Warner Electric MCS-204 Installation instructions

Tension Control System
MCS-166, MCS-203, MCS-204
Installation & Operation Instructions
P-0257-WE
819-9027

2Warner Electric • 800-825-9050 P-0257-WE • 819-9027
Table of Contents
Introduction ............................................................................................................................................................3
Specifications ..................................................................................................................................................... 3-4
Installation
Control Housings........................................................................................................................................ 4-7
Sensor............................................................................................................................................................7
System Wiring
MCS-166/MCS-203 ................................................................................................................................... 8-9
MCS-166/MCS-204 ............................................................................................................................... 10-12
System Start-UP & Adjustments
MCS-166/MCS-203 ............................................................................................................................... 13-16
MCS-166/MCS-204 ............................................................................................................................... 17-20
System Troubleshooting
MCS-166/MCS-203 ............................................................................................................................... 21-22
MCS-166/MCS-204 .....................................................................................................................................23
Replacement Parts Listing ....................................................................................................................................24
Listing of Figures and Illustrations .........................................................................................................................24
Notes: Installation must be made in accordance with the instructions found in this manual. Failure to do so may
damage the controls and void their warranty.
Warning: Contact with the electrical voltages present in the controls covered in this manual can cause injury or
death. To avoid these consequences, make sure all power is off during installation.

Warner Electric • 800-825-9050 P-0257-WE • 819-9027 3
Tension Control System Installation and Operating Instructions
MCS-166/MCS-203/MCS-204
Introduction
All Warrior Electric Tension Control Systems are
comprised of an electric tension brake, a power supply
module, an electronic control module, and a sensor or
input control device.
This manual has been designed to cover the full range
of installation, start-up, operation, and maintenance
of your tension control system. System selection and
brake information can be found in Warner Electric’s
Tension Control Systems Catalog, P-771.
Power Supply
The MCS-166 Power Supply Module is designed to
operate either the MCS-203 Dancer Control or the
MCS-204 Remote/Analog Control. The MCS-166
accepts either 120 VAC or 220/240 VAC input power
and provides 26-28 VDC output power for operation of
the control modules and a brake.
Controls
The MCS-203 Dancer Control Module is a solid state
electronic control that receives a signal from a dancer
pivot-point sensor and transmits the appropriate
current to the brake to maintain a stable dancer
position. The MCS-203 is a closed loop control.
The MCS-204 Remote/Analog Control Module is
a solid state electronic control that will accept a
variety of input signals and provide an output current
proportional to the input. This system is open loop and
any change in output to the brake must be input to
the control from the signal source. The MCS-204 can
be operated by the local torque knob on its face or
remotely by external potentiometer, voltage input, or
current loop input.
The MCS-605-1 or TCS-605-5 Pivot Point Sensors
provide the dancer position signal to the MCS-
203 Dancer Control. The MCS-605-1 is coupled to
the dancer pivot when rotation is no more than 60
degrees, while the TCS-605-5 covers rotation up to
300 degrees.
Specications
MCS-166 Power Supply Module
Part Number: 6910-448-013
Input Power: 120VAC or 220/240VAC, 50/60 Hz,
10% switch selectable
Ambient
Temperature: +32° F to +120° F (0° C to +49° C)
Output: 26-28VDC, unregulated, 10% 1.5 amps
maximum. Over voltage protected.
Fusing: 3/8 amp, 250V fast-acting, type 3AG,
AC input.
MCS-203 Dancer Control Module
Part Number: 6910-448-014
Input Power: 26-28VDC 10% 1.5 amps maximum
with single brake, 3.0 amps with dual
brake. From single or dual MCS-166
power supplies.
Ambient
Temperature: +32° F to +120° F (0° C to +49° C)
Output: (Forward direction) 0-24VDC, pulse
width modulated 3 amps maximum
(Reverse direction) Anti-residual mode,
0 to 1.8VDC into 10 ohm load, or 0 to
180 mA. maximum
Fuses: 3 amp, 120V, fast acting, type 3AG, DC
input
Control Input: From MCS-605-1 or TCS-605-5 pivot
point sensor
Protection: Internal short circuit protection on
driver output stage. Reverse polarity
protection on DC input power
connections.
Auxiliary
Inputs: Brake On - Applies full output, 24VDC,
to brake. Active low.
Brake Off - Removes brake power and
applies anti-residual current (reverse
voltage) to brake. Active low.
Anti-Drift - Provides integrator reset
function. Active low.
Switch inputs can be controlled by
switch closure between input and
DC common or open collector, NPN
transistor to DC common.
Switch or transistor rating: 20VDC
minimum, .02 amps maximum rating.
Adjustments: Front Panel:

