Warner Electric • 800-825-9050
P-2106-WE • 819-0550
3
THEORY OF OPERATION
The Warner Electric Tension Control System is
comprised of a control transformer supplied by the
customer, a control module, Electro Disc tension brake,
and input sensor (optional) . Depending on the type of
system desired, the input sensor may vary .
The customer supplied transformer converts the
incoming AC voltage to a 24 to 30 VAC level which
supplies power to the TCS-200 . The primary voltage of
this transformer will be dependent on the AC line voltage
available at the machine .
The TCS-200 rectifies the 24 to 28 VAC to provide a
usable DC voltage level for powering the internal logic as
well as supplying current for brake operation .
The front panel tension adjust provides for setting the
brake output level when the control is operated in
the local torque adjusted mode . This potentiometer
provides a voltage which is fed to a comparator along
with a signal obtained from the current source amplifier
circuits . The sense amplifier monitors the current through
the sense magnet and provides for constant current
operating by increasing or decreasing the reference
signal to maintain a fairly constant current through the
brake for a given level of input signal .
The signal obtained from the current and tension adjust
comparator is then fed to another comparator that
provides a pulse-width-modulated signal . The pulse
width from this circuit is dependent on the current
required for the brake .
The pulse width output from this stage is then fed to the
output driver circuits that provide current to the brake
magnets . A short circuit detector is employed to shut
down the driver should a short circuit condition occur in
any of the magnets .
Logic circuits are used to provide “brake-on,” “brake-off”
and run modes of operation either through the internal
selector switch located on the TCS-200 front panel or via
an external customer supplied switch . In the run mode,
output operation is normal and is controlled by the
tension adjust potentiometer . “Brake-off” mode overrides
the tension adjustment and provides for resetting the
short circuit indicator . The “brake-on” input provides for
full output current to the brake .
A green power on indicator is provided as a visual aid to
indicate when AC power is applied to the control . A red
short circuit indicator is provided to indicate when the
short circuit indicator has triggered and the output driver
has been shut down .
When the TCS-200 is operated with a remote tension
adjust potentiometer or with a roll follower input, the front
panel tension adjust potentiometer becomes the span
adjust . The span adjust sets the maximum input from the
remote potentiometers .
Because this is a very simple tension control, no
antiresidual circuits, zero adjust circuits, or other complex
control circuits found in other Warner Electric tension
control systems are included in the TCS-200 .
