Warner Electric TCS-200-1H - Manual (Page 2)

2 Warner Electric • 800-825-9050 P-2003-2 • 819-0420
Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . 3
Technical Specifications. . . . . . . . . . . . . . . . . . . 3
Installation
Control Mounting. . . . . . . . . . . . . . . . . . . . . . 4
External Sensor Mounting. . . . . . . . . . . . . . . 5
System Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . 5
System Start-Up and Adjustment . . . . . . . . . . 11
Voltage Tables . . . . . . . . . . . . . . . . . . . . . . . . . 19
System Troubleshooting. . . . . . . . . . . . . . . . . . 20
Component Parts List
Coupling, MCS-605-1 284-8000-003
Roll Pin (Drive) for Sensor Coupling 679-8001-067
TCS-200-1 Tension Control 6910-448-086
TCS-200-1H Tension Control 6910-448-087
Ultrasonic Sensor 4-40in 7600-448-001
List of Illustrations and Figures
Figure 1 Dimensional Data, Mounting . . . . . . .6
Figure 2 Power Connections . . . . . . . . . . . . . .7
Figure 3 Brake Connections . . . . . . . . . . . . . . .8
Figure 4 Remote Torque and Roll
Follower Connections . . . . . . . . . . . . .9
Figure 5 Remote Switch, Analog Input and
Analog Input Isolation Connections .10
Tables 1,2,3 Voltage/Current Tables . . . . . . . . . . .19
Templates
TCS-200-1H Template . . . . . . . . . . .21
TCS-200-1 Template . . . . . . . . . . . .21
Introduction
The Warner Electric Tension Control system is
comprised of a tension brake, control module, and
optional external sensor input.
This manual has been designed to cover
installation, start-up, adjustment, and
maintenance of your tension control system and
covers the control system only. Further
information on brake sizing and selection can be
found in catalogs P-1234 or P-771.
Power Source
The TCS-200-1 series Tension Controls operates
from a power source of 115 or 230 VAC, 50/60 Hz
input. Primary voltage is determined by the
customer's input voltage source. The control is
factory set to accept 115 VAC input. Refer to the
wiring section for 230 VAC input connections.
Control
The TCS-200-1 series controls are selectable
voltage or current controlled power supply
designed to power up to a 16 magnet Electro Disc
tension brake system, Electromagnetic Particle
Brakes, TB series brakes or Advanced Technology
tension brakes. This control can be operated
manually from the front panel or remotely via an
analog voltage input, a current input, a remote
pot, or a roll follower. External inputs are also
provided for remote brake "off", "run", and "stop"
functions, as well as front panel control of these
functions.
The analog voltage and current inputs are
electrically isolated from the main power circuitry
of the control when 15-35 VDC supply is provided
to maintain full isolation. If isolation is not
needed, an on board 15 VDC supply is jumpered
to act as a default.
Sensors
When the TCS-200-1 series controls are operated
in a remote torque adjust mode, a 1,000 ohm
potentiometer is required. This should be a linear
type potentiometer with a rating of .5 watts, 10
percent tolerance, and a .5 percent linearity.
For roll follower input applications, a 1,000 ohm
potentiometer with a rating of .5 watts, 10 percent
tolerance, and .5 percent linearity is required for
best performance.
Brakes
All 24 VDC tension brakes that Warner Electric
offers, to a maximum of 4.25 amps, can be used
with the TCS-200-1 tension control. For all 24
VDC tension brakes that require greater current
capability from the control (not to exceed 5.8
amps), use a TCS-200-1H. The brake converts
electrical current supplied by the control into
torque, which retards material flow, maintaining
the desired web tension.