TCS and TCS-200-1H Tension Controls

Transcription

1 TCS and TCS-200-1H Tensin Cntrls P WE Service & Installatin Instructins An Altra Industrial Mtin Cmpany

2 Cntents Intrductin...2 Thery f Operatin...3 Technical Specificatins...3 Installatin Cntrl Munting...4 External Sensr Munting....5 System Wiring...5 System Start-Up and Adjustment...11 Vltage Tables...19 System Trubleshting...20 Cmpnent Parts List Cupling, MCS Rll Pin (Drive) fr Sensr Cupling TCS Tensin Cntrl TCS-200-1H Tensin Cntrl Ultrasnic Sensr 4-40in List f Illustratins and Figures Figure 1 Dimensinal Data, Munting... 6 Figure 2 Pwer Cnnectins Figure 3 Brake Cnnectins... 8 Figure 4 Remte Trque and Rll Fllwer Cnnectins Figure 5 Remte Switch, Analg Input and Analg Input Islatin Cnnectins.. 10 Tables 1,2,3 Vltage/Current Tables Templates TCS-200-1H Template TCS Template Intrductin The Warner Electric Tensin Cntrl system is cmprised f a tensin brake, cntrl mdule, and ptinal external sensr input. This manual has been designed t cver installatin, start-up, adjustment, and maintenance f yur tensin cntrl system and cvers the cntrl system nly. Further infrmatin n brake sizing and selectin can be fund in catalgs P-1234 r P-771. Pwer Surce The TCS series Tensin Cntrls perates frm a pwer surce f 115 r 230 VAC, 50/60 Hz input. Primary vltage is determined by the custmer s input vltage surce. The cntrl is factry set t accept 115 VAC input. Refer t the wiring sectin fr 230 VAC input cnnectins. Cntrl The TCS series cntrls are selectable vltage r current cntrlled pwer supply designed t pwer up t a 16 magnet Electr Disc tensin brake system, Electrmagnetic Particle Brakes, TB series brakes r Advanced Technlgy tensin brakes. This cntrl can be perated manually frm the frnt panel r remtely via an analg vltage input, a current input, a remte pt, r a rll fllwer. External inputs are als prvided fr remte brake ff, run, and stp functins, as well as frnt panel cntrl f these functins. The analg vltage and current inputs are electrically islated frm the main pwer circuitry f the cntrl when VDC supply is prvided t maintain full islatin. If islatin is nt needed, an n bard 15 VDC supply is jumpered t act as a default. Sensrs When the TCS series cntrls are perated in a remte trque adjust mde, a 1,000 hm ptentimeter is required. This shuld be a linear type ptentimeter with a rating f.5 watts, 10 percent tlerance, and a.5 percent linearity. Fr rll fllwer input applicatins, a 1,000 hm ptentimeter with a rating f.5 watts, 10 percent tlerance, and.5 percent linearity is required fr best perfrmance. Brakes All 24 VDC tensin brakes that Warner Electric ffers, t a maximum f 4.25 amps, can be used with the TCS tensin cntrl. Fr all 24 VDC tensin brakes that require greater current capability frm the cntrl (nt t exceed 5.8 amps), use a TCS-200-1H. The brake cnverts electrical current supplied by the cntrl int trque, which retards material flw, maintaining the desired web tensin. 2 Warner Electric P

3 Thery f Operatin When in peratin, the cntrl is pwered by a standard 115/230 VAC line. The cntrl has a transfrmer that cnverts that vltage t a level suitable fr any 24 VDC brake system. The signal is rectified t DC and pulse width mdulated (PWM) t the desired brake current via the TENSION ADJUST knb. The frnt panel TENSION ADJUST feeds a small vltage t a cmparatr, which cmpares this signal t a triangular wave. This is where the PWM pulse is generated. This pulse is then inverted and used t drive a pwer circuit. The main brakes and a sense brake are then energized by the pwer circuit at regular intervals. Frm the sense brake, a grwth and decay signal is cnverted t a vltage that can be added t the signal by setting a jumper n the inside f the cver. This signal, when selected, is used t maintain cnstant current t the brake. The signal must nt be selected when n sense brake is cnnected. The cntrl has several ptins that allw fr external/remte tensin adjust in additin t the tensin adjust pt n the frnt f the panel. Tw such ptins are the remte pt r a rll fllwer. Anther is the ptin fr an analg input f vltage r current frm a PLC r ultrasnic sensr. A special feature f the analg inputs is that they are ptically islated frm the rest f the cntrl circuitry if an external pwer surce is used t pwer the islated circuits. The islatin is needed when using a PLC r an external pwer supply fr the ultrasnic sensr. An internal pwer surce is als available and jumpered in as default if islatin is nt necessary. The tensin adjust pt n the frnt f the panel becmes a span adjust when any f the external cntrl ptins are cnnected. The cntrl als has the capability t duplicate the frnt panel selectr switch at a remte lcatin. Brake ff mde verrides the tensin adjustment and prvides fr resetting the shrt circuit indicatr. In the run mde, utput peratin is nrmal and is cntrlled by any f the frnt panel r remte tensin adjust features discussed abve. The brake stp mde prvides fr full utput current t the brake. The tw indicatrs n the frnt f the panel are green fr pwer n and red t indicate a shrt circuit. When a shrt ccurs in the brake, the cntrl disables the pwer circuits t prevent damage. Turn the switch t ff t reset the shrt circuit indicatr. Because this is a basic tensin cntrl, n anti-residual circuits, zer adjust circuits, r ther cmplex cntrl circuits (fund in ther Warner Electric tensin cntrl systems) are included in the TCS series cntrls. Technical Specificatins TCS200-1 and TCS200-1H Input Pwer 115/230 VAC 50/60 Hz Output TCS Adjustable 0-24 VDC. Maximum f 4.25 amps cntinuus. Can be used with any 24 VDC tensin brake with r withut the need fr a sense cil. Output TCS-200-1H Adjustable 0-24 VDC. Maximum f 5.8 amps cntinuus. Can be used with any 24 VDC tensin brake with r withut the need fr a sense cil. Ambient Temperature -20 t 125 F (-29 t 51 C) Fuse 2.5 Amp, 250 VAC, Slw-Blw Prtectin Internal shrt-circuit prtectin n driver utput stage Sensr Inputs Remte Trque Adjust 1,000Ω Rll Fllwer 1,000Ω Analg vltage input, 0-10 VDC (Optically islated when VDC supplied frm external surce) Analg current input, 4-20mA (Optically islated when VDC supplied frm external surce) Warner Electric P

