the operation mode .
Set the power to OFF. Set the DIP switch to select When the key lock function is set in the operation
the operation mode. Set the power to ON. mode , change of the setting of a displayed item and
menu selec tion are prohibited in the simple mode .

Tension setting monitor Tension setting monitor Tension setting monitor Tension setting monitor
1 :Taper setting 1 :Taper setting
Material thickness setting 2 :Stop timer setting 2 :Stop timer setting
Initial diameter setting 3 :Stop gain setting 3 :Stop gain setting
4 :Stop bias setting 4 :Stop bias setting
5 :Deceleration gain setting 5 :Deceleration gain setting
6 :Acceleration gain setting 6 :Acceleration gain setting

For the teaching procedure when the winding Material thickness setting
diameter input is used , refer to p . 14. Initial diameter setting

12
 Operating / Setting Procedure
4.3 Details of set items
• Material thickness setting
When the material thickness key is pressed, its set value is displayed.
The unit of the material thickness setting is changed over between 1 Éþm and 0.1 Éþm in
accordance with the setting of the DIP switch. The decimal point is displayed on the 7-seg-
When the reel ment display for the material thickness setting. When the material thickness setting is
diameter input is changed while the reel diameter is being calculated, the reel diameter calculation is
changed in proportion to the material thickness.
used, refer to p. 14.
By this function, in the material thickness setting, the calculated reel diameter and the actual
reel diameter can be aligned with each other. When many materials are wound in one layer
as in a wire material, the setting shall be in accordance with the following formula.
Material thickness set value = (Thickness of one layer/Number of turns of one layer)

• Initial diameter setting

φ When the winding diameter key is pressed, its set value is displayed.
After the material has been changed, after the reel diameter reset key is pressed
and held for 1 sec or more or while the [RSD] terminal input remains ON, the initial
diameter setting is valid. The initial diameter setting is regarded as the diameter at
start of the reel diameter calculation (preset value for winding diameter calculation).

Every time the PALAM key is pressed, the items are displayed one by one in turn as shown
PALAM. below.
Display symbols are represented in simplified alphabets as shown below.

• Tension setting monitor . . . TNS.P (TeNsion Set. Present)

Monitors the tension set value, and displays the percentage set by the tension set trimmer.
This item is displayed before the taper setting.

1. Taper setting . . . TAP (TAPer)

Calculates the taper ratio in the advanced function mode while regarding the setting 100% as
the constant tension operation.
The taper control is same both in unwinding and winding. Reverse taper calculation for un-
winding is not performed. Same control pattern is used both in the unwinding control mode
and the winding control mode.
Taper ratio = 100 - (100 - taper set value %)Å~ (Current winding diameter/Maximum winding
diameter)

2. Stop timer setting - - -SPT (StoP Timer)

Sets the inertia compensation timer for stop in the advanced function mode.
After the RUN contact input is set from ON to OFF, the stop gain and the stop bias are valid
for the control output for the period set here.

3. Stop gain setting - - - -SPG (StoP Gain)

Sets the inertia compensation which determines the control output magnification ratio while
the stop timer is available in the advanced function mode.
The gain can be set within the range of 5 to 400% so that a same value can be used both in
unwinding and winding.

4. Stop bias setting - - -SPB (StoP Bias)

Determines the bias for the control output while the stop timer is available in the advanced
function mode.
Set the stop bias when the tension of the material is fluctuated caused by the mechanical in-
ertia while the reel diameter is small and the control output is also small.

5. Deceleration gain setting - - - - DEG (DEceleration Gain)

Sets the inertia compensation which determines the gain for the control output while the DCC
contact input is ON in the advanced function mode. The set range is 5 to 400%.

6. Acceleration gain setting - - - - ACG (ACceleration Gain)

Sets the inertia compensation which determines the gain for the control output while the ACC
contact input is ON in the advanced function mode. The set range is 5 to 400%.

7. Mechanical loss setting - - - - - MLS (Mechanical LoSs)

Sets the mechanical loss bias for the control output used in winding control. The set range is
0 to 50%.

