8
Warner Electric • 800-825-9050
P-0257-WE • 819-9027
SYSTEM WIRING
System Wiring Precautions
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.
These wiring precautions will help you properly install
and wire a trouble-free system.
1. Use proper gauge wire for all circuits.
2. If possible, segregate AC and DC power
lines, brake output lines, signal lines, and
switch wiring.
3. Shielded cable is recommended for sensor
connections and external switching circuits.
4. Do not operate external accessories from the
MCS-166, MCS-203, or MCS-204 controls.
5. Do not use controls for purposes other than
those intended. Such use could damage the
control and void the warranty.
MCS-166/MCS-203
Refer to connection diagrams, Figures 7 and 8, page
9, for wiring connections.
❑
1. Wire AC input power to terminals 1, 2, and
3 of the MCS-166 terminal block: Terminal
1 neutral, Terminal 2 hot, Terminal 3 earth
ground.
❑
2. Wire DC output from MCS-166 Terminal
Block to Input Power Terminals on MCS-
203 as follows:
• MCS-166 DC Common Terminal 4 to MCS-
203 DC Common Terminal 4.
• MCS-166 (+) DC Terminal 5 of MCS-166 to
(+) Terminal 3 of MCS-203.
❑
3. Connect wiring from brake magnets to
Terminals 1 and 2 of the MCS-203 terminal
block.
❑
4. Sensor Wiring
Determine the direction of potentiometer
shaft rotation as viewed from the connector
end of the pivot-point sensor.
CW
❑
a. For CW rotation, connect sensor wires
as follows: Black to Terminal 5, green to
Terminal 6, red to Terminal 7. Shield lead
should be connected to Terminal 7.
CCW
❑
b. For CCW rotation, connect sensor
wires as follows: Red to Terminal 5,
green to Terminal 6, black to Terminal
7. Shield lead should be connected to
Terminal 7.
❑
5. External Switch Connections (optional)
❑
a. Anti-Drift or integrator Switch Connect
switching circuit between terminals 8
and 9 of MCS-203 terminal strip.
NOTE: The anti-drift input can be a limit switch which
closes based on dancer arm position or it can be a
relay circuit activated by the machine start cycle.
CAUTION: The switch or relay used for the anti-
drift input should be open during
normal running operation to prevent
unpredictable reactions.
❑
b. Brake-Off Switch
Connect switch contacts between
Terminals 10 and 11 of MCS-203
terminal strip.
❑
c. Brake-On Switch
Connect switch contacts between
Terminals 10 and 12 of MCS-203
terminal strip.
NOTE: For single brake off function only, use a Single
Pole-Single Throw, maintained contact switch. For
both functions, a three position switch as shown in
Figures 7 and 8, page 9, is recommended.
❑
6. Double check all wiring connections per
Figure 7 or 8. Insure all terminals are tight.
❑
7. Reconnect the front housing of either wall
or shelf mounting and secure the latches. If
shelf mounting is used, secure the housing
with the four (4) bolts for each section.
❑
8. Do not insert the control modules at this
time. Proceed to the MCS-166/MCS-203
start-up section of this manual.