4 Auxiliary Inputs Brake Stp Applies full vltage t the cnnected brakes. Active high input. Brake Run Vltage t the brake is cntrlled by any f the sensr inputs and/r the frnt panel tensin adjust. Active high input. Brake Off Remves utput current t the brake. Puts the brake at zer current level. Active high input. Nte 1: The remte input signal fr these functins requires a minimum cntact rating f 20 VDC at.01 amps and a maximum f state leakage current less than 100 micr-amps. Nte 2: The remte switch input verrides the frnt panel switch. Frnt Panel Tensin Adjust Prvides current adjust t the brake frm 0 t 100%. In the remte and analg input mde, prvides fr maximum utput level set t the brake. Brake Mde Switch Mdes: stp -brake full n run -nrmal peratin ff -brake ff Indicatrs (Frnt Panel) Green LED indicates AC pwer has been applied t the cntrl. Red LED indicates there is a shrt n the utput. Turn the frnt panel switch ff t reset the shrt circuit. General The cntrl chassis must be cnsidered NEMA 1 and shuld be kept clear f areas where freign material, dust, grease, r il might affect cntrl peratin. Ptentimeters (supplied by the custmer) Remte Trque Adjust 1,000 hms, 10% tlerance,.5% linearity,.5 watts, linear taper Rll Fllwer 1,000 hms, 10% tlerance,.5% linearity,.5 watts, linear taper 1. If yu are using a PLC r an external pwer supply with this cntrl, yu must enable the islatin f the cntrl. 2. The TCS cannt perate a single brake r brakes that require mre than 4.25 amps cntinuus. 3. The TCS-200-1H cannt perate a single brake r brakes that require mre than 5.8 amps cntinuus. This Installatin and Operatin Manual has been arranged fr the systematic installatin and start-up f yur tensin cntrl system. T achieve the best pssible results, we recmmend checking ff each cmpleted step in the space prvided befre prceeding t the next step. Sample Attach the TCS-200 cntrl chassis t the munting surface and secure with munting hardware. Check bx after cmpleting each step. Cntrl Munting 1. Determine a suitable lcatin fr the cntrl t be munted. Cnsideratin shuld be given t whether the frnt panel adjustments will require access by the peratr. 2. Using the dimensinal data supplied in Figure 1a and Figure 1b, drill fur munting hles using a #16 drill if #8 thrugh-blts are used. Fr #8 capscrew munting, use a #29 drill and tap hles fr #8 screws. Templates fr hle drilling are fund n page Attach the TCS r TCS-200-1H cntrl chassis t the munting surface and secure with munting hardware. Nte: The cntrl chassis has been designed t accmmdate tw half-inch cnduits fr wiring when the cntrl is munted t the machine frame. 4 Warner Electric P

5 4. Attach cnduit r seal tight cnnectrs. The cntrl is nw ready t be wired. Refer t the wiring sectin f this manual fr prper system wiring. Brake Installatin Refer t the brake manual that is apprpriate fr the brake selected fr its installatin prcedures. External Sensr Munting (Optinal) Optins fr fur types f external sensr inputs are available. These cnsist f either an external trque adjust, rll fllwer input that prvides a signal directly prprtinal t the diameter f the rll t be prcessed, analg vltage, r analg current input. Determine which type f external sensr will be used and prceed t the apprpriate sectin f this manual. Remte Trque Adjust Ptentimeter (Optinal) 1. Select an apprpriate munting lcatin fr the external trque-adjust ptentimeter. Nte: In determining this munting lcatin, take int cnsideratin the ruting f the wires necessary t cnnect the cntrl, access fr the peratr, and space required by the physical size f the ptentimeter. 2. Drill a munting hle based n the bushing diameter f the ptentimeter selected. 3. Munt and secure the ptentimeter. This cmpletes the munting fr an external remte trque adjust ptentimeter. Refer t the wiring sectin f this manual fr prper cntrl wiring. Rll Fllwer Adjust Ptentimeter (Optinal) 1. Munt the rll fllwer ptentimeter and determine the amunt f angular rtatin at the ptentimeter shaft. Nte: If angular rtatin is nt adequate, insufficient utput frm the cntrl is pssible. In this case, a timing belt drive between the rll fllwer pivt-pint and the sensr ptentimeter may be necessary t btain adequate angular rtatin. 2. Secure the rll fllwer ptentimeter. This cmpletes the munting fr a rll fllwer ptentimeter. Refer t the wiring sectin f this manual fr prper cntrl wiring. Analg Input (Optinal) 1. Select an apprpriate munting lcatin fr the PLC r ultrasnic sensr. 2. Munt and secure the PLC r ultrasnic sensr accrding t the specificatins fr thse prducts. This cmpletes the munting. Refer t the wiring sectin f this manual fr prper cntrl wiring. System Wiring System Wiring Precautins The fllwing wiring precautins will help yu prperly wire and install a truble free system. 1. Use a prper gauge wire fr all wiring. 2. Insure that wires are cut and stripped s that n excess bare wire is expsed. 3. Segregate AC input pwer frm cntrl switching and external sensr wiring (if used). 4. D nt run AC pwer lines with DC pwer, input sensr wiring, r switching wiring. Nise transients can be easily transferred, causing erratic cntrl peratin. 5. Use shielded cable when pssible fr cnnecting the TCS t external switches, the sensr ptentimeter, PLC s, and ultrasnic sensr. 6. Under n circumstances shuld auxiliary accessries be perated frm the TCS cntrl. Warner Electric P

6 POWER SHORT CL WARNER ELECTRIC TCS-200-1H TENSION ADJUSTMENT BRAKE MODE DIA. 2 PLCS. FOR 1/2 CONDUIT 3.75 TCS-200-1H with Heat Sink Figure 1a POWER SHORT WARNER ELECTRIC TCS TENSION ADJUSTMENT BRAKE MODE Dia..875 DIA. 2 PLCS CS Figure 1b 6 Warner Electric P

