8
Warner Electric • 800-825-9050
P-2003-2 • 819-0420
o
2 . In a system with more than one magnet,
connect the remaining red wires from magnets 2
through 16 to terminal 2 of terminal block TB2 of
the TCS-200-1 .
o
3 . Connect all black magnet wires to terminal 3
of terminal block TB2 of the TCS-200-1 .
Note:
Magnets of the Electro Disc tension brake
must be properly connected, otherwise the control
system will not function properly .
All Other 2 Wire Tension Brakes
To connect all other 2-wire tension brakes [Warner
Electric’s Magnetic Particle Brakes, Precision
Torque Magnetic Particle Brakes, TB series brakes,
or Advanced Technology (AT) tension brakes],
refer to Figure 3b for 2-wire tension brakes wiring
connections .
o
1 . Connect one wire from the brake magnet to
terminal 2 of terminal block TB2 of the TCS-200-
1 . Secure the terminal screw .
o
2 . Connect the second wire from the brake
magnet to terminal 3 of terminal block TB2 of the
TCS-200-1 . Secure the terminal screw .
o
3 . Locate the five position jumper in the inside
cover of the TCS-200-1 . Move the 2-position
black selector jumper from positions 1 & 2 to 2
& 3 . This allows the control to operate without a
brake sense magnet .
Remote Torque Adjust Input (Optional)
Refer to Figure 4a for remote torque adjust input
connections .
o
1 . Wire a three conductor shielded cable to the
remote sensor potentiometer previously installed .
Note:
Using a shielded cable with wire colors
red, black, and green is recommended to simplify
potentiometer and terminal connections:
a . Black wire to low resistance end terminal of
potentiometer .
b . Red wire to high resistance end terminal of
potentiometer .
c . Green wire to wiper terminal of potentiometer .
Do not connect the shield lead of
the cable at the potentiometer end. Cut the
shield lead off at this end.
o
2 . Route the cable from the sensor potentiometer
to the control, keeping the cable segregated from
high voltage AC power lines and other wiring that
may cause noise transients .
o
3 . Connect the black wire from the low resistance
end of the remote potentiometer to terminal 11
of terminal block TB1 in the TCS-200-1 . Snug
terminal only .
o
4 . Connect the green wire from the wiper of the
remote potentiometer to terminal 9 of terminal
block TB1 in the TCS-200-1 . Secure the terminal
screw .
1
2
3
4
5
JP1
SEE FIG. 3
FOR THIS
JUMPER
LOCATION
REMOVE
THIS JUMPER
JP1-4 AND 5
FOR ANALOG
INPUT
TB1
1 2 3 4 5 6 7 8 9 10 11
STOP
ST
OP
SIGNAL
COMMO
N
OFF
RUN
+15V
OFF
SIGNAL
TB1
1 2 3 4 5 6 7 8 9 10 11
IS
O
COMMO
N
4-20m
A
4-20mA
INPUT
-
+
TB1
1 2 3 4 5 6 7 8 9 10 11
IS
O
COMMO
N
15-35
V
15-35VDC
ISOLATION
SUPPLY
-
+
TB1
1 2 3 4 5 6 7 8 9 10 11
IS
O
COMMO
N
0-10VDC
0-10VDC
INPUT
-
+
PI:1000
Ω
, 1/2 WATT,
10% TOLERANCE,
0.5% LINEARITY,
LINEAR TAPER
TB1
1 2 3 4 5 6 7 8 9 10 11
PI
REMOTE
PO
T
WIPER
COMMO
N
PI:1000
Ω
, 1/2 WATT,
10% TOLERANCE,
0.5% LINEARITY,
LINEAR TAPER
TB1
1 2 3 4 5 6 7 8 9 10 11
PI
ROLL
FOLLOWE
R
WIPER
COMMO
N
PLACE JUMPER
HERE FOR
2 WIRE TENSION
BRAKES
1
2
3
4
5
JP1
1
2
3
4
5
6
7
8
9
TB2
BRAKE
BRAKE
SENSE
BRAKE
RETURN
DO NOT WIRE
ANY MAGNETS
ON TB2, 1.
!
CAUTION
#1 RED
1
2
3
4
5
6
7
8
9
TB2
RED
BLK
2 THRU 16
BRAKE
MAGNETS
BRAKE
SENSE
BRAKE
RETURN
DO NOT WIRE MORE
THAN ONE MAGNET
BETWEEN TERMINALS
TB2, 1 AND TB2, 3.