4Warner Electric • 800-825-9050 P-0257-WE • 819-9027
Dancer Position: sets dancer operating
position.
Gain - controls overall system response
MCS-204 Remote/Analog Control Module
Part Number: 6910-448-017
Input Power: 26-28VDC, ±10%, 1.5 amps maximum
with single brake, 3.0 amps maximum
with dual brake. From single or dual
MCS-166 power supplies.
Ambient
Temperature: +32°F to +120°F (0°C to +49°C)
Output: (Forward direction) 0-24VDC pulse
width modulated 3 amps maximum.
(Reverse direction) Anti-residual mode,
0 to 1.8 VDC into 10 ohm load, or 0 to
180 mA. maximum.
Fuses: 3 amp, 120V, fast-acting, type 3AG, DC
input
Protection: Internal short circuit protection on
driver output stage. Reverse polarity
protection on DC input power
connections.
Control Input: Via terminal strip connections in control
housing, dependent on type of input
control function. (Manual, remote,
voltage source, current source.)
Auxilary
Inputs: Brake On - Applies full output, 24VDC,
to brake. Active low.
Brake Off - Removes brake power and
applies anti-residual current (reverse
voltage) to brake. Active low.
Switch inputs can be controlled by
switch closure between input and
DC common or open collector, NPN
transistor to DC common.
Switch or transistor rating: 20VDC
minimum, 0.02 amps maximum rating.
Adjustments: Front Panel:
Zero Adjust: Provides for adjustment
of minimum input to correspond to
minimum output level.
Torque Adjust/Span: Provides for either
manual adjust or span adjustment
when in all other modes of operation.
General Information
Control chassis must be considered NEMA1 and
should be kept clear of all areas where foreign
material, dust, grease, or oil might affect the operation
of the control. Control chassis should be electrically
grounded. Neither sensor nor brake wires are at
ground potential and should be considered “floating”
unless both sides of the AC input power to the MCS-
166 are disconnected.
Pivot Point Sensors
MCS-605-1. TCS-605-5
Part Numbers: MCS-605-1,7330-448-002, single turn
TCS-605-5, 7330-448-003, 5-turn
Control
Element: Precision potentiometer, 1000 ohms, 2
watts, ±5% tolerance.
Cable: 15 ft. long, shielded, with connector
General: The tension sensor should be kept free
from foreign material, dust, grease and
oil.
Tension Brakes
Data and technical specifications for the TB style
tension brakes can be found in Warner Electric’s
Master Catalog, P-137, or Tension Control Catalog,
P-771.
For detailed brake installation, refer to manual P-235.
Installation Instructions
Installation
This Installation and Operating Manual has been
arranged for the systematic installation and start-up of
your Tension Control System. Please check off each
step in the space provided before proceeding to the
next step.
Sample
❑Check box after completion of each step.
❑Remove control logic assembly by loosening two(2)
captive screws on the faceplate and slide the
assembly out of its housing.