7 7. D nt attempt t incrprate external switching schemes between tw r mre brakes and the TCS utput. This will damage the cntrl and vid the warranty. 8. D nt attempt t wire tw r mre cntrls in parallel. 2. Cnnect ne f the jumpers t terminals 5 and 6 f terminal blck TB2 and discard the spare jumper. 3. Cnnect the 230 VAC pwer t terminals 4 & 8 f terminal blck TB2. Secure the terminal screws. TCS Series Cntrls Wiring Refer t Figure 2 fr actual wiring cnnectins. 1. Unlatch the frnt cver f the TCS Cnnect an earth grund wire between terminal 9 f terminal blck TB2 and an unpainted metal surface f the cntrl panel t ensure a gd grund cnnectin. Secure the terminal screw. Make sure the panel itself is prperly grunded. Pwer Determine if 115 VAC r 230 VAC will be used t pwer the cntrl and prceed t that sectin f this manual. Insure pwer is ff and discnnects pen n the cntrl panel befre cnnecting the AC input. Failure t d s can result in damage t equipment and injury r even death t persnnel. 115 VAC Refer t Figure 2a fr 115 VAC pwer input cnnectins. 1. Cnnect the 115 VAC pwer t terminals 4 & 8 f terminal blck TB2 lcated in the base f the TCS enclsure. Secure the terminal screws. 2. Cnnect an earth grund wire between terminal 9 f terminal blck TB2 and an unpainted metal surface f the cntrl panel t ensure a gd grund cnnectin. Secure the terminal screw. Make sure the cntrl panel itself is prperly grunded. 230 VAC Input Refer t Figure 2b fr 230 VAC pwer input cnnectin. 1. Remve the factry installed jumpers frm terminals 4 & 5 and 6 & 7 f terminal blck TB2 lcated in the base f the TCS enclsure. FACTORY INSTALLED JUMPERS TB NEUTRAL HOT 115 VAC GND INSTALL JUMPER TB NEUTRAL HOT 230 VAC GND a. 115 AC Pwer Wiring b: 230 VAC Pwer Wiring Figure 2 Nte: D nt apply pwer t the system at this pint. Brake Determine the type f brake t be used with this cntrl and prceed t that sectin f this manual. Insure cnnectins are tightly secured. Intermittent cnnectin will cause the cntrl t shut dwn and utput current t the brake will be remved. Electr Disc Tensin Brake Refer t Figure 3a fr the Electr Disc Tensin Brake wiring cnnectins. 1. Cnnect the red wire frm ne brake magnet t terminal 1 f terminal blck TB2 f the TCS This becmes the sense magnet. Warner Electric P

8 2. In a system with mre than ne magnet, cnnect the remaining red wires frm magnets 2 thrugh 16 t terminal 2 f terminal blck TB2 f the TCS Remte Trque Adjust Input (Optinal) Refer t Figure 4a fr remte trque adjust input cnnectins. 3. Cnnect all black magnet wires t terminal 3 f terminal blck TB2 f the TCS Wire a three cnductr shielded cable t the remte sensr ptentimeter previusly installed. Nte: Magnets f the Electr Disc tensin brake must be prperly cnnected, therwise the cntrl system will nt functin prperly. All Other 2 Wire Tensin Brakes T cnnect all ther 2-wire tensin brakes [Warner Electric s Magnetic Particle Brakes, Precisin Trque Magnetic Particle Brakes, TB series brakes, r Advanced Technlgy (AT) tensin brakes], refer t Figure 3b fr 2-wire tensin brakes wiring cnnectins. Nte: Using a shielded cable with wire clrs red, black, and green is recmmended t simplify ptentimeter and terminal cnnectins: a. Black wire t lw resistance end terminal f ptentimeter. b. Red wire t high resistance end terminal f ptentimeter. c. Green wire t wiper terminal f ptentimeter. D nt cnnect the shield lead f the cable at the ptentimeter end. Cut the shield lead ff at this end. 1. Cnnect ne wire frm the brake magnet t terminal 2 f terminal blck TB2 f the TCS Secure the terminal screw. 2. Cnnect the secnd wire frm the brake magnet t terminal 3 f terminal blck TB2 f the TCS Secure the terminal screw. 3. Lcate the five psitin jumper in the inside cver f the TCS Mve the 2-psitin black selectr jumper frm psitins 1 & 2 t 2 & 3. This allws the cntrl t perate withut a brake sense magnet. 2. Rute the cable frm the sensr ptentimeter t the cntrl, keeping the cable segregated frm high vltage AC pwer lines and ther wiring that may cause nise transients. 3. Cnnect the black wire frm the lw resistance end f the remte ptentimeter t terminal 11 f terminal blck TB1 in the TCS Snug terminal nly. 4. Cnnect the green wire frm the wiper f the remte ptentimeter t terminal 9 f terminal blck TB1 in the TCS Secure the terminal screw. PLACE JUMPER HERE FOR ELECTRO DISC BRAKES SEE FIG. 5 FOR JUMPER REMOVAL. INSTALL THIS JUMPER FOR APPLICATIONS NOT USING ANALOG INPUTS. BRAKE SENSE BRAKE RETURN JP TB #1 RED RED 2 THRU 16 BLK BRAKE MAGNETS! CAUTION DO NOT WIRE MORE THAN ONE MAGNET BETWEEN TERMINALS TB2, 1 AND TB2, 3. Electr disc tensin braking system Figure 3a. PLACE JUMPER HERE FOR 2 WIRE TENSION BRAKES SEE FIG. 5 FOR JUMPER REMOVAL. INSTALL THIS JUMPER FOR APPLICATIONS NOT USING ANALOG INPUTS. BRAKE SENSE BRAKE RETURN JP TB BRAKE! CAUTION DO NOT WIRE ANY MAGNETS ON TB2, 1. All ther 2 wire tensin brake wiring Figure 3b. 8 Warner Electric P