13
 Details of set item
8. Little excitation current setting - - LSC (Low Supply Current)
Is valid in the advanced function mode exclusively and set so that the output does not become
0 and the little excitation current is applied in a powder clutch/brake even if the control output
is set to OFF by the ON/OFF switch or the output remote.
Adjust the little excitation current so that the reel shaft is rotated even when the material is re-
moved.

9. Reel shaft pulse quantity setting - - - PLS (reel shaft PuLSe)

Is set so that the reel shaft pulse per rotation of the reel shaft increases and the control output
is not drastically changed by input of the reel shaft pulse while the material is thick in the ad-
vanced function mode.
Set a larger value as the material is thicker.

A. Non-linearity compensation setting

- - -TNC (Torque Non-linear Compensation)
The non-linear torque characteristics for the impressed voltage of powder clutch and brake as
well as hysteresis clutch and brake is corrected.
The compensation numbers for the powder clutch and brake as well as hysteresis clutch and
brake, which are used in accordance with the table shown in Page 24, are set.
When the non-linearity compensation is not used, be sure to set to zero.

F. Minimum diameter setting - - - DMI (Diameter MInimum)

Displays the minimum diameter teaching data when the reel diameter is entered from the ex-
ternal analog input.
This item is displayed exclusively when the analog input is selected by the DIP switch.
When a value is set to this item, the analog voltage is entered and the teaching operation is
performed, the minimum reel diameter is automatically recognized.
Though the relationship between the voltage and the reel diameter is reverse each other be-
tween the touch arm and the ultrasonic sensor, the internal diameter calculation is automati-
cally changed based on evaluation of the maximum diameter teaching voltage.

0. Maximum diameter setting - - - DMA (Diameter MAximum)

Sets the maximum diameter of the machine.
All tension control calculations are performed based on a value set here.
When the tension set trimmer is set to the maximum value and the taper ratio is set to 100%,
the control output is regarded as 100% (24 V).

4.4 Teaching when the diameter analog input is used

[1] Turn off the power. Set the DIP switch to select the tunning mode. Turn on the power.
[2] When the PALAM key is pressed, the minimum diameter is displayed on the display in upper left
on the panel.
[3] By turning the pulser dial, adjust the value on the display in lower left so that it becomes the min-
imum diameter.
[4]Place the touch lever in the minimum diameter position. Or face the reel bobbin of the minimum
diameter against the ultrasonic sensor.
[5] Press and hold the reel diameter reset key on the panel.
[6] When the PALAM key is pressed again, the maximum diameter is displayed on the display in up-
per left on the panel.
[7] By turning the pulser dial, adjust the value on the display in lower left so that it becomes the max-
imum diameter.
[8] Place the touch lever in the maximum diameter position. Or face the reel bobbin of the maximum
diameter against the ultrasonic sensor.
[9] Press and hold the reel diameter reset key on the panel .

Now, teaching is completed. Example of characteristics

7.0V between the input voltage
The figure on the left shows an example of characteristics be- and the winding diameter
tween the input voltage and the reel diameter in which the di-
ameter analog input voltage is 7.0 V at the minimum diameter
100 and the diameter analog input voltage is 2.0 V at the max-
imum diameter 500.
The tension control unit saves the characteristics entered by 2.0V
teaching, calculates the reel diameter in accordance with the
actual input voltage, and generates the control output in accor- Minimum Maximum
dance with the calculated reel diameter. diameter 100 φ diameter 500 φ

14
 5. Inspection, Trial Run and Adjustment
5.1 Initial Inspection - - - - Power = OFF
1. Confirming the selection
• Before starting operation, make sure that a tension control unit, an actuator and sensors are correctly
selected. The output current of the type LD-30FTA tension control unit is 24 VDC, 3 A or less. If clutch-
es/brakes to be used exceed this output current, use power amplifies together.
• The capacity of an actuator is selected based on the production line speed multiplied by the operation
tension. A tension beyond this capacity can be set in a tension control unit. In such a case, however,
the actuator may be burned out.
Make sure that the operator understands the available upper limit tension determined based on the
heat capacity of the actuator.
• If the tension is too Low, operation becomes unstable when the machine is started up or stopped. De-
termine an appropriate lower limit, and let the operator understand it.

