Mitsubishi Electric LE-40MT Series User manual

Transition from LE-40MT Series, LE-30CTN(A) to
LE7-40GU-L Handbook

1
SAFETY PRECAUTIONS
(Read these precautions before use.)
Before using this product, please read this manual and the relevant manuals introduced in this manual carefully and pay full
attention to safety in order to handle the product correctly.
This manual classifies the safety precautions into two categories: [ WARNING] and [ CAUTION].
Depending on the circumstances, procedures indicated by [ CAUTION] may also cause severe injury.
It is important to follow all precautions for personal safety.
Store this manual in a safe place so that it can be read whenever necessary. Always forward it to the end user.
[DESIGN PRECAUTIONS]
[DESIGN PRECAUTIONS]
WARNING
●Make sure to set up the following safety circuits outside the tension controller to ensure safe system
operation even during external power supply problems or tension controller failure. Otherwise,
malfunctions may cause serious accidents.
- Note that when an error occurs in a relay or transistor of an output circuit, the output might stay on
or off. For output signals that may lead to serious accidents, external circuits and mechanisms
should be designed to ensure safe machinery operation in such a case.
●Most importantly, set up the following: an emergency stop circuit, a protection circuit, an interlock
circuit for opposite movements (such as normal vs. reverse rotation), and an interlock circuit (to
prevent damage to the equipment at the upper and lower torque limits and upper and lower tension
limits).
●In an output circuit, when a load current exceeding the current rating or an overcurrent caused by a
load short-circuit flows for a long time, it may cause smoke and fire. To prevent this, configure an
external safety circuit, such as a fuse.
●For the operating status of each station after a communication failure of the network, refer to relevant
manuals for the network. Incorrect output or malfunction may result in an accident.
CAUTION
●If a power failure or an abnormal voltage drop occurs, the tension controller stops, and output is
turned off.
WARNING Indicates that incorrect handling may cause hazardous conditions, resulting in
death or severe injury.
CAUTION Indicates that incorrect handling may cause hazardous conditions, resulting in
minor or moderate injury or property damage.

2
[INSTALLATION PRECAUTIONS]
[INSTALLATION PRECAUTIONS]
[POWER SUPPLY WIRING PRECAUTIONS]
WARNING
●Make sure to cut off all phases of the power supply externally before attempting installation or wiring
work. Failure to do so may cause electric shock or damage to the product.
●Use the product within the generic environment specifications described in LE7-40GU-L
APPLICATION MANUAL (SH-170022ENG). Never use the product in areas with excessive dust, oily
smoke, conductive dusts, corrosive gas (salt air, Cl2, H2S, SO2or NO2), flammable gas, vibration or
impacts, or expose it to high temperature, condensation, or rain and wind. If the product is used in
such conditions, electric shock, fire, malfunctions, deterioration or damage may occur.
CAUTION
●Do not touch the conductive parts of the product directly. Doing so may cause device failures or
malfunctions.
●Always wear an anti-static wristband and discharge static electricity from the body before handling the
extension option. Failure to do so may cause the extension option to fail or malfunction.
●When drilling screw holes or wiring, make sure that cutting and wiring debris do not enter the
ventilation slits of the tension controller. Failure to do so may cause fire, equipment failures or
malfunctions.
●For the product supplied together with a dust proof sheet, the sheet should be affixed to the ventilation
slits before installation and wiring work to prevent foreign objects such as cutting and wiring debris.
However, when the installation work is completed, make sure to remove the sheet to provide
adequate ventilation.
●Install the product on a flat surface. If the mounting surface is rough, undue force will be applied to the
PC board, thereby causing nonconformities.
●Install the product securely using mounting screws or fixtures.
●Connect the extension options securely to their designated connectors. Loose connections may
cause malfunctions.
●Make sure to affix the extension option with tapping screws. Tightening torque should follow the
specifications in the manual. If the screws are tightened outside of the specified torque range, poor
connections may cause malfunctions.
●Work carefully when using a screwdriver such as installation of the product. Failure to do so may
cause damage to the product or accidents.
●Connect the input/output cables and power cable securely to their designated connectors. Loose
connections may cause malfunctions.
●Turn off the power to the tension controller before attaching or detaching the optional devices. Failure
to do so may cause equipment failures or malfunctions.
CAUTION
●Use an online UPS (uninterruptible power supply) with a power distortion factor of 5% or less or a line
interactive UPS. If a standby UPS is used, use a Mitsubishi low-capacity UPS "FREQUPS FW-F
series" (hereinafter FW-F series). (Example: FWF10-0.3K/0.5K)