9 5. Cnnect the red wire frm the high resistance end f the remte ptentimeter t terminal 7 f terminal blck TB1 f the TCS Secure the terminal screw. REMOTE POT WIPER COMMON TB Cnnect the shield lead frm the cable t terminal 11 f terminal blck TB1 f the TCS Secure the terminal screw. Rll Fllwer Adjust Input (Optinal) Refer t Figure 4b fr rll fllwer adjust input cnnectins. 1. Wire a three cnductr shielded cable t the rll fllwer ptentimeter previusly installed. Nte: Using a shielded cable with wire clrs red, black, and green is recmmended t simplify ptentimeter and terminal cnnectins: PI:1000Ω, 1/2 WATT, 10% TOLERANCE, 0.5% LINEARITY, LINEAR TAPER PI CW Remte trque adjust input Figure 4a PI:1000Ω, 1/2 WATT, 10% TOLERANCE, 0.5% LINEARITY, LINEAR TAPER ROLL FOLLOWER TB PI WIPER CW Rll fllwer adjust input Figure 4b COMMON a. Black wire t lw resistance end terminal f ptentimeter. b. Red wire t high resistance end terminal f ptentimeter. c. Green wire t wiper terminal f ptentimeter. 2. Rute the cable frm the sensr ptentimeter t the cntrl, keeping the cable segregated frm high vltage AC Pwer lines and ther wiring that may cause nise transients. 3. Cnnect the black wire frm the lw resistance end f the rll fllwer ptentimeter t terminal 11 f terminal blck TB1 f the TCS D nt tighten the terminal screw. Snug dwn nly. 4. Cnnect the green wire frm the wiper f the rll fllwer ptentimeter t terminal 9 f terminal blck TB1 f the TCS Secure the terminal screw. 5. Cnnect the red wire frm the high resistance end f the rll fllwer ptentimeter t terminal 8 f terminal blck TB1 f the TCS Secure the terminal screw. 6. Cnnect the shield lead frm the cable t terminal 11 f terminal blck TB1 n the TCS Secure the terminal screw. Remte Mde Selectr Switch (Optinal) Refer t Figure 5a fr the remte mde selectr switch cnnectins. 1. Install selectr switch at a cnvenient lcatin. 2. Wire a three cnductr shielded cable t the external mde selectr switch. Nte: It is recmmended that a shielded cable with wire clrs f red, black, and green be used as this will simplify switch and terminal cnnectins. a. Black wire t cmmn cntacts f bth switch ples. b. Red wire t nrmally pen cntact fr n r stp ple. c. Green wire t nrmally pen cntact fr ff ple. Warner Electric P

10 D nt cnnect the shield lead f the cable at the switch cntacts. Cut the shield lead ff at this end. 3. Rute the remte mde switch cable t the cntrl, keeping the cable segregated frm high vltage AC pwer lines and ther cntrl wiring that may cause nise transients. 4. Cnnect the black wire frm the switch cmmn cntacts f the remte mde switch t terminal 10 f terminal blck TB1 f the TCS Tighten the screw. 5. Cnnect the red wire frm the nrmally pen cntact fr the n r stp psitin f the remte mde switch t terminal 5 f terminal blck TB1 f the TCS Tighten the screw. The TCS-200 Tensin Cntrl has nw been wired fr peratin. Befre applying pwer t the system, duble check the wiring and installatin fr prper cnnectin. After this check has been cmpleted, prceed t the start-up and adjustment sectin f this manual. Analg Input (Optinal) Tw ptins fr the analg input signal are available. These include 0-10 VDC r 4-20 ma signal. Determine which signal will be supplied and refer t the prper sectin f this manual belw. Als, determine if this input needs t be islated frm the cntrl grund. Fr example, if a PLC is used, this input must be islated. Then refer t the Islatin sectin f this manual. 6. Cnnect the green wire frm the nrmally pen cntact fr the ff psitin f the remte mde switch t terminal 6 f terminal blck TB1 f the TCS Tighten the screw. 7. Cnnect the shield wire frm the cable t terminal 11 f terminal blck TB1 f the TCS Securely tighten the screw. Nte: A shielded cable is recmmended fr the 0-10 VDC r 4-20 ma input t insure a gd signal VDC Refer t Figure 5b fr the 0-10 VDC analg input cnnectins. STOP SIGNAL OFF SIGNAL +15V COMMON ISO COMMON 0-10VDC TB TB OFF RUN STOP SEE FIG. 3 FOR THIS JUMPER LOCATION REMOVE THIS JUMPER JP1-4 AND 5 FOR ANALOG INPUT JP VDC INPUT a. Remte mde selectr switch b. 0-10v analg input INPUT ISO COMMON 4-20mA 15-35V ISO COMMON TB TB SEE FIG. 3 FOR THIS JUMPER LOCATION REMOVE THIS JUMPER JP1-4 AND 5 FOR ANALOG INPUT JP mA INPUT VDC ISOLATION SUPPLY c. 4-20m A analg input d. Islatin pwer supply Figure 5 10 Warner Electric P

11 1. Cnnect the psitive lead f the 0-10 VDC input t terminal 3 f terminal blck TB1. Securely tighten the screw. 2. Cnnect the negative side f the VDC external vltage supply t terminal 2 f terminal blck TB1. Securely tighten the screw. 2. Cnnect the negative lead f the 0-10 VDC input t terminal 2 f terminal blck TB1. Snug terminal nly. System Start-Up and Adjustment 3. Cnnect the shield wire t terminal 2 f terminal blck TB1. Securely tighten the screw. 4. Lcate the five-psitin jumper munted n the bard n the inside cver f the TCS Remve the tw psitin black selectr frm psitins 4 & 5 f jumper JP1 and discard ma Refer t Figure 5c fr the 4-20 ma Analg input cnnectins. Manual Tensin Adjust (Frnt Panel) 1. Apply pwer t the cntrl system. 2. Check that the green LED marked pwer is illuminated. 3. Using an AC vltmeter, measure the AC input vltage at terminals 4 and 8 f terminal blck TB2. This vltage shuld be 115 r 230 VAC, depending n the vltage chsen. 1. Cnnect the psitive lead f the 4-20 ma input t terminal 4 f terminal blck TB1. Securely tighten the screw. 4. Remve pwer frm the cntrl system and wait apprximately 30 secnds befre prceeding t the next step. 2. Cnnect the negative lead f the 4-20 ma input t terminal 2 f terminal blck TB1. Snug terminal nly. 3. Cnnect the shield wire t terminal 2 f terminal blck TB1. Securely tighten the screw. Electr Disc Tensin Brake Nte: If yu are nt using electr disc tensin brakes, prceed t step 5 under all ther 2 wire tensin brakes sectin. 4. Lcate the five-psitin jumper munted n the bard n the inside frnt cver f the TCS Remve the tw psitin black selectr frm psitins 4 & 5 f jumper JP1 and discard. Islatin Pwer Supply Refer t Figure 5d fr analg input islatin pwer supply cnnectins. Nte: T islate the analg input frm the TCS cntrl grund, a separate VDC vltage supply is needed. 1. Cnnect the psitive side f the VDC external vltage supply t terminal 1 f terminal blck TB1. Securely tighten the screw. 5. Remve the sense magnet lead frm terminal 1 f terminal blck TB2 and insert a DC current meter between the lead f the sense magnet and terminal 1 f terminal blck TB2. Nte: Use a DC current meter that reads 0 t 500 ma with the Psitive (+) lead cnnected t terminal 1 and negative (-) lead cnnected t the wire. 6. Reapply pwer t the cntrl system. 7. Place the mde selectr switch in the brake ff psitin. The meter shuld read zer current and the brake shuld free wheel. 8. Place the mde selectr switch in the brake n r stp psitin. The meter shuld read 345 t 375 ma and the brake shuld be lcked. Warner Electric P