2. Operation sequence
• Check the operation sequence and the emergency stop sequence.
Especially, when a servo motor is used as an actuator, the motor may become out of order if the ma-
terial is cut. When the material is cut, set the speed limit input for the motor to 0.

3. Checking the wiring

• Erroneous connection of the power terminal (confusion of phases also in a motor), contact of the DC I/
O cables and the power cable, short-circuit in the output cable may cause serious damages.
Before turning on the power, make sure that the power supply is correctly connected, that grounding is
correctly performed and that the I/O cables are correctly wired.
• Never perform the megger test (measurement of insulation resistance).

4. Setting the inside of the tension control unit

• Set the seven-bit DIP switch provided on the rear face of the panel. Set the operation mode to the
tunning mode.

5.2 Parameter Setting - - - Tension control unit power=ON

Set the parameters using the procedures described in p. 12 to p. 15.
Even if the easy mode is selected, make sure to set the maximum reel diameter when the diameter an-
alog input is not used.
When the diameter analog input is used, set the maximum diameter, set the minimum diameter and per-
form teaching.

5.3 Trial Run - - - - - - -All power=ON

Set the tension control unit to the manual mode. Give an appropriate output. Make sure that mechanical
operations are normal including the rotation direction of a motor. Especially, when a servo motor is used,
make sure preliminarily that the parameters of the servo amplifier are set appropriately.
(Set the servo loop type to the torque mode, and specify the regenerative option. Make sure that the
rated torque is achieved when a 5 V command is given.)

5.4 Automatic Operation Confirmation - - -All power=ON

Automatic Operation ConfirmationAll power = ON
Turn off the power of the tension control unit. Set the DIP switch to select the opelation mode. Turn on
the power. Perform automatic operation using the procedure described in p. 5 .
When the diameter analog input is not used, change the setting of the material thickness and the initial
diameter using the procedure described in p. 5 .
To prevent miss operation during operation, use the keyin inhibit key.
Make sure to select a menu while the machine is stopped. (In the advanced function mode, changeover
of the menu is disabled while the RUN terminal input is ON.)

15
5.5 Abnormality Inspection
Check abnormality of the tension control unit during trial run and adjustment or during actual operation in
accordance with the table shown below.
Item Phenomenon Countermeasures
1. Check whether the supply voltage between the L and N terminals
The power indicator lamp is 100 to 240 VAC (-15 to +10%), 50/60 Hz. If this voltage is not
given, correct the wiring.
is not lit even if the power
2. A fuse may be melted down caused by insertion of foreign
switch is set to ON. objects or abnormal load.Even if a melted fuse is replaced, the
tension control unit may not be recovered to the normal status.
1. When control output is not generated even if the output ON/OFF
Short-circuit of key provided on the panel is manipulated, check whether the
load related to clutch/brake model is appropriate (The rated current should be 3
power supply A or less.), whether the clutch/brake is correctly connected and
The control output is not whether short circuit has not occurred.
generated even if the 2. When short-circuit has occurred in the load, remove the cause,
pulser dial is turned in turn off the power for several minutes, and turn on the power
the manual mode. again. Then, the tension control unit will be recovered to the
normal status.
3. When the TOUT/AOC terminal is used, make sure that the load
resistance is 1kΩ or more.
Sufficient control output
If the maximum reel diameter parameter is not set appropriately,
is not generated in the
sufficient output cannot be obtained.
automatic mode.
1. When the diameter analog input is not used
Observe the reel shaft pulse monitor, and check whether the reel
shaft pulse is entered. If the pulse is not generated, check
whether an appropriate proximity switch is used, whether the
proximity switch is correctly wired and whether the ON duration
and the OFF duration are appropriate.Make sure that the voltage
of the reel shaft pulse between the input terminals SPA and SIC
Abnormal opera- is 1 V or less while the input is set to ON and 9 V or more while
tion in automatic Appropriate control out- the input is set to OFF.
mode put is not generated in
accordance with change 2. When the winding diameter input is used
in the winding diameter. Check whether the minimum diameter and the maximum diame-
ter are set appropriately and whether teaching has been per-
formed. Check whether change in the voltage between the input
terminals AID and AIC is appropriate against change from the
minimum diameter to the maximum diameter.Inside the tension
control unit, an analog value of 0 to 10 V is handled as a digital
value of 0 to 4095 steps. For example, when the variation of the
input voltage against change from the minimum diameter to the
maximum diameter is 1 V, the resolution becomes 409 steps.

