10
Warner Electric • 800-825-9050
P-2003-2 • 819-0420
Do not connect the shield lead of
the cable at the switch contacts. Cut the
shield lead off at this end.
o
3 . Route the remote mode switch cable to the
control, keeping the cable segregated from high
voltage AC power lines and other control wiring
that may cause noise transients .
o
4 . Connect the black wire from the switch
common contacts of the remote mode switch to
terminal 10 of terminal block TB1 of the
TCS-200-1 . Tighten the screw .
o
5 . Connect the red wire from the normally open
contact for the “on” or “stop” position of the
remote mode switch to terminal 5 of terminal
block TB1 of the TCS-200-1 . Tighten the screw .
o
6 . Connect the green wire from the normally
open contact for the “off” position of the remote
mode switch to terminal 6 of terminal block TB1
of the TCS-200-1 . Tighten the screw .
o
7 . Connect the shield wire from the cable to
terminal 11 of terminal block TB1 of the
TCS-200-1 . Securely tighten the screw .
The TCS-200 Tension Control has now been wired
for operation . Before applying power to the system,
double check the wiring and installation for proper
connection . After this check has been completed,
proceed to the start-up and adjustment section of
this manual .
Analog Input (Optional)
Two options for the analog input signal are available .
These include 0-10 VDC or 4-20 mA signal .
Determine which signal will be supplied and refer
to the proper section of this manual below . Also,
determine if this input needs to be isolated from the
control ground . For example, if a PLC is used, this
input must be isolated . Then refer to the Isolation
section of this manual .
Note:
A shielded cable is recommended for the 0-10
VDC or 4-20 mA input to insure a good signal .
0-10 VDC
Refer to Figure 5b for the 0-10 VDC analog input
connections .
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
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
a. Remote mode selector switch
b. 0-10v analog input
c. 4-20m A analog input
Figure 5
d. Isolation power supply