12 9. Place the mde selectr switch in the run psitin and set the tensin adjust ptentimeter t zer (r fully cunterclckwise). The meter shuld read zer current utput t the brake. 10. Slwly rtate the tensin adjust ptentimeter frm fully cunterclckwise t fully clckwise, nting that the utput current increases frm zer t ma at maximum utput. 11. This cncludes checkut f the cntrl system. Remve pwer and allw apprximately 30 secnds befre prceeding t the next step. 12. Remve the meter and reattach the sense magnet lead t terminal 1 f terminal blck TB2 and secure the lead. Prceed t step This cncludes check-ut f the cntrl system. Remve pwer and allw apprximately 30 secnds befre prceeding t the next step. 12. Remve the meter frm terminals 2 and 3 f terminal blck TB2 and secure. 13. Reapply pwer t the cntrl system. 14. Adjust the tensin ptentimeter fr the desired brake level required fr peratin. Nte: If start-up and adjustment prcedures d nt prduce the desired results, cnsult the trubleshting sectin f this manual. 15. If a remte mde selectr switch is used, repeat steps 5 thrugh 13 using the remte mde selectr switch. All ther 2 wire tensin brakes 5. Attach a DC vltmeter t terminals 2 and 3 f terminal blck TB2. Nte: A DC vltmeter with the capability f reading 0 t 24 VDC shuld be used. Psitive (+) t terminal 2 and negative (-) t terminal Reapply pwer t the cntrl system. 16. Clse the cver t the cntrl chassis using the cver screw supplied with the cntrl. Remte Tensin Adjust 1. Apply pwer t the cntrl system. 2. Check that the green LED marked pwer is illuminated. 7. Place mde selectr switch in the brake ff psitin. The meter shuld read zer vltage and the brake armature shuld be free-wheeling. 8. Place mde selectr switch in the brake stp psitin. The meter shuld read apprximately 24 VDC and the brake shuld be lcked up tight. 9. Place mde selectr switch in the brake run psitin and set the tensin adjust ptentimeter t zer r full cunterclckwise psitin. The meter shuld read zer utput vltage t the brake. 10. Slwly rtate the tensin adjust ptentimeter frm fully cunterclckwise t full clckwise, nting the utput vltage increases frm zer t apprximately 24 VDC at maximum utput. 3. Using an AC vltmeter, measure the vltage at terminals 4 and 8 f terminal blck TB2. This shuld be apprximately 115 VAC r 230 VAC, depending n the input vltage chsen. 4. Remve pwer frm the cntrl system and wait apprximately 30 secnds befre prceeding t the next step. Electr Disc Tensin Brake Nte: If yu are nt using electr disc tensin brakes, prceed t step 5 under all ther 2 wire tensin brake sectin. 12 Warner Electric P

13 5. Remve the sense magnet lead frm terminal 1 f terminal blck TB2 and insert a DC current meter in series with the lead f the sense magnet and terminal 1 f terminal blck TB2. All Other Tw Wire Tensin Brakes 5. Attach a DC vltmeter t terminals 2 and 3 f terminal blck TB2. Nte: Use a DC current meter that reads 0 t 500 ma with the Psitive (+) lead cnnected t terminal 1 and negative (-) lead cnnected t the wire. Nte: Use A DC vltmeter that reads frm 0 t 24 VDC. Cnnect the psitive (+) lead t terminal 2 and negative (-) lead t terminal Reapply pwer t the cntrl system. 6. Reapply pwer t the cntrl system. 7. Place the mde selectr switch in the brake ff psitin. The meter shuld read zer utput current and the brake shuld free wheel. 7. Place the mde selectr switch in the brake ff psitin. The meter shuld read zer vltage and the brake shuld free wheel. 8. Place the mde selectr switch in the brake n r stp psitin. The meter shuld read 345 t 375 ma and the brake shuld be lcked. 9. Place the mde selectr switch in the run psitin and set the tensin adjust ptentimeter t zer (r fully cunterclckwise). The meter shuld read zer current utput t the brake. 10. Slwly rtate the remte tensin adjust ptentimeter frm fully cunterclckwise t full clckwise, nting that the utput current increases frm zer t ma at maximum utput. Leave this ptentimeter at its maximum setting. 11. Slwly rtate the frnt panel tensin adjust ptentimeter frm its fully clckwise, r maximum setting, t its fully cunterclckwise, r minimum setting. Mnitr the meter, bserving that the current ges frm ma t zer at the minimum setting. 12. This cncludes the cntrl system checks. Remve pwer and allw apprximately 30 secnds befre prceeding t the next step. 13. Remve the meter and reattach the sense magnet lead t terminal 1 f terminal blck TB2 and secure it. Prceed t step 14 in next sectin. 8. Place the mde selectr switch in the brake stp psitin. The meter shuld read apprximately 24 VDC and the brake shuld be lcked. 9. Place the mde selectr switch in the brake run psitin and set the remte tensin adjust ptentimeter t the zer, r fully cunterclckwise, psitin. The meter shuld read zer vltage utput t the brake. 10. Slwly rtate the remte tensin adjust ptentimeter frm fully cunterclckwise t full clckwise, nting that the utput vltage increases frm zer t apprximately 24 VDC at its maximum. Leave the ptentimeter at its full clckwise, r maximum, psitin. 11. Slwly rtate the frnt panel tensin adjust ptentimeter frm its fully clckwise, r maximum setting, t its fully cunterclckwise, r minimum setting. Mnitr the meter, bserving that the vltage ges frm 24 VDC t zer at the minimum setting. 12. This cncludes the cntrl system checks. Remve pwer and allw apprximately 30 secnds befre prceeding t the next step. 13. Remve the meter frm terminals 2 and 3 f terminal blck TB2 and secure the leads t the terminals. 14. Reapply pwer t the cntrl system. Warner Electric P