5.6 Maintenance / Inspection

Consumable parts which may reduce the service life are not built in the type LD-30FTA tension control unit.
However, check the following items as periodical inspection.
• Make sure that the temperature inside the panel is not abnormally high caused by a heating
• body or direct sunlight.
• Make sure that powder dusts and conductive dusts are not present inside the panel.
• Make sure that abnormality in the wiring, loose terminals and other abnormalities are not detected.

DANGER • Provide the emergency stop circuit for the machine outside the tension control
unit.
If it is built in the tension control unit, the machine may become out of order and
accidents may be caused when malfunction occurs in the tension control unit.

CAUTION • Never manipulate switches and keys with wet hand. If you touch them with wet
hand, you may get electric shock.
• Never supply the power to or operate the tension control unit while the main body
door, the terminal cover, etc. are open. If the high voltage portion is exposed, you
may get electric shock.

16
 6. Setting Examples

6.1 Application example : Proximity switch

This is an example of intermittent feeding with which feeding of the material is paused and punching is per-
formed. Though it is intermittent feeding, the winding motor is continuously rotating and the clutch is con-
tinuously slipping and applying tension.
Line speed : V=6m / min
reel diameter :D=φ 92→φ 500
Feed roll
Tension : F=50~100N
Punching Number of times of
unit
intermittent feeding : 10 times/min
Material : Paper (thickness = 200 µm)

Proximity
switch
Other applications
• Hot stamping
• Screen printer

Powder clutch
ZKB-2.5BN
Geared motor
GM-H0.2KW1/60 Tension control unit
LD-30FTA

Use example of a proximity switch (simple mode)

When the winding diameter is changed from 92 to 500 and the material thickness remains 200 φm in the example above.

Setting of the DIP switch (This step is required only at the time of initial startup,
and is not required during normal operation.)
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
ON Unwinding ×1 Unused Unused Always Normal Easy Operation ON Unwinding ×1 Unused Unused Always Normal Easy Operation

Memory Memory
DIP Controlled Thickness Winding Output No Function Operation DIP Controlled Thickness Winding Output No Function Operation
diameter initiali diameter initiali
switch shaft unit remote function mode mode switch shaft unit
input remote function mode mode
input zation zation

OFF Winding ×0.1 Used Used Initialization Advanced Tunning OFF Winding ×0.1 Used Used Initialization Advanced
function Tunning
function

(Initial value setting ) Set the eighth (operation mode) DIP switches
to "RUN" when you drive.

Maximum diameter setting

• Maximum
(This step is required only at the time of initial startup, and is not required during diameter display
normal operation.)
• Select the maximum reel diameter using the initial diameter set key, and enter
φ500 by turning the pulser dial. µm
• Change the operation mode of the DIP switch to "run", and turn on the power again. • Winding
diameter display

Setting procedure (This step is required only when the material is changed.) • Material
• Press the material thickness set key, and set the material thickness to 200µm thickness display
by turning the pulser dial.
• Press the initial diameter set key, and set the reel diameter to φ92 by turning
the pulser dial. φ
• Press the reel diameter reset key.
• Winding
diameter display

φ
Trial run (This step is required only at the initial startup, and is not required during easy operation.)
• Press the manual control mode key, and set the output ON/OFF switch to ON.
• Check diversified functions such as the motor and the sequence.
Automatic operation
• Press the automatic control mode key (only when the manual mode is selected).
• Adjust the tension to an appropriate value by turning the tension set trimmer.

