Related Manuals for Warner Electric MCS-204
Summary of Contents for Warner Electric MCS-204
- Page 1 Tension Control System MCS-166, MCS-203, MCS-204 Installation & Operation Instructions P-0257-WE 819-9027...
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Page 2: Table Of Contents
Warning: Contact with the electrical voltages present in the controls covered in this manual can cause injury or death. To avoid these consequences, make sure all power is off during installation. 2 Warner Electric • 800-825-9050 P-0257-WE • 819-9027... -
Page 3: Introduction
This system is open loop and protection on DC input power any change in output to the brake must be input to connections. the control from the signal source. The MCS-204 can Auxiliary be operated by the local torque knob on its face or Inputs:... - Page 4 Data and technical specifications for the TB style Control Input: Via terminal strip connections in control tension brakes can be found in Warner Electric’s housing, dependent on type of input Master Catalog, P-137, or Tension Control Catalog, control function. (Manual, remote, P-771.
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Page 5: Installation Control Housings
Do not connect the front sections yet. The controls are now ready to be wired. Proceed to the wiring section of this manual for the appropriate instructions. Figure 1. Wall/shelf enclosure dimensions Warner Electric • 800-825-9050 P-0257-WE • 819-9027 5... - Page 6 6, drill four (4) 13/64” mounting holes for each housing to provide clearance for the #10 mounting studs. Figure 3. Panel mount cut-out dimensions Figure 4. Panel mount housing dimensions 6 Warner Electric • 800-825-9050 P-0257-WE • 819-9027...
- Page 7 ❑ 10. The sensor is now ready to be wired. Refer separated by 5/16”. to the wiring section starting on page 8 of this manual for complete instructions. Figure 6. MCS-605-1 & TCS-605-5 Mounting Details Warner Electric • 800-825-9050 P-0257-WE • 819-9027 7...
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Page 8: Sensor
Do not operate external accessories from the unpredictable reactions. MCS-166, MCS-203, or MCS-204 controls. ❑ b. Brake-Off Switch Do not use controls for purposes other than Connect switch contacts between those intended. - Page 9 Figure 7. MCS-166/MCS-203 Wiring - Single Brake Figure 8. MCS-166/MCS-203 Wiring - Dual Brakes Warner Electric • 800-825-9050 P-0257-WE • 819-9027 9...
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Page 10: Mcs-166/Mcs-204
MCS-166 DC common terminal 4 to 12. Connect the shunt resistor MCS-204 DC common terminal 4. MCS- between MCS-204 terminals 7 166 (+) DC terminal 5 to MCS-204 (+) input and 9. terminal 3. ❑ 2. Connect the (+) side of the ❑... - Page 11 Secure the latches. If shelf mounting is used, secure the housings with the four (4) bolts for each section. Figure 9. MCS-166/MCS-204 Wiring - Single Brake Figure 10. MCS-166/MCS-204 Wiring - Dual Brakes Warner Electric • 800-825-9050 P-0257-WE • 819-9027 11...
- Page 12 Figure 11. MCS-204 Input Configuration Figure 12. Analog Photoelectric - Roll Follower Wiring 12 Warner Electric • 800-825-9050 P-0257-WE • 819-9027...
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Page 13: Mcs-166/Mcs-203
NOTE: If the “brake” indicator is the reverse of this, mate, but do not apply excessive force. the Pivot-Point Sensor is wired backwards. Refer to (NEW STYLE UNITS WITH RIBBON the MCS-166/MCS-203 wiring section for correct CABLES) connections. Warner Electric • 800-825-9050 P-0257-WE • 819-9027 13... - Page 14 TCS-900. control module and/or power module. *Applies only to “older style” units without ribbon cable C. Start-Up and Dynamic Adjustments assemblies. ❑ 1. Verify that power is on. 14 Warner Electric • 800-825-9050 P-0257-WE • 819-9027...
- Page 15 If difficulties are encountered which cannot be response range should be used. resolved using this manual, contact your local CAUTION: When switching to higher response ranges, Warner Electric Representative or the factory. R16 should be set full CCW. Factory Settings: “P” (R32) = 100% CW “I”...
- Page 16 Figure 13. Control Adjustment Locations MCS-166/MCS-203 16 Warner Electric • 800-825-9050 P-0257-WE • 819-9027...
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Page 17: Mcs-166/Mcs-204
Tracer” will ALWAYS be toward the top of Refer to Figure 14, page 19, for exact location of the control. adjustments and indicators. ❑ 6. Slide the MCS-204 Control Module into its A. Preliminary Set-Up housing and secure with the two captive fasteners on the faceplate. - Page 18 This is a true adjustments. zero output to the brake. ❑ c. Now rotate the “torque/span” NOTE: Set-up adjustment is the same for all three potentiometer toward its maximum current range inputs. 18 Warner Electric • 800-825-9050 P-0257-WE • 819-9027...
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Page 19: Mcs-166/Mcs-204
NOTE: At maximum roll diameter, the output of the WARNING: The maximum input level must not exceed MCS-204 should be set for the required tension. This 14.5 VDC or damage may occur to control may not correspond to the full output level of the logic circuits. - Page 20 Figure 14. Control Adjustment Locations MCS-166/MCS-204 20 Warner Electric • 800-825-9050 P-0257-WE • 819-9027...
- Page 21 Roll shaft not free to rotate with control off. Brake and shaft must be free to rotate with control off. Sensor incorrectly connected to control Verify Verify sensor connections. sensor connections, terminals. Warner Electric • 800-825-9050 P-0257-WE • 819-9027 21...
- Page 22 If the indication is erratic, the sensor should be replaced; if the indication is not erratic, the cable assembly should be replaced. If above steps seem normal, recheck dancer arm length (most applications require a dancer arm at least 12” long). 22 Warner Electric • 800-825-9050 P-0257-WE • 819-9027...
- Page 23 TROUBLESHOOTING Applies to MCS-204 Control, MCS-166 Power Supply With the exception of the dancer input, general MCS-166/MCS-204 system troubleshooting is quite similar to troubleshooting the MCS-166/MCS-203. The chart below will be helpful in isolating problems causes. Probable Cause Suggested Solution Check for power LED illumination on MCS-204.
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Page 24: Replacement Parts Listing
MCS-204 Output/Driver Board ......6910-448-023 MCS-204 Housing, Panel Mount ......6910-448-015 MCS-204 Housing, Wall/Shelf Mount....6910-448-016 Rear P/C Board Assy. MCS-204 P/M end ..6910-101-023* Rear P/C Board Assy. MCS-204 W/S end ..6910-101-021* Fuse, 3 Amp, 250 Volt, Fast Acting ....458-8001-006 MCS-605-1 Pivot-Point Sensor, Single Turn ..7330-448-002 TCS-605-5 Pivot-Point Sensor, 5 Turn ....7330-448-003...