Availability
Normally held in stock. Orders confirmed before midday China time usually ship within 2–3 working days. That is dispatch, not delivery — transit time depends on the courier and destination, and we quote it with the price.
Automatic Tension Controller
TC100 Automatic Tension Controller
TC100 is an automatic tension controller for maintaining stable web tension in unwind, process and rewind sections. It supports constant tension, taper tension and speed-synchronous control for converting and web handling lines.
Key Features
Built for practical web tension control applications.
- 4.3-inch color screen with LED digital display for clear operation and monitoring.
- Dual potentiometers for direct tension setting and manual output setting.
- One-step zero adjustment and tension calibration.
- Opto-isolated or magnetic-isolated outputs help improve anti-interference performance in industrial environments.
- Supports fully automatic, semi-automatic and speed-synchronous tension control modes.
- Compatible with magnetic powder clutches and brakes, pneumatic clutches and brakes, torque motors, servo motors and dual-frequency motors.
- Dual-axis output supports pre-output during A/B axis switching to reduce tension fluctuation during splicing.
- Supports embedded, wall-mounted and integrated installation.
| Model | TC100 |
|---|---|
| Product Type | Automatic tension controller |
| Display | 4.3-inch color screen with LED digital displays |
| Control Modes | Automatic constant tension, taper tension, semi-automatic control and speed-synchronous tension control |
| Manual Setting | Dual potentiometers for tension and manual output setting |
| Calibration | One-step zero adjustment and tension calibration |
| Output / Drive Compatibility | Magnetic powder clutch/brake, pneumatic clutch/brake, torque motor, servo motor and dual-frequency motor |
| Axis Output | Dual-axis output for A/B axis switching |
| Installation | Embedded, wall-mounted or integrated installation |
Replacement & Spare Part
Replacing a TC100 on an existing machine?
TC100 drives magnetic powder clutches and brakes, pneumatic clutches and brakes, torque motors, servo motors and dual-frequency motors. When replacing a tension controller, the output side is what decides whether a unit drops in — the controller has to match the actuator the machine already has.
What to send us
A photo of the controller in the panel with its wiring, the make and model of the brake, clutch or motor it drives, and the load cell model if the line runs closed loop. Panel cut-out size matters if the housing has to fit an existing opening.
What ships
The controller. Load cells and signal amplifiers are separate items. Brakes, clutches and motor drives are not supplied — the controller is selected to work with the ones already on the machine.
Output and drive compatibility is the first thing to confirm, then the control modes the line needs and the panel installation type. Compare them against the table above.
Dimension drawing: available on request. Ask for it by email and check it against the unit on your machine before ordering.
Commonly reported TC100 symptoms
Not every fault that looks like a failed unit is one. These are the patterns we are asked about most often, and what they usually turn out to mean.
Tension climbs steadily as the unwind roll empties
Normal behaviour for an open loop or for a broken feedback path. Check that the load cell signal is reaching the controller before assuming the controller has failed. See how tension control works.
Output stuck at zero or at full
Can be the output stage, but a seized brake or a disconnected drive command looks the same from the panel.
Display works but the calibration will not hold
Often the load cell or the signal amplifier rather than the controller. Recalibrating against a known weight will separate the two.
Taper mode has no visible effect on the roll
Check the taper setting and the diameter signal source. Roll defects can also come from nip pressure and winding geometry rather than tension.
If the symptom is not on this list, describe it in your message. It is cheaper for both of us to identify the actual fault than to ship the wrong part.
System Wiring Reference
Reference wiring diagram for TC100 tension control configuration.
Compatible Components
Signal Amplifier
SAMP03 Signal Amplifier
Signal amplifier for tension sensors, converting sensor feedback into standard outputs for PLCs, computers or controllers.
View ModelTension Sensors
LC100A Pedestal-Mount Tension Sensor
Compact pedestal-mount tension sensor with low temperature drift, high stability and good linearity.
View ModelLS100A Through-Shaft Tension Sensor
Stainless-steel through-shaft tension sensor with IP66 protection for harsh converting environments.
View ModelLF100A Through-Shaft Tension Sensor
Live-shaft flange tension sensor with built-in self-aligning bearings for reliable web tension measurement.
View ModelLFP100A Through-Shaft Tension Sensor
Compact flange tension sensor with self-aligning bearings for easy roller installation and maintenance.
View ModelLX100A Cantilever Tension Sensor
Cantilever roller tension sensor for stable detection independent of web position on the roller.
View ModelTypical Applications
Unwind Tension Control
Maintains stable tension as roll diameter changes during unwinding.
Rewind Tension Control
Supports taper tension and consistent roll formation during rewinding.
Printing & Converting Lines
Stable web tension for printing, coating, laminating and converting processes.
Slitter Rewinders
Tension control support for unwind, process and rewind sections.
New to tension control? See what web tension control is and how it works for how this component fits into the control loop.