Warner Electric • 800-825-9050 P-0257-WE • 819-9027 5
Installation Control Housings
A. Wall/Shelf Mounting
The tongue and groove joints on the sides of each
housing module allow any number of them to be
joined together to form one housing.
1. Connecting the Housings
❑a. Remove the PC Board assemblies from the
housings, if installed by loosening the two
captive screws on each front panel and sliding
the assemblies out.
❑b. Loosen the latches holding the two part
housings together and separate the two pieces.
The latches are located on the inside tops and
bottoms of the housing.
❑c. Working from right to left, join the rear sections
of each housing by sliding them together.
Repeat the process for the front sections, but do
not fasten them together yet.
2. Wall Mounting
❑a. If bottom-entry conduit entrance is required,
remove the L-shaped bracket and discard it.
Reinsert the screws into the control after the
bracket has been removed.
❑ b. Using the dimensions shown Figure 1, page
5, drill four (4) 13/64” mounting holes for each
housing to provide clearance for #10 bolts.
❑ c. Apply the terminal strip label supplied with the
control logic module to the PC Board as shown
in Figure 2, page 6.
CAUTION: Be sure to apply the label in the proper
position with the brake (+) terminal at
the top.
❑ d. Mount the rear sections loosely to the mounting
surface. Do not connect the front sections yet.
The controls are now ready to be wired. Proceed to
the wiring section of this manual for the appropriate
wiring instructions.
3. Shelf Mounting
❑ a. If bottom conduit-entrance is required remove
the two (2) screws attaching the brackets to
the housing. Rotate the brackets to face away
from the housings and reinsert and tighten the
screws.
❑ b. Using the dimensions shown in Figure 1, page
5, drill your (4) 13/64” mounting holes for each
housing to provide clearance for #10 bolts.
❑ c. Apply the terminal strip label supplied with the
control logic module to the PC Board as shown
in Figure 2, page 6.
CAUTION: Be sure to apply the label in the proper
position with the brake (+) terminal at
the top.
❑ d. Mount the rear sections loosely to the mounting
surface. Do not connect the front sections yet.
The controls are now ready to be wired. Proceed to
the wiring section of this manual for the appropriate
instructions.
Figure 1. Wall/shelf enclosure dimensions

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B. Panel Mounting
NOTE: Panel mount housings cannot be joined
together.
❑1. Insure the PC Board Assemblies have been
removed from the housings if installed by
loosening the two captive screws on the
front panels and sliding the assemblies out.
❑2. Using the dimensions shown in Figure 3,
page 6, cut an opening 3 5/16” x 6 1/16”
info the mounting panel for each housing
assembly.
❑3. Using the dimensions shown in Figures 3,
page 6, drill four (4) 13/64” mounting holes
for each housing to provide clearance for the
#10 mounting studs.
❑4. Slide the housing assemblies into the
mounting panel cutouts. Securely fasten the
housings to the mounting panel with the four
nuts on each housing.
❑5. Apply the terminal strip label to the housing
panel near the terminal block as shown in
Figure 5, page 7.
CAUTION: Be sure to apply the label in the proper
position with the brake (+) terminal at
the top.
The controls are now ready to be wired. Proceed to
the wiring section of this manual for the appropriate
instructions.
Figure 3. Panel mount cut-out dimensions Figure 4. Panel mount housing dimensions
Figure 2. Terminal strip label orientation

Warner Electric • 800-825-9050 P-0257-WE • 819-9027 7
Figure 5. Terminal strip label orientation
MCS-605-1 Sensing Potentiometer
❑1. Using a No. 2 drill, drill a 1/2” deep hole in
the center of the dancer pivot shaft.
❑2. Drive the supplied pin into the hole in the
shaft until half its length remains exposed.
❑3. Assemble the two brackets supplied with
the two 10-32 screws.
❑4. Mount the sensor to the brackets using the
three 8-32 screws.
❑5. Position the sensor and bracket so that
the sensor shaft and pin are aligned and
separated by 5/16”.
❑6. While holding the sensor and bracket in this
position, mark the centers of the bracket
holes on the machine.
❑7. Drill and tap three (3) holes for 8-32 screws
in the machine.
❑8. Connect the sensor shaft to the pin with the
supplied universal coupling. The index mark
on the sensor shaft must be aligned with
the index mark on the sensor face when
the dancer arm is at the midpoint position.
❑9. Mount the sensor and bracket to the
machine with three (3) 8-32 screws.
❑10. The sensor is now ready to be wired. Refer
to the wiring section starting on page 8 of
this manual for complete instructions.
Figure 6. MCS-605-1 & TCS-605-5 Mounting Details