!
1
2
3
4
5
JP1
CAUTION
NEUTRAL
1
2
3
4
5
6
7
8
9
115 VAC
HOT
TB2
NEUTRAL
1
2
3
4
5
6
7
8
9
230 VAC
HOT
TB2
FACTORY
INSTALLED
JUMPERS
INSTALL
JUMPER
SEE FIG. 5
FOR JUMPER
REMOVAL.
INSTALL THIS
JUMPER FOR
APPLICATIONS
NOT USING
ANALOG INPUTS.
SEE FIG. 5
FOR JUMPER
REMOVAL.
INSTALL THIS
JUMPER FOR
APPLICATIONS
NOT USING
ANALOG INPUTS.
PLACE JUMPER
HERE FOR
ELECTRO DISC
BRAKES
1
2
3
4
5
JP1
SEE FIG. 3
FOR THIS
JUMPER
LOCATION
REMOVE
THIS JUMPER
JP1-4 AND 5
FOR ANALOG
INPUT
GND
GND
CW
CW
Electro disc tension braking system
Figure 3a.
1
2
3
4
5
JP1
SEE FIG. 3
FOR THIS
JUMPER
LOCATION
REMOVE
THIS JUMPER
JP1-4 AND 5
FOR ANALOG
INPUT
TB1
1 2 3 4 5 6 7 8 9 10 11
STOP
ST
OP
SIGNAL
COMMO
N
OFF
RUN
+15V
OFF
SIGNAL
TB1
1 2 3 4 5 6 7 8 9 10 11
IS
O
COMMO
N
4-20m
A
4-20mA
INPUT
-
+
TB1
1 2 3 4 5 6 7 8 9 10 11
IS
O
COMMO
N
15-35
V
15-35VDC
ISOLATION
SUPPLY
-
+
TB1
1 2 3 4 5 6 7 8 9 10 11
IS
O
COMMO
N
0-10VDC
0-10VDC
INPUT
-
+
PI:1000
Ω
, 1/2 WATT,
10% TOLERANCE,
0.5% LINEARITY,
LINEAR TAPER
TB1
1 2 3 4 5 6 7 8 9 10 11
PI
REMOTE
PO
T
WIPER
COMMO
N
PI:1000
Ω
, 1/2 WATT,
10% TOLERANCE,
0.5% LINEARITY,
LINEAR TAPER
TB1
1 2 3 4 5 6 7 8 9 10 11
PI
ROLL
FOLLOWE
R
WIPER
COMMO
N
PLACE JUMPER
HERE FOR
2 WIRE TENSION
BRAKES
1
2
3
4
5
JP1
1
2
3
4
5
6
7
8
9
TB2
BRAKE
BRAKE
SENSE
BRAKE
RETURN
DO NOT WIRE
ANY MAGNETS
ON TB2, 1.
!
CAUTION
#1 RED
1
2
3
4
5
6
7
8
9
TB2
RED
BLK
2 THRU 16
BRAKE
MAGNETS
BRAKE
SENSE
BRAKE
RETURN
DO NOT WIRE MORE
THAN ONE MAGNET
BETWEEN TERMINALS
TB2, 1 AND TB2, 3.
!
1
2
3
4
5
JP1
CAUTION
NEUTRAL
1
2
3
4
5
6
7
8
9
115 VAC
HOT
TB2
NEUTRAL
1
2
3
4
5
6
7
8
9
230 VAC
HOT
TB2
FACTORY
INSTALLED
JUMPERS
INSTALL
JUMPER
SEE FIG. 5
FOR JUMPER
REMOVAL.
INSTALL THIS
JUMPER FOR
APPLICATIONS
NOT USING
ANALOG INPUTS.
SEE FIG. 5
FOR JUMPER
REMOVAL.
INSTALL THIS
JUMPER FOR
APPLICATIONS
NOT USING
ANALOG INPUTS.
PLACE JUMPER
HERE FOR
ELECTRO DISC
BRAKES
1
2
3
4
5
JP1
SEE FIG. 3
FOR THIS
JUMPER
LOCATION
REMOVE
THIS JUMPER
JP1-4 AND 5
FOR ANALOG
INPUT
GND
GND
CW
CW
All other 2 wire tension brake wiring
Figure 3b.