17
6.2 Application example : Ultrasonic sensor
Electric wire not processed by the sheathing unit yet is unwound while such a tension as not to slack the
electric wire is applied.
Because the open loop control is performed, hunting does not occur in the traverse direction.
Because an ultrasonic sensor detects the reel diameter, the initial diameter and the wire diameter are not
required to be set.

to the next process

Ultrasonic
sensor
Sheathing unit

Line speed : V=30→50m / min

Winding diameter :D= φ300→φ80
Tension : F=20~50N
Hysteresis brake Material : Electric wirer (diameter = 1.2)
ZHY-40A

Other applications
Sheet cutter which is often started up and stopped
Tension control unit
＋ Analog input board
LD-30FTA LD-30FTA-1AD

Use example of an ultrasonic sensor (simple mode) (equivalent for a touch lever)
When the reel diameter is changed from 300 to 80 in the example above

Setting of the DIP switch (This step is required only at the time of initial startup, and
is not required during normal operation.)
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
ON Unwinding ×1 Unused Unused Always Normal Easy Operation ON Unwinding ×1 Unused Unused Always Normal Easy Operation

Memory Memory
DIP Controlled Thickness Winding Output No Function Operation DIP Controlled Thickness Winding Output No Function Operation
diameter initiali diameter initiali
switch shaft unit remote function mode mode switch shaft unit remote function mode mode
input zation input zation

Advanced
OFF Winding ×0.1 Used Used Initialization function Tunning OFF Winding ×0.1 Used Used Initialization Advanced
function Tunning

(Initial value setting ) Set the eighth (operation mode) DIP switches
to "RUN" when you drive.

Teaching procedure
(This step is required only at the time of initial • Minimum
startup, and is not required during normal op- diameter display
eration.)
• Set the minimum diameter (φ80) by turning µm
the pulser dial. Set the reel bobbin of the
minimum diameter. Press the reel diameter
reset key. φ
Winding bobbin

• Select the maximum reel diameter using the • Maximum Ultrasonic

diameter display sensor
PALAM key, set the maximum diameter
(φ300) by turning the pulser dial. Set the reel
bobbin of the maximum diameter. Press the µm
reel diameter reset key. In the case of
maximum diameter

• Set the operation mode of the DIP switch to φ In the case of

minimum diameter

"run", and turn on the power again.

Manual operation (This step is required only at the initial startup, and is not required during normal op-
eration.)
• Press the manual control mode key, and set the output ON/OFF switch to ON.
• Check diversified functions such as the motor and the sequence.

Automatic operation
• Press the automatic control mode key (only when the manual mode is selected).
• Adjust the tension to an appropriate value by turning the tension set trimmer.
18
 7. Supplements on Operating Procedure

7.1 Manual torque adjustment and the role of the pulser dial
Power switch 1 is set to ON. → Power indicator lamp is lit. Manual control mode key 17 is pressed. → Manual
operation mode indicator lamp is lit.
Output ON/OFF key 13 is pressed. → Output indicator lamp is lit. Display selector key 8 is pressed. → Unit
indicator lamp " % " is lit.
When the manual control mode is selected, the manual control
100% output value just before becomes valid and is displayed on the
monitor display 11.
Counterclockwise When the pulser dial 16 is turned clockwise or counterclockwise
rotation in this status, the control output is increased or decreased. After
Control the control mode is changed over from manual to automatic, the
output output is gradually shifted to the output in accordance with the
Clockwise
rotation winding diameter.
Current value All other diversified set data is saved in the memory inside the
tension control unit.
When this data is read and displayed, then adjusted (increased
Pulser dial or decreased) using the pulser dial, the adjusted result is saved
as the latest data.
7.2 Relationship between the tension setting and the maximum tension
Power switch 1 is set to ON. → Power indicator lamp is lit. Automatic control mode key 14 is pressed. → Auto-
matic operation mode indicator lamp is lit.
Output ON/OFF key 13 is pressed. → Output indicator lamp is lit.( PALAM key 8 is pressed. → Set value
is displayed on display 4 in lower left.)
The set tension is changed within the range of 0 to 100% in accor-
100% dance with the setting of the scales 0 to 10 of the tension set trim-
mer 15.
Operation tension F% When the scale of the tension set trimmer 15 is required to be
read correctly, press the PALAM key 8. Then, the set value is dis-
played as 0 to 100% on the display in lower left on the panel.
The 100% tension indicates the rated torque of the actuator divid-
ed by the maximum radius of the reel bobbin.
However, if a speed reducer is provided between the reel bobbin
and the actuator, the 100% tension shall be the rated torque con-
verted for the reel shaft.
0 Tension set scale 10 The maximum radius shall be the maximum reel diameter set by
the parameter divided by 2.
7.3 Role of the keyin inhibit key
Tunning mode
• While the DIP switch is set to select the tunning mode, all the parameters can be adjusted without re-
gard to the setting status of the keyin inhibit function. However, parameters to which the keyin inhibit
function is set in the adjustment mode cannot be displayed or set when the DIP switch is switched over
to the operation mode.
• For example, if the keyin inhibit function is set to all the parameters in the tunning mode, the material
thickness setting, the reel diameter setting and the tension setting exclusively are valid in the operation
mode. (The system parameters can be set in the tunning mode exclusively without regard to the set-
ting status of the keyin inhibit function.)
• Parameters to which the keyin inhibit function can be set.
Taper ratio, stop timer, stop gain, stop bias, deceleration gain and acceleration gain.
Operation mode
• When the keyin inhibit function is set in the operation mode, items for which change of the setting was valid
become invalid with regard to change of the setting, and do not accept manipulation of the pulser dial. Such
items do not accept the menu selection key either in the easy mode. (Manual control is valid.)
• The reel diameter reset key is valid without regard to the setting status of the keyin inhibit function. It
is actuated when it is pressed and held for 1 sec or more.
In the advanced function mode, however, menu selection is not accepted while the machine is operating.
7.4 How to use the menu selection function
When eight types of menus are preliminarily registered by combining diversified parameters, the operator
can perform optimal operation using diversified operation constants only by selecting a registered menu.
The following parameters can be registered for these menus.
In the easy mode : Material thickness and initial diameter
In the advanced function mode : Material thickness, initial diameter, taper ratio, stop timer, stop gain,
stop bias, deceleration gain and acceleration gain
The parameters marked with underline are changed by the menu selection even if displayed at the op-
eration mode.
Menu can be changed at either sasy mode or advanced function mode during control output is off.