8Warner Electric • 800-825-9050 P-0257-WE • 819-9027
SYSTEM WIRING
System Wiring Precautions
WARNING: Contact with the electrical voltages
present In the controls covered in this manual
can cause Injury or death. To avoid these
consequences, make sure all power Is off during
installation.
These wiring precautions will help you properly install
and wire a trouble-free system.
1. Use proper gauge wire for all circuits.
2. If possible, segregate AC and DC power
lines, brake output lines, signal lines, and
switch wiring.
3. Shielded cable is recommended for sensor
connections and external switching circuits.
4. Do not operate external accessories from the
MCS-166, MCS-203, or MCS-204 controls.
5. Do not use controls for purposes other than
those intended. Such use could damage the
control and void the warranty.
MCS-166/MCS-203
Refer to connection diagrams, Figures 7 and 8, page
9, for wiring connections.
❑1. Wire AC input power to terminals 1, 2, and
3 of the MCS-166 terminal block: Terminal
1 neutral, Terminal 2 hot, Terminal 3 earth
ground.
❑2. Wire DC output from MCS-166 Terminal
Block to Input Power Terminals on MCS-
203 as follows:
• MCS-166 DC Common Terminal 4 to MCS-
203 DC Common Terminal 4.
• MCS-166 (+) DC Terminal 5 of MCS-166 to
(+) Terminal 3 of MCS-203.
❑3. Connect wiring from brake magnets to
Terminals 1 and 2 of the MCS-203 terminal
block.
❑4. Sensor Wiring
Determine the direction of potentiometer
shaft rotation as viewed from the connector
end of the pivot-point sensor.
CW❑a. For CW rotation, connect sensor wires
as follows: Black to Terminal 5, green to
Terminal 6, red to Terminal 7. Shield lead
should be connected to Terminal 7.
CCW❑b. For CCW rotation, connect sensor
wires as follows: Red to Terminal 5,
green to Terminal 6, black to Terminal
7. Shield lead should be connected to
Terminal 7.
❑5. External Switch Connections (optional)
❑a. Anti-Drift or integrator Switch Connect
switching circuit between terminals 8
and 9 of MCS-203 terminal strip.
NOTE: The anti-drift input can be a limit switch which
closes based on dancer arm position or it can be a
relay circuit activated by the machine start cycle.
CAUTION: The switch or relay used for the anti-
drift input should be open during
normal running operation to prevent
unpredictable reactions.
❑b. Brake-Off Switch
Connect switch contacts between
Terminals 10 and 11 of MCS-203
terminal strip.
❑c. Brake-On Switch
Connect switch contacts between
Terminals 10 and 12 of MCS-203
terminal strip.
NOTE: For single brake off function only, use a Single
Pole-Single Throw, maintained contact switch. For
both functions, a three position switch as shown in
Figures 7 and 8, page 9, is recommended.
❑6. Double check all wiring connections per
Figure 7 or 8. Insure all terminals are tight.
❑7. Reconnect the front housing of either wall
or shelf mounting and secure the latches. If
shelf mounting is used, secure the housing
with the four (4) bolts for each section.
❑8. Do not insert the control modules at this
time. Proceed to the MCS-166/MCS-203
start-up section of this manual.

Warner Electric • 800-825-9050 P-0257-WE • 819-9027 9
Figure 7. MCS-166/MCS-203 Wiring - Single Brake
Figure 8. MCS-166/MCS-203 Wiring - Dual Brakes