14 15. Adjust the frnt panel tensin adjust ptentimeter t the maximum utput level required fr the applicatin. Nw set the remte tensin adjust ptentimeter between maximum and zer. 6. Reapply pwer t the cntrl system. 7. Set the mde selectr switch t the brake ff psitin. The meter shuld read zer current and the brake shuld free wheel. Nte: If start-up and adjustment prcedures d nt prduce the desired results, cnsult the trubleshting sectin f this manual. 8. Place the mde selectr switch in the brake stp psitin. The meter shuld read 345 t 375 ma and the brake shuld be lcked. 16. If a remte mde selectr switch is used, repeat steps 5 thrugh 13 using the remte mde selectr switch. 17. Clse the cntrl frnt cver and latch it by tightening the screw that is prvided. 9. Place the mde selectr switch in the brake run psitin and set the tensin adjust ptentimeter t its maximum (fully clckwise) setting. Nte: Refer t Table 1 fr varius inputs and utputs when using the rll fllwer system Rll Fllwer Tensin Adjust 1. Apply pwer t the cntrl system. 2. Check that the green LED marked pwer is illuminated. 3. Using an AC vltmeter, measure the AC input vltage at terminals 4 and 8 f terminal blck TB2. This vltage shuld be apprximately 115 r 230 VAC, depending n the vltage chsen. 4. Remve pwer frm the cntrl system and wait apprximately 30 secnds befre prceeding t the next step. Electr Disc Tensin Brake Nte: If yu are nt using electr disc tensin brakes, prceed t step 5 under all ther 2 wire tensin brake sectin. 5. Remve the sense magnet lead frm terminal 1 f terminal blck TB2 and insert a DC current meter in series with the lead f the sense magnet and terminal 1 f terminal blck TB2. Nte: Use a DC current meter that reads 0 t 500 ma with the psitive (+) lead cnnected t terminal 1 and the negative (-) lead cnnected t the wire. 10. Cnnect a secnd DC vltmeter between terminals 9 and 11 f terminal blck TB1. Nte: Use a DC vltmeter capable f measuring zer t 10 vlts DC. 11. With the rll fllwer ptentimeter discnnected frm the rll fllwer arm, psitin the fllwer arm t its true zer psitin, which shuld be the centerline f the unwind spindle. 12. Adjust the rll fllwer ptentimeter t a zer vltage reading n the vltmeter which is cnnected per step 10, page Cnnect the rll fllwer ptentimeter t the rll fllwer arm. After cupling the fllwer arm t the ptentimeter, recheck the vltage between terminals 9 and 11 f terminal blck TB1 t insure the vltage is still zer VDC. 14. Place a full rll f material n the unwind stand. 15. Set the rll fllwer arm n the unwind rll. 16. Check the vltage between terminals 9 and 11 f terminal blck TB1 and refer t Table 1. If the vltage reading is less than 0.8 VDC, refer t Table 1 fr the nminal utput current available. 14 Warner Electric P

15 Nte: If maximum starting trque available is less than the actual starting trque required, the amunt f angular travel f the rll fllwer ptentimeter must be increased. If the vltage reading is greater than 1.3 VDC, decrease the frnt panel tensin adjust until a 2.5 VDC reading is btained. 17. Set the frnt panel tensin adjust fr the desired starting trque required fr the applicatin. 18. Start the machine and draw the web thrugh. 19. Mnitr the vltage at terminals 9 and 11 f terminal blck TB1, as well as the brake current n terminal 1 f terminal blck TB2. As the rll diameter decreases, the sensr vltage and the brake current will decrease, keeping the tensin relatively cnstant. 20. After an initial run has been cmpleted, remve pwer frm the system and wait apprximately 30 secnds befre prceeding t the next step. apprximately 24 VDC and the brake shuld be lcked. 9. Place the mde selectr switch in the brake run psitin and set the tensin adjust ptentimeter t its maximum (fully clckwise) setting. Nte: Refer t Table 1 fr varius inputs and utputs when using the rll fllwer system. 10. Cnnect a secnd DC vltmeter between terminals 9 and 11 f terminal blck TB1. Nte: Use a DC vltmeter that measures zer t 10 VDC and cnnect the psitive (+) lead t terminal 9 and the negative (-) lead t terminal With the rll fllwer ptentimeter discnnected frm the rll fllwer arm, psitin the fllwer arm t true zer, which shuld be the centerline f the unwind spindle. 12. Adjust the rll fllwer ptentimeter t zer vltage n the vltmeter cnnected between terminals 9 and 11 f terminal blck TB Discnnect the meter frm the sense magnet lead t terminal blck TB2. Tighten the lead screws. Prceed t step 23 in next sectin. All Other Tw Wire Tensin Brakes 5. Cnnect a DC vltmeter between terminals 2 and 3 f terminal blck TB2. Nte: Use a DC vltmeter that reads frm 0 t 24 VDC. Cnnect the psitive (+) lead t terminal 2 and the negative (-) lead t terminal Cnnect the rll fllwer ptentimeter t the rll fllwer arm. After cupling the fllwer arm t the ptentimeter, recheck the vltage between terminals 9 and 11 f terminal blck TB1 t insure that the vltage is still zer VDC. 14. Place a full rll f material n the unwind stand. 15. Set the rll fllwer arm n the unwind rll. 16. Check the vltage between terminals 9 and 11 f terminal blck TB1 and refer t Table 1. If the vltage reading is less than 0.8 VDC, refer t Table 1 fr the nminal utput vltage available. 6. Reapply pwer t the cntrl system. 7. Place the mde selectr switch in the brake ff psitin. The meter shuld read zer vltage and the brake shuld be free wheel. 8. Place the mde selectr switch in the brake stp psitin. The meter shuld read Nte: If maximum starting trque available is less than the actual starting trque required, the amunt f angular travel f the rll fllwer ptentimeter must be increased. If the vltage reading is greater than 1.3 VDC, decrease the frnt panel tensin adjust until a 1.3 VDC reading is btained. Warner Electric P

