10
Warner Electric • 800-825-9050
P-0257-WE • 819-9027
System Wiring
MCS-166/MCS-204
Refer to Figures 9,10,11,12, pages 11 & 12, for actual
wiring connections.
❑
1. Wire AC input to terminals 1, 2 and 3 of the
MCS-166 terminal block: terminal 1 to be
AC neutral, terminal 2 AC hot, and terminal
3 earth ground.
❑
2. Wire MCS-166 DC output to MCS-204
input: MCS-166 DC common terminal 4 to
MCS-204 DC common terminal 4. MCS-
166 (+) DC terminal 5 to MCS-204 (+) input
terminal 3.
❑
3. Connect brake magnet(s) wires to terminals
1 and 2 of MCS-204 Terminal Block.
❑
4. External Switch Connections (optional)
❑
a. Brake-Off Switch
Connect switch contacts between
terminals 10 and 11 of MCS-204
terminal strip.
❑
b. Brake-On Switch
Connect switch contacts between
terminals 10and 12 of MCS-204
terminal strip.
NOTE: If only a single brake-off function is used,
an SPST maintained contact switch may be used.
If both functions are used, a three position switch is
recommended, as shown in Figure 9 and 10, page 11.
❑
5. Control Input Connections
Refer to Figures 11 and 12, page 12, for various input
connection configurations.
❑
a. Local Torque Adjust Mode
Connect jumper between MCS-204
terminals 6 and 8, per-Figure 11B, page
12.
❑
b. Remote Torque Adjust/Roll Follower Pot
Connect remote potentiometer or roll
follower potentiometer to MCS-204
terminals 5, 6, and 7, per Figure 11C,
page 12.
NOTE: Wiper will always be connected to terminal 6.
End points should be connected so that turning the
remote pot CCW or moving the roll follower pot toward
the core will decrease voltage at terminal 6.
❑
c. Voltage Source Input
Connect (+) side of external voltage
source to terminal 6 and (-) side (or
common) of external voltage source to
MCS-204 terminal 7, per Figure 11D,
page 12.
CAUTION: The input level from an external
voltage source must not exceed 14.5
VDC. Voltage levels higher than 14.5
VDC will damage the control’s input
circuits.
❑
d. Current Source input
❑
1. Determine the current range
from the external current source
and select a shunt resistor from
the chart in Figure 11E, page
12. Connect the shunt resistor
between MCS-204 terminals 7
and 9.
❑
2. Connect the (+) side of the
external current source to MCS-
204 terminal 6 and the (-) side
(common) to terminal 7, per
Figure 11E, page 12.
❑
e. Analog Photoelectric Sensor Input
Refer to Figure 12, page 12 for
connection information.
❑
1. Make sure the MCS-166 and
MCS-204, power, and brake are
connected per Figure 12, if not
already done.
❑
2. Connect sensor to MCS-204,15
VDC power source: Sensor blue
lead to DC common terminal 7
and sensor brown lead to +15
VDC terminal 5.
❑
3. Connect sensor output (black
lead) to (+) input on Iso-verter,
terminal 7.
❑
4. Connect (+) output of Iso-verter
terminal 2 to input of MCS-204
terminal 6.
❑
5. Connect MCS-204 terminal 7
(DC common) to both input and
output (-) terminals 1 and 8 of the
Iso-verter.
❑
6. Connect a shunt resistor between
terminals 7 and 9 of MCS-204
terminal strip.
NOTE: To prevent pick-up of stray electrical noise,
connect the shield wire to terminal 7 only. Use of
shielded cable is strongly recommended for sensor
pot, voltage or current source input, and connection of
the Iso-verter to the MCS-204 inputs.