3
[WIRING PRECAUTIONS]
[WIRING PRECAUTIONS]
[STARTUP AND MAINTENANCE PRECAUTIONS]
WARNING
●Make sure to cut off all phases of the power supply externally before attempting installation or wiring
work. Failure to do so may cause electric shock or damage to the product.
●Make sure to properly wire to the terminal block (Spring clamp type) in accordance with the following
precautions. Failure to do so may cause electric shock, equipment failures, a short-circuit, wire
breakage, malfunctions, or damage to the product.
- The disposal size of the cable end should follow the dimensions described in the manual.
- Twist the ends of stranded wires and make sure that there are no loose wires.
- Do not solder-plate the electric wire ends.
- Do not connect more than the specified number of wires or electric wires of unspecified size.
- Affix the electric wires so that neither the terminal block nor the connected parts are directly
stressed.
CAUTION
●Perform class D grounding (grounding resistance: 100 or less) of the grounding terminal on the
tension controller with a wire 0.2 to 1.5 mm2. Do not use common grounding with heavy electrical
systems.
●Connect the power supply wiring to the dedicated terminals described in this manual. If an AC power
supply is connected to a DC input/output terminal or DC power supply terminal, the tension controller
will burn out.
●Do not wire vacant terminals externally. Doing so may damage the product.
●Install module so that excessive force will not be applied to terminal blocks, power wire, or
communication cables. Failure to do so may result in wire damage/breakage or tension controller
failure.
●Make sure to observe the following precautions in order to prevent any damage to the machinery or
accidents due to malfunction of the tension controller due to the effects of noise.
- Do not bundle the power line and communication cables together with or lay them close to the
main circuit, high-voltage line, load line or power line. As a guideline, lay the power line, control
line and communication cables at least 100 mm away from the main circuit, high-voltage line, load
line or power line.
- Ground the shield of the shielded wire or shielded cable at one point on the tension controller.
However, do not use common grounding with heavy electrical systems.
- Ground the shield of the analog input/output cable at one point on the signal receiving side.
However, do not use common grounding with heavy electrical systems.
WARNING
●Do not touch any terminal while the tension controller's power is on. Doing so may cause electric
shock or malfunctions.
●Before cleaning, cut off all phases of the power supply externally. Failure to do so in the power ON
status may cause electric shock.

4
[STARTUP AND MAINTENANCE PRECAUTIONS]
[DISPOSAL PRECAUTIONS]
[TRANSPORTATION PRECAUTIONS]
CAUTION
●Do not disassemble or modify the product. Doing so may cause fire, equipment failures, or
malfunctions.
*For repair, contact your local Mitsubishi Electric representative.
●Turn off the power to the tension controller before connecting or disconnecting any extension cable.
Failure to do so may cause equipment failures or malfunctions.
●Turn off the power to the tension controller before attaching or detaching the optional devices. Failure
to do so may cause equipment failures, or malfunctions.
CAUTION
●Please contact a certified electronic waste disposal company for the environmentally safe recycling
and disposal of your device.
CAUTION
●The tension controller is a precision instrument. During transportation, avoid impacts larger than those
specified in the general specifications described in LE7-40GU-L APPLICATION MANUAL (SH-
170022ENG) by using dedicated packaging boxes and shock-absorbing palettes. Failure to do so
may cause failures in the tension controller. After transportation, verify operation of the tension
controller and check for damage of the mounting part, etc.
●When fumigants that contain halogen materials such as fluorine, chlorine, bromine, and iodine are
used for disinfecting and protecting wooden packaging from insects, they cause malfunction when
entering our products. Please take necessary precautions to ensure that remaining materials from
fumigant do not enter our products, or treat packaging with methods other than fumigation (heat
method). Additionally, disinfect and protect wood from insects before packing products.