16 17. Set the frnt panel tensin adjust fr the starting trque required fr the applicatin. 18. Start the machine and draw the web thrugh. 3. Using an AC vltmeter, measure the AC input vltage at terminals 4 and 8 f terminal blck TB2. This vltage shuld be apprximately 115 r 230 VAC, depending n the vltage chsen. 19. Mnitr the vltage at terminals 9 and 11 f terminal blck TB1, as well as the brake vltage at terminals 2 and 3 f terminal blck TB2. As the rll diameter decreases, the sensr and the brake vltage will decrease, keeping the tensin relatively cnstant. 4. Remve pwer frm the cntrl system and wait apprximately 30 secnds befre prceeding t the next step. Electr Disc Tensin Brake 20. After an initial run has been cmpleted, remve pwer frm the system and wait apprximately 30 secnds befre prceeding t the next step. Nte: If start-up and adjustment prcedures d nt prvide the desired results, cnsult the truble shting sectin f this manual. 21. Remve the meter frm terminals 2 and 3 f terminal blck TB2 and tighten the terminal screws. If yu are nt using electr disc tensin brakes, prceed t step 5 under All ther 2 wire tensin brake sectin. 5. Remve the sense magnet lead frm terminal 1 f terminal blck TB2 and cnnect a DC current meter that reads frm 0 t 500 milliamps between the lead f the sense magnet and terminal 1 f terminal blck TB2. Cnnect the psitive (+) lead t terminal Reapply the pwer t the cntrl system. 22. Discnnect the secnd vltmeter used frm terminals 9 and 11 f terminal blck TB Reapply pwer t the cntrl system. 24. If the remte mde selectr switch is used, repeat steps 5 thrugh 21 using the remte mde selectr switch. Nte: If start-up and adjustment prcedures d nt prvide the desire results, cnsult the trubleshting sectin f this manual. 7. Place the mde selectr switch in the brake ff psitin. The meter shuld read zer current and the brake shuld free wheel. 8. Place the mde selectr switch in the brake run psitin. The meter shuld read 345 t 375 ma and the brake shuld be lcked. 9. Place the mde selectr switch in the brake run psitin and set the tensin adjust ptentimeter t its maximum (fully clckwise) setting. 25. Clse the cver f the TCS and latch it by tightening the screw that is prvided. Nte: Refer t Table 2 and Table 3 fr varius inputs and utputs when using the analg input system. Analg Input 1. Apply pwer t the cntrl system. 2. Check that the green LED marked pwer is illuminated. 10. If using a 0-10 VDC input, cnnect a secnd DC vltmeter capable f reading frm zer t 10 VDC between terminals 3 and 2 f terminal blck TB1. Cnnect the psitive (+) lead t terminal 3 and the negative (-) lead t terminal Warner Electric P

17 If using a 4-20 ma input, remve the wire frm terminal 4 f terminal blck TB1 and cnnect a secnd DC current meter capable f reading zer t 20 ma between this terminal and the psitive 4-20 ma signal wire. Cnnect the psitive (+) lead t terminal 4 and the negative (-) lead t the wire. All Other Tw Wire Tensin Brakes 5. Attach a DC vltmeter capable f reading zer t 24 VDC between terminals 2 and 3 f terminal blck TB2. Cnnect the psitive (+) lead t terminal 2 and the negative (-) lead t terminal Adjust the analg input t btain a zer vltage reading n the vltmeter cnnected between terminals 3 and 2, r a 4 ma reading n the current meter cnnected n terminal 4 f terminal blck TB1. 6. Reapply pwer t the cntrl system. 7. Place the mde selectr switch in the brake ff psitin. The meter shuld read zer vltage and the brake shuld free wheel. 12. Place a full rll f material n the unwind stand. 13. Set the frnt panel tensin adjust fr the starting trque required fr the applicatin. 14. Start the machine and draw the web thrugh. 15. Mnitr the vltage at terminals 3 and 2 r the current at terminal 4 f terminal blck TB1, as well as the brake current n terminal 1 f terminal blck TB2. a. If using a sensr: As the rll diameter decreases, the sensr vltage r current will decrease which will cause the brake trque t decrease, keeping the tensin prprtinal t the rll size. b. If using a PLC: As the rll diameter decreases, the analg signal frm the PLC must decrease t keep the tensin prprtinal t the rll size. 16. After an initial run has been cmpleted, remve pwer frm the system and wait apprximately 30 secnds befre prceeding t the next step. 17. Remve the meter frm between the sense magnet lead t terminal 1 f terminal blck TB2 and tighten the terminal screw. 8. Place the mde selectr switch in the brake stp psitin. The meter shuld read apprximately 24 VDC and the brake shuld be lcked. 9. Place the mde selectr switch in the brake run psitin and set the tensin adjust ptentimeter t its maximum (fully clckwise) setting. Nte: Refer t Table 2 and Table 3 fr varius inputs and utputs when using the analg input system. If using a 4-20 ma input, remve the wire frm terminal 4 f terminal blck TB1 and cnnect a secnd DC current meter capable f reading zer t 20 ma between this terminal and the psitive 4-20 ma signal wire. Cnnect the psitive (+) lead t terminal 4 and the negative (-) lead t the wire. 11. Adjust the analg input t btain a zer vltage reading n the vltmeter cnnected between terminals 3 and 2, r a 4 ma reading n the current meter cnnected n terminal 4 f terminal blck TB Place a full rll f material n the unwind stand. 13. Set the frnt panel tensin adjust fr the starting trque required fr the applicatin. Prceed t step Start the machine and draw the web thrugh. Warner Electric P

18 15. Mnitr the vltage at terminals 3 and 2 r the current at terminal 4 f terminal blck TB1, as well as the brake current n terminal 1 f terminal blck TB2. a. If using a sensr: As the rll diameter decreases, the sensr vltage r current will decrease which will cause the brake trque t decrease, keeping the tensin prprtinal t the rll size. b. If using a PLC: As the rll diameter decreases, the analg signal frm the PLC must decrease t keep the tensin prprtinal t the rll size. 16. After an initial run has been cmpleted, remve pwer frm the system and wait apprximately 30 secnds befre prceeding t the next step. 17. Remve the meter frm between the sense magnet lead t terminal 1 f terminal blck TB2 and tighten the terminal screw. 18. Discnnect the secnd vltmeter frm terminals 2 and 3 f terminal blck TB Reapply pwer t the cntrl system. 20. If the remte mde selectr switch is used, repeat steps 5 thrugh 17, using the remte mde selectr switch. Nte: If start-up and adjustment prcedures d nt prvide the desired results, cnsult the trubleshting sectin f this manual. 21. Clse the cver f the TCS and latch by tightening the screw that is prvided. 18 Warner Electric P