10 Warner Electric • 800-825-9050 P-0257-WE • 819-9027
System Wiring
MCS-166/MCS-204
Refer to Figures 9,10,11,12, pages 11 & 12, for actual
wiring connections.
❑1. Wire AC input to terminals 1, 2 and 3 of the
MCS-166 terminal block: terminal 1 to be
AC neutral, terminal 2 AC hot, and terminal
3 earth ground.
❑2. Wire MCS-166 DC output to MCS-204
input: MCS-166 DC common terminal 4 to
MCS-204 DC common terminal 4. MCS-
166 (+) DC terminal 5 to MCS-204 (+) input
terminal 3.
❑3. Connect brake magnet(s) wires to terminals
1 and 2 of MCS-204 Terminal Block.
❑4. External Switch Connections (optional)
❑a. Brake-Off Switch
Connect switch contacts between
terminals 10 and 11 of MCS-204
terminal strip.
❑b. Brake-On Switch
Connect switch contacts between
terminals 10and 12 of MCS-204
terminal strip.
NOTE: If only a single brake-off function is used,
an SPST maintained contact switch may be used.
If both functions are used, a three position switch is
recommended, as shown in Figure 9 and 10, page 11.
❑5. Control Input Connections
Refer to Figures 11 and 12, page 12, for various input
connection configurations.
❑a. Local Torque Adjust Mode
Connect jumper between MCS-204
terminals 6 and 8, per-Figure 11B, page
12.
❑b. Remote Torque Adjust/Roll Follower Pot
Connect remote potentiometer or roll
follower potentiometer to MCS-204
terminals 5, 6, and 7, per Figure 11C,
page 12.
NOTE: Wiper will always be connected to terminal 6.
End points should be connected so that turning the
remote pot CCW or moving the roll follower pot toward
the core will decrease voltage at terminal 6.
❑c. Voltage Source Input
Connect (+) side of external voltage
source to terminal 6 and (-) side (or
common) of external voltage source to
MCS-204 terminal 7, per Figure 11D,
page 12.
CAUTION: The input level from an external
voltage source must not exceed 14.5
VDC. Voltage levels higher than 14.5
VDC will damage the control’s input
circuits.
❑d. Current Source input
❑1. Determine the current range
from the external current source
and select a shunt resistor from
the chart in Figure 11E, page
12. Connect the shunt resistor
between MCS-204 terminals 7
and 9.
❑2. Connect the (+) side of the
external current source to MCS-
204 terminal 6 and the (-) side
(common) to terminal 7, per
Figure 11E, page 12.
❑e. Analog Photoelectric Sensor Input
Refer to Figure 12, page 12 for
connection information.
❑1. Make sure the MCS-166 and
MCS-204, power, and brake are
connected per Figure 12, if not
already done.
❑2. Connect sensor to MCS-204,15
VDC power source: Sensor blue
lead to DC common terminal 7
and sensor brown lead to +15
VDC terminal 5.
❑3. Connect sensor output (black
lead) to (+) input on Iso-verter,
terminal 7.
❑4. Connect (+) output of Iso-verter
terminal 2 to input of MCS-204
terminal 6.
❑5. Connect MCS-204 terminal 7
(DC common) to both input and
output (-) terminals 1 and 8 of the
Iso-verter.
❑6. Connect a shunt resistor between
terminals 7 and 9 of MCS-204
terminal strip.
NOTE: To prevent pick-up of stray electrical noise,
connect the shield wire to terminal 7 only. Use of
shielded cable is strongly recommended for sensor
pot, voltage or current source input, and connection of
the Iso-verter to the MCS-204 inputs.

Warner Electric • 800-825-9050 P-0257-WE • 819-9027 11
❑6. Double check all wiring connections per
Figures 9, 10, 11, or 12 for accuracy and
tightness.
❑7. Reconnect the front housings if either
wall or shelf mounting is used. Secure the
latches. If shelf mounting is used, secure
the housings with the four (4) bolts for each
section.
❑8. Do not insert the control modules at this
time. Proceed to the MCS-166/MCS-204
start-up section of this manual.
Figure 9. MCS-166/MCS-204 Wiring - Single Brake
Figure 10. MCS-166/MCS-204 Wiring - Dual Brakes

12 Warner Electric • 800-825-9050 P-0257-WE • 819-9027
Figure 11. MCS-204 Input Configuration
Figure 12. Analog Photoelectric - Roll Follower Wiring

