Summary of Contents for Altra Industrial Motion Warner Electric MCS-166
- Page 1 Pneumatic Tension Control System MCS-166/MCS-207/MCS-208 Installation & Operating Instructions P-276 819-9045...
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Page 2: Table Of Contents
Contents This manual has been designed to cover the full range of installation, startup, operation, and maintenance Introduction ....... . 2 procedures for your tension control system. -
Page 3: System Components
System Components Brake Specifications The Air Disc brake develops braking torque that is proportional to the air pressure applied to the brake's MCS-166 Power Supply Module air chambers. The pressure required to control tension Part Number: is supplied by the electro-pneumatic transducer. 6910-448-013 The Pneumatic Tension Control System can be used to Input Power:... - Page 4 DC common or open collector, NPN transistor to DC common . Torque Adjust/Span –– Provides for Switch or transistor rating –– 20 manual adjust when in the manual VDC minimum, 0.02 amps maximum mode. Provides for span adjust when in rating other modes of operation.
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Page 5: Installation Control Housings
Supply Pressure sections, but do not fasten them together yet. Effect: 1.5 Psig for 25 Psig supply change 2. Wall Mounting Pipe Size: 1/4” NPT (transducer and filter) a. If bottom-entry conduit entrance is For a more detailed list of specifications, see the required, remove the L-shaped bracket information supplied with the transducer and filter. - Page 6 Dimensions NoTe: All dimensions are nominal BOTTOM VIEW Front bracket may be Braket base mount may be mounted mounted either way either way as shown for shelf mount. as shown. Remove entirely for wall mount. BACK VIeW SIDe VIeW Figure 3. Wall/Shelf enclosure dimensions Power supply Power supply must be...
- Page 7 Figure 5. Panel mount cut-out dimensions Figure 6. Panel mount housing dimensions B. Panel Mounting 4. Slide the housing assemblies into the mounting panel cutouts. Securely fasten the housings to NoTe: Panel mount housings cannot be joined the mounting panel with the four nuts on each together.
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Page 8: Sensor
Installation - MCS-605-1 Sensing 6. While holding the sensor and bracket in this position, mark the centers of the bracket holes Potentiometer on the machine. 7. Drill and tap three (3) holes for 8-32 screws in 1. Using a No. 2 drill, drill a 1/2” deep hole in the the machine. -
Page 9: Air Disc Tension Brake
Installation - Air Disc Tension Brake 3. Shielded cable is recommended for sensor connections and external switching circuits. For brake installation, refer to the pneumatic 4. Do not operate external accessories from tension brake installation instructions, WC-68. the MCS-166, MCS-207, or MCS-208 controls. -
Page 10: T-6000 Transducer
The switch or relay used for the 1. Wire AC input to terminals 1, 2 and 3 of the MCS-166 terminal block: terminal 1 to be AC anti-drift input should be open during normal neutral, terminal 2 AC hot, and terminal 3 earth running operation to prevent unpredictable ground. - Page 11 to terminal 6 and (-) side (or common) of external voltage source to MCS-208 2. Connect the (+) side of the external terminal 7, per Figure 11D, page 12. current source to MCS-208 terminal 6 and the (-) side (common) to terminal The input level from an external 7, per Figure 11E, page 12.
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Page 12: System Start-Up And Adjustments
Figure 11. MCS-208 Input Configuration 8. Do not insert the control modules at this time. a. For 120 VAC, set to High Position Proceed to the MCS-166/MCS-208 start-up b. For 240 VAC, set to High Position section of this manual. ... - Page 13 B. Static Adjustment and Check Out 6. Set the “Dancer Position” to its midpoint 1. Install a pressure gage into the output of the range and the “Gain” to “5” on the MCS- transducer. 207 faceplate. 2. Apply air pressure to the system. ...
- Page 14 outside of the transducer. Use care when adjusting Adjustment Transducer Range these potentiometers. Variable 1-5(ma-DC) 4-20(ma-DC) 10-50(ma DC) 1-5(VDC) 1-9(VDC) a. Place the Brake-Off switch in the Y min* brake-off mode. Y max* b. If the pressure reads above 0 psig, P max**(Psi) turn the zero pot on the transducer CCW until the pressure just reaches...
- Page 15 NoTe: This is only a preliminary gain setting. A final pressure or rapidly depressing the web or dancer arm will provide the gain setting is required at core diameter for optimum transient. Observe the dancer’s system performance. response. 7. Run the system until the unwind roll is ...
- Page 16 f. Remove jumper on anti-drift input (connecting terminal to DC common terminal 9). 3. “I” Integrator gain adjustment, R24. The “I” gain adjustment controls how far the dancer must move to compensate for unwind roll diameter changes. Any adjustment must be made strictly in accordance with the instructions below.
- Page 17 Figure 12. Control Adjustment Locations, MCS-166/MCS-207 Warner Electric • 800-825-9050 P-276 • 819-9045...
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Page 18: Mcs-166/Mcs-208/Transducer
System Start-Up and Adjustment 5. Slide the power module into its housing and secure with the two captive fasteners on the faceplate. MCS-166/MCS-208 Transducer Pull the ribbon cable forward so The MSC-208 is factory set and calibrated for a 4-20 that the connector is in front of the housing ma output. - Page 19 with the machine stationary. Check that the ** If shop air does not maintain 80 psi minimum, the P “Power” indicators on both the MCS-166 max and P cal should be set lower. P max should be at and MCS-208 are illuminated. least 5 psi lower than the minimum supply pressure.
- Page 20 c. If the pressure reads 0 psig, turn the b. Set the remote torque adjust zero pot CW until the pressure rises potentiometer to maximum. above zero. Then slowly turn the pot CCW until the pressure just reaches ...
- Page 21 b. Adjust the external voltage source for e. Adjust the torque span potentiometer the minimum input level to be used. to provide the estimated pressure required to the brake. c. Set the zero adjust potentiometer f. Set the roll follower arm back through the front panel to obtain a transducer pressure output of zero.
- Page 22 Figure 13. Control Adjustment Locations, MCS-166/MCS-208 Warner Electric • 800-825-9050 P-276 • 819-9045...
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Page 23: System Troubleshooting Dancer Tension Control System
TRoUBLeSHooTING Applies to the Dancer Control System General: The chart below will be helpful when isolating exact problems which may occur in the control system. The chart will also prove helpful when encountering problems with the initial start-up of the system. - Page 24 Brake is not releasing as dancer is raised • Check the mechanical parts of the brake to assure they are in (even though voltage decreases) good operating condition and properly installed. Check to see if brake-on input is activated. Symptom C: Dancer moves to and remains at upper limit after operating in a normal running position for a period of time. Probable Cause Suggested Solution Incorrect dancer position setting...
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Page 25: Remote/Analog Control Sytem
TRoUBLeSHooTING Applies to the Remote/Analog Control System With the exception of the dancer input, general MCS-166/MCS-208 system troubleshooting is quite similar to troubleshooting the MCS-166/MCS-207. The chart below will be helpful in isolating problem causes. Probable Cause Suggested Solution No DC power to the control. •... - Page 26 Warranty Warner Electric LLC warrants that it will repair or replace (whichever it deems advisable) any product manufactured and sold by it which proves to be defective in material or workmanship within a period of one (1) year from the date of original purchase for consumer, commercial or industrial use. This warranty extends only to the original purchaser and is not transferable or assignable without Warner Electric LLC’s prior consent.
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