19
7.5 Flickering of indicator lamps and its meaning
• When the material thickness set key is pressed and the material thickness can be set using the pulser dial,
the unit indicator lamp µm flickers. It is lit when the initial diameter set key is pressed and the initial di-
ameter unit lamp φflickers when the PALAM key is pressed.
• When the initial diameter set key is pressed and the initial diameter can be set using the pulser dial, the
unit indicator lamp É” flickers. It is lit when the material thickness set key is pressed and the material thick-
ness uni lamp µm flickers when the PALAM key is pressed.
• When the material thickness set key, the initial diameter set key or the PALAM key is pressed in the manual
control mode, the manual operation mode indicator lamp flickers. At this time, the manual output is fixed
to a value just before, and parameters can be set based on each set key using the pulse dial. When the
manual control key is pressed again, the manual operation mode indicator lamp is lit and the manual out-
put can be adjusted using the pulser dial.
• In the automatic control mode, the automatic operation indicator lamp is lit.
In the advanced function mode, however, the automatic operation indicator lamp is lit while the RUN input
is ON or flickers while the RUN input is OFF.
While the stop timer is operating, the automatic operation indicator lamp is temporarily extinguished.
• Immediately after the power is turned on, the version flickers.
• When the calculated reel diameter is 2,000 mm or more, φ2000 flickers as the reel diameter. When the
calculated reel diameter is less than 0 mm, "-0.0.0." flickers as the reel diameter.
• While the control output is OFF, " OFF " flickers. While the weak excitation output is generated, a value
flickers on the monitor display.

7.6 Taper ratio setting and output characteristics

Turn off the power, and set the DIP switch to select the advanced function mode. Turn on the power, then
set the taper ratio.
Automatic control mode key 14 is pressed → Automatic operation mode indicator lamp is lit.
Output ON/OFF key 13 is pressed → Output indicator lamp is lit. Tension is set using tension set trimmer
15. → F% on previous page.
When the taper ratio is set to 100%, the con-
F% Taper ratio setting =100 % stant tension operation is performed.
As the taper ratio is decreased, the tension at
Taper ratio setting = 80%
the maximum reel diameter is also decreased
Taper ratio setting = 60% in accordance with the taper ratio.
Operation
tension Taper ratio setting = 40% Note that an ideal control shown in the figure on
Taper ratio the left is not performed because the relation-
setting=0% Taper ratio setting = 20%
ship between the control output and the actua-
tor torque is nonlinear when a clutch brake is
Winding
diameter 0
Minimum
winding diameter
Maximum
winding diameter used as an actuator.

