Mitsubishi LE-40MTA-E Automatic Tension Controller

The Mitsubishi LE-40MTA-E is an automatic tension controller designed for precise management of material tension during unwinding, feeding, and winding operations in continuous web processing applications. This controller automatically regulates tension by receiving signals from a fine displacement tension detector and outputting appropriate control commands to an actuator such as a powder clutch, powder brake, hysteresis clutch, air clutch, or servo motor operating in torque mode. The device is widely used in printing presses, packaging machines, textile processing equipment, and converting machinery where consistent material tension is critical to product quality.

Actuator Compatibility and Control Output

The LE-40MTA-E provides a voltage output of 24 V DC at a maximum current of 4 A for driving the actuator. This output is compatible with powder clutches and brakes, hysteresis clutches and brakes, air clutches and brakes, and servo motors configured for torque mode operation. The actuator selection is made based on line speed and required operating tension, with the controller's rated output current of 4 A determining the maximum permissible actuator load. The P‑N output of the tension controller is rated at 24 V DC, 4 A maximum. An auxiliary 12 V DC output rated at 2 A is provided for a 10-second duration, suitable for momentary high-demand operations.

Power Supply and Electrical Specifications

The controller accepts a wide-range AC input voltage from 85 V to 264 V AC at 50 or 60 Hz, allowing global deployment without voltage selection switches or external transformers. Power consumption is modest, and the unit incorporates a switching power supply design that contributes to its compact size and reduced weight. The control signal output range is 0 to ±5 V DC, while the tension signal output provides 0 to 5 V DC for external monitoring devices such as recorders or remote displays. A converter signal output of 4 to 20 mA is available for connection to other process control equipment. The controller also provides DC 0 to ±5 V output for pre-set adjustments.

User Interface and Display Configuration

The LE-40MTA-E features a comprehensive operator interface consisting of a 2-line by 40-character LCD display and a seven-segment LED numeric display. The LCD screen presents menu-based parameter configuration, diagnostic messages, and status information in text format. The bar graph on the upper right of the screen continuously displays the operating tension value as a percentage of the full scale. The seven-segment LED display shows either the operating tension or the control output numerically, selectable via the front-panel selector switch. The LCD and LED displays operate simultaneously, providing operators with both analog and digital representations of tension values. Front-panel controls include a POWER switch with LED indicator, OUTPUT ON/OFF switch with LED indicator, TENSION SET trimmer, MANUAL SET trimmer, numeric input keys, cursor control keys, CANCEL and ENTER keys, and three operational mode buttons for AUTO, MANUAL, and DISPLAY SELECTOR functions.

Automatic and Manual Operation Modes

In automatic operation mode, the controller uses its internal PID control algorithm to maintain tension at the setpoint determined by the TENSION SET trimmer, which scales from 0 to 100 percent of the full-scale tension value programmed during initial setup. The controller also supports taper tension control, where the tension setpoint is reduced proportionally to increasing reel diameter, preventing core crushing or telescoping winding during roll building. When manual operation mode is selected, the operator directly adjusts the torque output using the MANUAL SET trimmer, providing independent control for setup, troubleshooting, or special processing conditions. The control output is displayed both on the LCD bar graph and the seven-segment numeric display, with the unit of measurement selectable between kilograms-force and Newtons via parameter configuration.

Automatic Calibration and Tuning Functions

The LE-40MTA-E offers several automatic adjustment features to simplify commissioning and maintain long-term accuracy. The automatic zero adjustment function calibrates the tension detector's zero point without requiring manual potentiometer adjustment. The span adjustment function sets the full-scale tension range for the sensor. An automatic control gain adjustment function (autogain) continuously optimizes the PID response based on detected process dynamics, reducing the need for manual gain tuning and compensating for changes in material properties or line speed. These features make the controller suitable for applications with variable operating conditions or where skilled engineering support is limited.

Data Management and External Connectivity

The controller provides interface terminals for connection to external devices including a recorder for trend logging, an E/P regulator for pneumatic actuator control, an amplifier output, and remote operation stations. A dedicated memory cassette interface supports the FX-EEPROM-4 or FX-EEPROM-8 optional modules, allowing users to save and restore configuration parameters, tension recipes, and calibration data for quick changeover between different products or materials. The controller also provides contact outputs for material running detection and alarm conditions. Command inputs are provided for run/stop signal, stall memory reset, inching operation, and cut torque selection, enabling integration with broader machine control systems without requiring a separate PLC in some applications.

Environmental and Mechanical Specifications

The LE-40MTA-E is designed for industrial environments with an operating temperature range of 0°C to 40°C and humidity limit of 80 percent relative humidity non-condensing. Vibration tolerance is 10 to 55 Hz with 0.5 mm amplitude. Electrical withstand voltage is 1500 V AC for one minute, and the device requires a Class 3 ground connection. The unit is not resistant to corrosive gases, dust, or direct water exposure and must be installed in a suitable control cabinet. Mounting options include floor standing, wall mounting, or panel cutout installation. The device weighs approximately 3.5 kg. Applications include printing and converting machinery, textile processing lines, and packaging equipment where consistent web tension is required.

IS220PSVOH1A GE General Electric 
GE SR760 760-P5-G5-S5-HI-A20-R-T PLC Module

GE SR760 760-P5-G5-S5-HI-A20-R PLC Module
BMEP586040 SCHNEIDER Modicon BME P58 6040