5
INTRODUCTION
Thank you very much for purchasing the tension controller.
Before using, read this document, and thoroughly understand the functions and performance of the tension controller to use it
correctly.
Regarding use of this product
• This product has been manufactured as a general-purpose part for general industries, and has not been designed or
manufactured to be incorporated in a device or system used in purposes related to human life.
• Before using the product for special purposes such as nuclear power, electric power, aerospace, medicine or passenger
movement vehicles, consult Mitsubishi Electric.
• This product has been manufactured under strict quality control. However when installing the product where major
accidents or losses could occur if the product fails, install appropriate backup or failsafe functions in the system.
Note
• If in doubt at any stage during the installation of the product, always consult a professional electrical engineer who is
qualified and trained in the local and national standards. If in doubt about the operation or use, please consult the nearest
Mitsubishi Electric representative.
• Since the examples indicated by this manual, technical bulletin, catalog, etc. are used as a reference, please use it after
confirming the function and safety of the equipment and system. Mitsubishi Electric will accept no responsibility for actual
use of the product based on these illustrative examples.
• This manual content, specification etc. may be changed, without a notice, for improvement.
• The information in this manual has been carefully checked and is believed to be accurate; however, if you notice a doubtful
point, an error, etc., please contact the nearest Mitsubishi Electric representative. When doing so, please provide the
manual number given at the end of this manual.

6
CONTENTS
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
RELEVANT MANUALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
TERMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
CHAPTER 1 OUTLINE 9
1.1 Request to Customers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2 Recommended Alternative Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
CHAPTER 2 TRANSITION FROM LE-40MTA, B(-E) TO LE7-40GU-L 10
2.1 Differences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.2 Comparison of I/O Terminal Blocks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.3 Comparison Between Optional Terminal Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
CHAPTER 3 TRANSITION FROM LE-30CTN(A) TO LE7-40GU-L 16
3.1 Differences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.2 Comparison of I/O Terminal Blocks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
CHAPTER 4 DIFFERENCES IN SEQUENCE OPERATION 20
4.1 Stall Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Differences in operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.2 Output Gain Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
CHAPTER 5 DIFFERENCES IN FLOW AT MACHINE STARTUP ADJUSTMENT 23
5.1 Differences in Operation Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.2 Difference in Operation Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.3 Protection Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
REVISIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
TRADEMARKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

7
CONTENTS

8
RELEVANT MANUALS
TERMS
Unless otherwise specified, this manual uses the following terms.
Manual name <Manual number> Description
LE7-40GU-L APPLICATION MANUAL
<SH-170022ENG>
How to handle, install and set the tension controller LE7-40GU-L
LE-40MTA-E INSTRUCTION MANUAL
<JZ990D30601>
How to handle, install and set the tension controller LE-40MTA-E
LE-40MTB-E INSTRUCTION MANUAL
<JZ990D30801>
How to handle, install and set the tension controller LE-40MTB-E
LE-30CTN APPLICATION MANUAL
<JZ990D33401>
How to handle, install and set the tension controller LE-30CTN
LE-30CTA APPLICATION MANUAL
<JZ990D33001>
How to handle, install and set the tension controller LE-30CTA
LE7-DCA APPLICATION MANUAL
<SH-081825ENG>
How to handle, install and set the reel diameter calculation option LE7-DCA
LE7-CCL APPLICATION MANUAL
<SH-081828ENG>
How to handle, install and set the network option LE7-CCL
LE-40MD INSTRUCTION MANUAL
<JZ990D41301>
How to handle, install and set the diameter calculation unit LE-40MD
LE7-ATT INSTRUCTION MANUAL
<IB-0800588>
How to handle and install the attachment LE7-ATT
Terms Description
Option Generic term for extension options, memory cassette
Extension options Generic term for reel diameter calculation option, network option
Reel diameter calculation option Generic term for the reel diameter calculation option LE7-DCA
Network option Generic term for the network option LE7-CCL
LE7-40GU-L Abbreviation for the tension controller LE7-40GU-L
LE7-DCA Abbreviation for the reel diameter calculation option LE7-DCA
LE7-CCL Abbreviation for the network option LE7-CCL
LE7-ATT Abbreviation for the attachment LE7-ATT
LE-40MTA(-E) Abbreviation for the tension controller LE-40MTA(-E)
LE-40MTB(-E) Abbreviation for the tension controller LE-40MTB(-E)
LE-40MD Abbreviation for the diameter calculation unit LE-40MD
LE-30CTN(A) Abbreviation for the tension controller LE-30CTN(A)