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 .