Warner Electric • 800-825-9050 P-0257-WE • 819-9027 13
System Start-Up and Adjustment
MCS-166/MCS-203
Once set, most MCS-166/MCS-203 adjustments
should require no further attention. Exceptions are the
“Dancer Position” and “Gain” controls on the MCS-
203 front panel. The following start-up and adjustment
procedure will provide a stable operating system.
Refer to Figure 13, page 16, for the exact location of
internal adjustment potentiometers.
A. Preliminary Set-Up
❑1. Set voltage selector switch on MCS-166
for proper input voltage range. This will be
either 120 VAC or 220/240 VAC.
NOTE: An additional switch has been added to the
MCS-166 for selecting 220 or 240 VAC operation. This
switch is labeled Low-High. For older style units with
a single 20/220-240 VAC selector switch, proceed to
step 5 below.
❑2. Set the Low-High Switch as follows:
❑a. For 120 VAC, set to High Position.
❑b. For 240 VAC, set to High Position.
❑c. For 220 VAC, set to Low Position.
NOTE: The Low-High switch is used primarily for
selecting 220 or 240 VAC operation when the line
selector switch is set for 240 VAC, but it can also be
used if low line input voltage exists.
❑3. Low line input: For 108 VAC input when set
on 120 VAC or 198 VAC input when set on
240 VAC, set the Low-High switch to the
Low position.
❑4. High line input: For 132 VAC input when set
on 120 VAC or for 268 VAC input when set
for 240 VAC, set the Low-High switch to
the High Position.
CAUTION:lmproperly setting the120/240VAC
Selector Switch and the High-Low
Selector Switch can damage the power
supply and/or control Module and void
their Warranties.
❑5. Slide the power module into the housing
and secure with the two captive fasteners
on the faceplate.
CAUTION:(OLD STYLE BACK BOARDS ONLY)
The connectors must mate properly
when inserting the control modules into
the housings. If the module does not
slide in smoothly, gently rock the module
from side to side until the connectors
mate, but do not apply excessive force.
(NEW STYLE UNITS WITH RIBBON
CABLES)
Pull the ribbon cable forward so that the
connector end is in front of the housing
assembly. Fasten the ribbon cable
connector to the pin connector on the
control module. Pin 1 (Red Tracer) on the
ribbon cable must connect to pin 1 on
the control module as shown. This “Red
Tracer” will ALWAYS be toward the top
of the control.
❑6 Set the “Dancer Position* to its midpoint
range and the “Gain” to “5” on the MCS-
203 faceplate.
❑7. Set the internal adjustments per Figure 13,
page 16, as follows:
❑a. Proportional gain, “R32” fully clockwise
(CW).
❑b. Integrator gain, “R24” at 60% clockwise.
❑c. Differentiator gain, “R16” at 75%
clockwise.
❑d. Differentiator response switch 1 “on” and
switches 2 and 3 “off.”
❑8. Slide the control module into the housing
and secure with the two captive fasteners
on the faceplate.
CAUTION: OLD STYLE BACK BOARDS ONLY)
The connectors must mate properly
when inserting the control modules into
the housings. If the module does not
slide in smoothly, gently rock the module
from side to side until the connectors
mate, but do not apply excessive force.
(NEW STYLE UNITS WITH RIBBON
CABLES) Pull the ribbon cable forward
so that the connector end is in front of
the housing assembly. Fasten the ribbon
cable connector to the pin connector on
the control module. Pin 1 (Red Tracer)
on the ribbon cable must connect to pin
1 on the control module as shown. This
“Red Tracer” will ALWAYS be toward the
top of the control.
B. Static Adjustment and Check Out
❑1. Apply power to the tension control system
with the machine in a non-running or off
mode. Check that the “power” indicators
on both the MCS-166 and MCS- 203 are
illuminated.
❑2. Move the dancer arm to the shortest web-
loop position and note that the “brake”
indicator goes “off.” Then move the dancer
to the longest web-loop position and note
that the “brake” indicator illuminates.
NOTE: If the “brake” indicator is the reverse of this,
the Pivot-Point Sensor is wired backwards. Refer to
the MCS-166/MCS-203 wiring section for correct
connections.

