TC818 Tension Controller Instruction Manual
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8.2. Troubleshooting

Appearance of failure Possible malfunction Solution
The controller does not work after powered on

  • Power fails

  • Fuse fused

  • Check the connection of power supply.

  • Replace new fuse(4A)
Can not measure, display "A/D error".

  • A/D IC damaged

  • In need of repair
Can not measure, display "sigl error"

  • Signal range and sensor do not match

  • Sensor fails or incorrect connection.

  • Select the right range for Signal[25]

  • Check the connections and signal, replace new sensor.
Can not measure, display "over range"

  • Invalid calibration

  • Sensor fails or incorrect connection

  • Bad value for Sensor[23]

  • Recalibrate

  • Check connections and signal, replace new sensor.

  • Set Sensor[23] according to real condition.
Not stable in manual and automatic mode

  • Tension sensing roller out of roundness, bearing damaged, roller bended.

  • Bad clutch/brake or driver

  • Signal fails or incorrect calibration

  • Reinstall

  • Use the appropriate drive unit

  • Use the appropriate sensor and recalibrate
Stable in manual mode but not stable in automatic mode

  • Bad type of tension sensor.

  • Bad type of clutch, brake or driver.

  • Bad value for Prop. Band[05], Inte. Time[06] and Dead Band[07]

  • Use the appropriate sensor and recalibrate

  • Use the appropriate drive unit

  • Alter the value of these three parameters
Incorrect calculation of radius

  • The setting of radius calc related parameter is incorrect.

  • Wrong proximity switch/encoder.

  • proxmity switch/encoder damaged or incorrect connection.

  • Set proper values for the radius calc. related parameters.

  • Use proximity switch or encoder with NPN signal

  • Check connection or replace new proximity switch or encoder
No output

  • Output has been turned off

  • Output short-circuit protection

  • Incorrect connection of Reel A and Reel B

  • Press the OUTPUT ON/OFF switch to turn on

  • Switch power off, switch on after 30 seconds

  • Connect the drive unit properly
The keys and digital knob do not work Keypad has been locked Check the Lock indicator, if Lock is on, the keypad is locked. Press LOCK key to unlock.
The controller does not start after MC1 is on

  • Sync. Mode[39] is enabled.

  • Bad value for Action Mode[38].

  • Disable the Sync. Mode[39] function.

  • The proximity switch must be mounted on the main reel while enabled and set right value for Start Freq.[03].

  • Set right value for Action Mode[38].
Can't switch to automatic mode

  • The automatic/manual switching is disabled when error appears

  • The measured tension is incorrect

  • Keypad locked

  • Check sensor, connections, parameters and recalibrate until getting the correct measurement

  • Keypad locked, press LOCK key to unlock.
Tension too high or too low after restarting

  • MC1 is on when system stop

  • MC4 is off, output memory is disabled

  • Keep the MC1 off before stopping

  • keep the MC4 on
Setting tension(SV) changes after switching from manual mode to automatic mode While switching the controller from manual mode to automatic mode, the measured tension before switching will be used as the setting tension for automatic control This is normal, it makes the smooth transition.
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