19 Ω Resistance Degrees Vltage Tables Table 1 Input Vltage frm Rll Fllwer Brakes 2-Wire Mde Output Vltage MTB Brakes 3-Wire Mde Current Output V mA V mA V mA V mA V mA V mA V mA V mA V mA V mA V mA V mA V mA Analg Input Vltage Table 2 Brakes 2-Wire Mde Vltage On Brake MTB Brakes 3-Wire Mde Current On Brake Sense mA mA mA mA mA mA mA mA mA mA Current Input Table 3 Brakes 2-Wire Mde Vltage On Brake MTB Brakes 3-Wire Mde Current On Brake Sense 4mA 0 0 6mA mA 8mA m 10mA mA 12mA mA 14mA mA 16mA mA 18mA mA 20mA mA Warner Electric P

20 Trubleshting General: The chart belw will be helpful when islating exact prblems that may ccur in the cntrl system. When the system has been running fr sme time, the chart will als prve helpful when checking fr wrn, brken r frayed wires; bent r brken cntrl system parts; blwn fuses; lse terminal cnnectins and defective wire cnnectins. Symptm A: Green LED indicatr des nt illuminate with pwer n Prbable Cause Slutin N pwer is applied t the cntrl Check that AC pwer is n. Fuse Blwn Symptm B: Red LED illuminates shrt circuit Shrted magnet cil Brake cnnectins imprperly wired Transient Nise Check fuse and replace if blwn. Check magnet cil resistance fr apprximately hms cld fr MTB s. Cil resistance fr 2-wire brakes, TB s, ATT s and Magnetic Particle units will vary. Check resistance specificatins in Tensin Catalg P-771 r apprpriate service manual. Check wiring and rewire if necessary. Check fr surce f nise and suppress. Segregate wiring. Used shielded cable. Nte: After checking cntrl. Reset cntrl by turning the switch t ff and then t run. Symptm C: Brake is nt engaging Mde switch in brake ff psitin Set mde selectr t run psitin. Tensin set at zer Remte mde switch in brake ff psitin Remte sensrs incrrectly wired N signal n analg inputs Increase tensin adjust. Set remte mde switch t run psitin. Check wiring and rewire if necessary. Check wiring and signal frm PLC r ultrasnic sensr. N pwer t cntrl Refer t Symptm A. Symptm D: Brake is nt releasing Mde switch in brake n r stp psitin Tensin adjust set at maximum Remte mde switch in brake n r stp psitin Remte sensr incrrectly wired Set mde selectr switch t run psitin. Reduce level and see if brake rtates. Set remte mde selectr t run. Check wiring and rewire if necessary. Mechanical binding Symptm E: Brake des nt have adequate trque capacity Brake is incrrectly sized Check brake fr freewheeling when cntrl pwer is ff. Crrect if mechanical prblems still exist. Verify brake sizing by repeating the selectin prcedure in Tensin Catalg P-771. Brake is incrrectly wired Lcal r remte tensin adjust Recheck wiring and magnet cnnectins and rewire if necessary. Recheck set-up prcedures fr the incrrectly set mde f peratin in which the cntrl is used. Readjust if necessary. 20 Warner Electric P

21 TCS-200-1H with Heat Sink TCS-200-1H PLCS PLCS 6.92 REF. Template 1 TCS Munting Template 4 TCS / Template 2 Warner Electric P

22 Warranty Warner Electric LLC warrants that it will repair r replace (whichever it deems advisable) any prduct manufactured and sld by it which prves t be defective in material r wrkmanship within a perid f ne (1) year frm the date f riginal purchase fr cnsumer, cmmercial r industrial use. This warranty extends nly t the riginal purchaser and is nt transferable r assignable withut Warner Electric LLC s prir cnsent. Warranty service can be btained in the U.S.A. by returning any defective prduct, transprtatin charges prepaid, t the apprpriate Warner Electric LLC factry. Additinal warranty infrmatin may be btained by writing the Custmer Satisfactin Department, Warner Electric LLC, 449 Gardner Street, Suth Belit, Illinis 61080, r by calling A purchase receipt r ther prf f riginal purchase will be required befre warranty service is rendered. If fund defective under the terms f this warranty, repair r replacement will be made, withut charge, tgether with a refund fr transprtatin csts. If fund nt t be defective, yu will be ntified and, with yur cnsent, the item will be repaired r replaced and returned t yu at yur expense. This warranty cvers nrmal use and des nt cver damage r defect which results frm alteratin, accident, neglect, r imprper installatin, peratin, r maintenance. Sme states d nt allw limitatin n hw lng an implied warranty lasts, s the abve limitatin may nt apply t yu. Warner Electric LLC s bligatin under this warranty is limited t the repair r replacement f the defective prduct and in n event shall Warner Electric LLC be liable fr cnsequential, indirect, r incidental damages f any kind incurred by reasn f the manufacture, sale r use f any defective prduct. Warner Electric LLC neither assumes nr authrizes any ther persn t give any ther warranty r t assume any ther bligatin r liability n its behalf. WITH RESPECT TO CONSUMER USE OF THE PRODUCT, ANY IMPLIED WARRANTIES WHICH THE CONSUMER MAY HAVE ARE LIMITED IN DURATION TO ONE YEAR FROM THE DATE OF ORIGINAL CONSUMER PURCHASE. WITH RESPECT TO COMMERCIAL AND INDUSTRIAL USES OF THE PRODUCT, THE FOREGOING WARRANTY IS IN LIEU OF AND EXCLUDES ALL OTHER WARRANTIES, WHETHER EXPRESSED OR IMPLIED BY OPERATION OF LAW OR OTHERWISE, INCLUDING, BUT NOT LIMITED TO, ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS. Sme states d nt allw the exclusin r limitatin f incidental r cnsequential damages, s the abve limitatin r exclusin may nt apply t yu. This warranty gives yu specific legal rights and yu may als have ther rights which vary frm state t state. Changes in Dimensins and Specificatins All dimensins and specificatins shwn in Warner Electric catalgs are subject t change withut ntice. Weights d nt include weight f bxing fr shipment. Certified prints will be furnished withut charge n request t Warner Electric. An Altra Industrial Mtin Cmpany 31 Industrial Park Rad New Hartfrd, CT Fax: P WE /14 Printed in USA