7.7 Non-linearity compensation function

• The nonlinear torque characteristics for the impressed voltage of powder clutch and brake as well as hys-
teresis clutch and brake is compensated.
• The compensation numbers for the powder clutch and brake as well as hysteresis clutch and brake, which
are used in accordance with the table shown in Page 23, are set.
• The control output after compensation is made after nonlinear compensation for the signal which is in pro-
portion of the reel diameter. (The control output is not in proportion of the reel diameter any more.)
• In the manual control mode, nonlinear compensation function is not operated.

20
7.8 Guideline of allowable minimum tension
The allowable minimum tension with which opera- α: Acceleration /deceleration
tion is possible in the torque tension control unit Minimum operation tension
( m/ min/s)

can be obtained using the following simplified for- 500

mula. 450
α=30
Fmin / (W+0.2) ≥ 0.85α 400

Minimum operation tension (N)

α=25
350
Fmin : Minimum operation tension (kgf)
W : Fully wound reel bobbin weight (ton) 300
α=20
α : Acceleration/deceleration (m/min/s) 250
α=15
The graph on the left represents this formula. 200

150 α=10
If the machine is operated with a tension less than
100
the minimum tension, stable operation cannot be
assured when the machine is accelerated or de- 50
celerated.
0
0.0 0.5 1.0 1.5
Fully wound winding bobbin weight (×10 3kg)

7.9 Major differences from the type LD-FB type tension control unit
The table below shows major differences between the conventional type LD-FB tension control unit and the
type LD-30FTA tension control unit. The type LD-30FTA can be used as a succeeding model of the type
LD-FB tension control unit.
Type LD-FB tension control unit Type LD-30FTA tension control unit
Power supply 100/110 VAC dedicated, uninsulated output 100 to 240 VAC system, insulated output
Output DC24V 3.6A DC24V 3.0A
capacity
Winding Integrated thickness method based on reel Integrated thickness method based on reel shaft
diameter shaft pulse (1rotation = 1 pulse) Initial diameter pulse (1rotation = 1, 2, 4 or 8 pulses) When an
calculation and material thickness are set by digital optional card is mounted, reel diameter can be
method switches on panel. entered.
Inertia
compensation Acceleration gain and deceleration gain are set Acceleration gain, deceleration gain, stop gain, stop
control by externally installed trimmer. bias and stop timer are set by parameters.
Little excitation output, mechanical loss correction
Other functions and taper ratio are set. Material thickness unit is
changed over.

7.10 Output remote input and the output ON/OFF key provided on the panel
When this input is turned on/off, the remote function of control output is turned on/off.
This input has the priority over the OUTPUT ON/OFF switch provided on the panel.

REM OFF ON OFF

OUTPUT
ON/OFF Switch

Control output

(Note) Use the Output ON/OFF key 13 or [REM] input without using
the Power switch 1 when the output is turned on and off.
• Allowable power switch life cycles : 20,000 times

21
7.11 Relationship between the acceleration/deceleration gain and the
winding / unwinding/backward rotation input
• The acceleration gain and the deceleration gain can be set respectively to 5 to 400% of the current output.
To activate such gains, the ACC terminal (for the acceleration gain) and the DCC terminal (for the decel-
eration gain) are set to ON.

• In unwinding control, it is ideal to decrease the control output when the machine is started up and increase
the control output when the machine is stopped.
In winding control, it is normal to increase the control output when the machine is started up and decrease
the control output when the machine is stopped.

• Use any combination in accordance with your application without sticking to terms "acceleration" and "de-
celeration".
When the operation direction is reversed and the backward rotation/forward rotation is given, arithmetic
operation for pulses is automatically changed over between addition and subtraction.
However, as to the acceleration gain and the deceleration gain, change them over using an external se-
quence and set an appropriate control input ACC (or DCC) side to ON.

