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Warner Electric • 800-825-9050
P-2106-WE • 819-0550
TCS-200
TABLE OF CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . 4
Installation
Control
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
External Sensor . . . . . . . . . . . . . . . . . . . . . 5
System Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
System Start-Up and Adjustment . . . . . . . . . . . . . . . . 9
System Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 11
Warranty Information . . . . . . . . . . . . . . . . . . Back Cover
Follow the installation instructions in this manual
carefully to ensure safe, reliable operation. All
stated or implied warranties are voided if this
product is not installed in accordance with these
instructions.
COMPONENT PARTS LIST
TCS-200 Tension Control
6910-448-126
LIST OF ILLUSTRATIONS AND FIGURES
Figure 1 Dimensional Data, Mounting . . . . . . . . . . . . 5
Figure 2 Power and Brake Connections . . . . . . . . . . 6
Figure 3 Remote Sensor and Switch
Connections
. . . . . . . . . . . . . . . . . . . . . . . . 7
Chart 1 Roll Follower Input and Output
Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INTRODUCTION
The Warner Electric Tension Control system is comprised
of the Electro Disc tension brake, a 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 catalog P-771 .
Power Source
The TCS-200 Tension Control operates from a
power source of 24-30 VAC, 50/60 Hz input . Primary
voltage is determined by the customer’s input voltage
source . Specifications for the transformer are located
in the technical data section of this manual . It is the
responsibility of the user to supply the transformer .
Control
The TCS-200 is a current controlled power supply
designed to handle up to a 12 magnet Electro Disc
tension brake . This control can be operated as either
a manually adjusted tension control via the front panel
tension adjustment or via a remote tension adjustment .
The control also has the capability of being used for
simple roll follower applications .
External inputs are provided for remote “brake-on” and
“brake-off” switching circuits, as well as front panel
control of these functions .
Because the control provides constant current output,
brake torque is not substantially affected by changes
in brake operating temperatures . This provides for
repeatable brake torques for given input levels .
When the TCS-200 is operated in a remote torque or
roll follower adjust mode, a 1000 ohm potentiometer is
required . This should be a linear type potentiometer with
a rating of .5 watts, 10 percent tolerance, and .5 percent
linearity .
Brakes
Any of the Electro Disc tension brakes can be used with
the TCS-200 Tension Control . Brake can use from one
magnet to a maximum of twelve magnets . The brake
converts electrical current supplied by the control into
torque, which retards material flow, maintaining the
desired web tension .