The tension detector supports three installation methods: horizontal installation, vertical installation, and side installation. It can be fixed through the bottom mounting holes or side mounting holes.

Key precautions:

• A universal bearing seat must be used for transitional installation. Rigid installation is strictly prohibited.
• All fixing screws must not be too long, otherwise they may damage the detector reed or internal measuring mechanism.
• For vertical installation, the fulcrum side, which is the lead wire end, must face upward.
• Strong impact or vibration to the detector is strictly prohibited.

The power cable should be kept as far away as possible from electrical interference sources, such as buttons, AC contactors, and other electrical components.

After powering on the controller, enter Menu 6: Sensor Monitoring. Under normal no-load conditions, the displayed value should be between 1000 and 20000.

Press the detector gently by hand. If the value increases significantly, the detector is working normally. If the value is lower than 1000 or higher than 20000, check whether the installation is correct or whether the sensor is damaged.

Tare removal is used to eliminate the external weight of parts installed on the detector, such as guide rollers and bearing seats, so that the measured tension returns to zero.

Operation method: In the no-load state, enter Menu 1: Tare Removal, then press the execute switch to complete the operation.

Follow these steps:

1. Perform tare removal once to reset the measured tension to zero.
2. Hang a standard weight close to the full rated tension at the center of the two detectors.
3. Enter Menu 5: Tension Calibration, input the actual suspended weight value, and press the execute switch to complete calibration.

Press the manual switch on the panel to enter manual mode. The manual indicator will light up, and the output ratio can be adjusted directly.

Press the automatic switch to enter automatic mode. The automatic indicator will light up, and the controller will automatically adjust the output according to the set tension.

A sudden change in roll diameter before or after roll changing may cause tension fluctuation. Press the tension reset switch. The controller output ratio will return to the preset value in Menu 3: Shaft Change Output, helping eliminate sudden tension changes.

In automatic mode, if the controller does not receive a pulse signal from the Hall switch within one second, it will automatically pause output ratio adjustment and display “Pause”.

This prevents the controller from mistakenly judging insufficient tension after the machine stops and increasing the output, which could cause excessive tension and material breakage at the next startup.

The Hall switch is used to detect the spindle speed and coordinate the start and stop of tension adjustment.

Installation notes:

• The magnetic steel has a front and back side, so orientation must be correct.
• If the equipment speed is too low, the number of magnetic steels can be increased to shorten the pulse interval.

The password for all parameter settings is 888.

There are three control modes, which can be selected in Menu 8: Control Mode:

• Tension Feedback Mode: Factory default mode. It provides high-precision closed-loop control and is suitable for applications requiring constant tension accuracy.
• Rewinding Taper Mode: Uses the Hall switch to detect roll diameter changes and perform fuzzy tension control. It is suitable for applications where constant tension accuracy is not highly demanding. It can also help prevent the material roll from being wound too tightly or skewed.
• Unwinding Taper Mode: Also uses roll diameter change detection for fuzzy tension control and is suitable for less demanding constant tension applications.

This parameter is used during dual-station rewinding or unwinding shaft changes. It presets the output ratio reassigned to the working shaft, making the tension as close as possible to the set value at the moment of shaft change. This helps shorten the shaft changing process and reduce tension fluctuation.

Enter Menu 7: Restore Factory Settings, then press the execute switch. All internal parameters will be restored to the factory default values.

Cause: In automatic mode, the controller output ratio has reached the limit of 0% or 999%, and the controller can no longer maintain constant tension.

Solution: The limit relay will act automatically. An external buzzer can be connected for alarm indication, or the relay can be linked to stop the motor. Check whether the sensor is faulty, the material is broken, or the mechanical system is jammed.

Adjust Menu 12: Stop Gain and Menu 13: Stop Time.

The stop gain setting range is 0–4000%. For example, when it is set to 2000%, the output value will be doubled during stopping to offset material inertia and prevent loose winding.

Adjust Menu 16: Display Filtering. The setting range is 10–50.

A larger value makes the display more stable, but the response speed becomes slower. Adjust it according to the actual working conditions.

The controller supports the following output types:

• Two channels of 24V constant current output, which can directly drive magnetic powder clutches or brakes.
• One channel of 0–5V analog output. The SA output can be selected as 0–10V through Menu 14. It can drive servo motors or torque motors, and can also be used to indicate the output ratio.

The controller includes a built-in dual-station rewinding and unwinding control function.

After setting the output ratio in Menu 3: Shaft Change Output, the main and secondary transmission shafts can be automatically switched through an external dual-station transfer switch. This allows smooth tension transition during shaft changing.