7.12 Attachment of the reel diameter input

In the case of ultrasonic sensor In the case of touch lever
Ultrasonic Touch lever
sensor

Potentiometer

Maximum Backlash
winding diameter
Reel bobbin Reel bobbin
Minimum
winding diameter
Install the ultrasonic sensor to that the dis- Install the touch lever so that the operation an-
tance detected by the ultrasonic sensor is in gle of the potentiometer becomes as large as
accordance with the sensor model, and be- possible.
comes maximum when the reel diameter is If the touch lever is vibrated caused by eccen-
minimum. tricity of the reel bobbin, provide a backlash
between the touch lever and the potentiome-
ter drive shaft so that minute motions of the
potentiometer are not repeated.

22
7.13 Non-linear compensation number table
Powder clutch Powder brake
Type name No. Type name No.
ZKG-5AN 101 ZKG-5YN 51
ZKG-10AN 102 ZKG-10YN 52
ZKG-20AN 103 ZKG-20YN 53
ZKG-50AN 104 Self-cooling ZKG-50YN 54
Self-cooling
ZKG-100AN 105 ZKB-0.06YN 1
ZKB-0.06AN 81 ZKB-0.3YN 2
ZKB-0.3AN 82 ZKB-0.6YN 3
ZKB-0.6AN 83 ZKB-1.2XN 4

Parojection shaft type

ZKB-1.2BN 84 ZKB-2.5XN 5
Parojection shaft type

ZKB-2.5BN 85 Self-cooling ZKB-5XN 6

Self-cooling ZKB-5BN 86 (Air- cooling) ZKB-10XN 7
(Air- cooling) ZKB-10BN 87 ZKB-20XN 8
ZKB-20BN 88 ZKB-40XN ∗ 9
ZKB-40BN ∗ 89 ZKB-2.5HBN 21
ZKB-5HC 121 ZKB-5HBN 22
Heat-pipe ZKB-10HC ∗ 122 Sermo-block ZKB-10HBN 23
ZKB-20HC ∗ 123 ZKB-20HBN 24
ZKB-5CM2 111 ZKB-40HBN ∗ 25
Water-cooling ZKB-10CM2 ∗ 112 ZKB-2.5WN 41
ZKB-20CM2 ∗ 113 ZKB-5WN 42
ZKB-40CM2 ∗ 114 Water-cooling ZKB-10WN 43
ZKB-1.2B4-909 131 ZKB-20WN 44
ZKB-5B4-909 132 ZKB-40WN ∗ 45
ñhîöédól
ZKB-10B2-909 ∗ 133 ZA-0.6Y 11
ZKB-20B2-909 ∗ 134 ZA-1.2Y1 12
ZA-0.6A 91 ZA-2.5Y1 13
Penetration shaft type

ZA-1.2A1/AN 92 Self-cooling ZA-5Y1 14

ZA-2.5A1/AN 93 ZA-10Y1 15
Self-cooling
ZA-5A1/AN 94 ZA-20Y1 16
Penetration shaft type

ZA-10A1/AN 95 ZA-40Y 17
ZA-20A1 96 ZKA-2W 61
ZKA-1A1 141 ZKA-6W 62
ZKA-2A1 142 Water-cooling ZKA-10W 63
ZKA-6A2 143 ZKA-20W 64
ZKA-10A2 144 ZKA-45W 65
Self-cooling
ZKA-20A3 145
ZKA-45AT ∗ 146
ZKA-65AT ∗ 147
ZKA-100AT ∗ 148

Hysteresis clutch Hysteresis brake

Type name No. Type name No.
ZHA-0.6B 151 ZHY-0.6B 71
Parojection shaft ZHA-1.2A 152 Parojection shaft ZHY-1.2A 72
type ZHA-2.5A 153 type ZHY-2.5A 73
ZHA-5A 154 ZHY-5A 74
ZHA-10A 155 ZHY-10A 75
Penetration shaft ZHA-20A 156 ZHY-20A 76
Penetration shaft
type ZHA-40A 157 ZHY-40A 77
type
ZHA-60A 158 ZHY-60A 78
ZHY-100A2 79

As the rated current of the models indicated by ∗ mark will exceed the rated output current (3A) of LD-
30FTA, please connect the power amplifier satisfying the rated current of each model to the TOUT-AOC
terminal, then control through this power amplifier.

23
 JZ990D41401D
24