14 Warner Electric • 800-825-9050 P-0257-WE • 819-9027
❑3 Brake-On/Brake-Off Switch Check
(optional)
❑a. Place Brake-Off switch in brake-off
mode and note that the “brake” indicator
goes out.
❑b. Return the Brake-Off switch to its normal
run mode.
❑c. If used, turn on the Brake-On switch and
note that the “brake” indicator goes full on.
❑d. Return Brake-On switch to its normal
Running , position.
NOTE: If operation of the Brake-On/Brake-Off
switches produced the opposite results in 3a and 3c
above, the wiring is reversed.
Refer to the MCS-166/MCS-203 wiring section for the
proper connections.
❑4. Anti-Residual Adjustment
❑a. Activate the Brake-Off switch (if used) or
move the dancer to the shortest web-
loop position.
❑b. Check that the brake armature floats
away from the brake magnet with no
sticking.
❑c. If the armature sticks to the magnet,
adjust the anti-residual potentiometer
CW or CCW until the armature is free
with no sticking.
❑d. Reapply the brake either by moving
the dancer to its longest web-loop or
by returning the brake off switch to its
normal run position and activating the
brake-on input.
❑e. Repeat steps 4a through 4d above.
❑f. If brake releases freely, make no further
adjustments as the anti-residual is now set.
NOTE: CCW rotation decreases the anti-residual
output while CW rotation increases it. Excessive CW
rotation can cause brake engagement.
❑5. Frequency Adjustment
The frequency adjustment changes
the modulation frequency to eliminate
brake “hum” or “howl” when the brake is
stationary. The frequency is factory set and
normally requires no adjustment.
❑a. Turn CW if a low pitch hum is present
or CCW if hum is high pitched.
*CAUTION:To set the frequency, the control must
be unplugged from its housing. Do
not unplug control unless power is
off. Failure to turn power off before
unplugging will result in damage to
control module and/or power module.
C. Start-Up and Dynamic Adjustments
❑1. Verify that power is on.
❑2. Start the machine and draw material.
❑3. After the Dancer has stabilized, adjust the
front panel “Dancer Position” potentiometer
for the desired dancer running position.
❑4. If the system is providing stable dancer
operation, increase the “Gain” until the
dancer hunts or oscillates. Note the gain
position number where this occurs.
❑5. Reduce the “gain” setting from step 4
above one to two digits.
❑6. If dancer instability is apparent from initial
start, reduce the gain until it becomes
stable.
NOTE: This is only a preliminary gain setting. A final
gain setting is required at core diameter for optimum
system performance.
❑7. Run the system until the unwind roll is
within two to four inches of core diameter.
❑8. If the system has been stable, re-set the
front panel “gain” until dancer hunting or
oscillation occurs, noting the gain setting
number, then reduce the setting one or two
digits.
NOTE: This is the optimum gain setting. No further
adjustments are necessary.
❑9. If system stability cannot be achieved
through front panel “gain” adjustment, it
may be necessary to adjust gain functions
internally.
CAUTION:Internal P-l-D gain adjustments should
be made only after all other attempts
to achieve system stability have failed.
These adjustments should be made by
qualified personnel only.
NOTE: Internal access is required for the set-up
adjustments which follow. This can be accomplished
with the TCS-900 set-up and diagnostic tester or by
removing the side panel plate from the housing, or, on
new versions with ribbon cable connectors, by sliding
the control module partially out of the housing.
CAUTION: If side panel plate on the control housing
is to be removed, insure the power is off
before removing the control module from
the housing. Failure to disengage power
before removing the module will result
in damage to the control and/or power
module.
IMPORTANT: Follow the sequence outlined below
to properly adjust the P-l-D circuit
gains. If the TCS-900 is used, follow
the instructions included with the
TCS-900.
*Applies only to “older style” units without ribbon cable
assemblies.

Warner Electric • 800-825-9050 P-0257-WE • 819-9027 15
D. P-l-D Gain Adjustments
❑1. ”P” - Proportional gain adjustment, R32
❑a. Jumper the anti-drift input (terminal
8) to DC common (terminal 9) on the
MCS-203 terminal block to disable the
integrator circuit.
❑b. Inject a transient into the system by
rapidly changing the dancer position.
Suddenly changing dancer air pressure
or rapidly depressing the web or dancer
arm will provide the transient. Observe
the dancer’s response.
❑c. The dancer should stabilize within one to
two cycles. If oscillations do not subside,
reduce the “P”gain potentiometer, R32,
CCW in small increments, observing the
effects.
❑d. Repeat steps b and c above as
necessary until desired response is
obtained.
NOTE: “P” gain settings are a function of brake size.
R32 is factory set at 100% CW. Generally, the larger
the brake, the lower the R32 setting.
NOTE: If response is not obtained with “P” gain
adjustment, it may be necessary to make “D” gain
adjustments as well.
❑2. ”D” - Differentiator gain adjustment, R16
❑a. Insure anti-drift (terminal 8) is still
grounded.
❑b. Inject a transient into the web as
described in step 1b above.
❑c. If dancer stability is achieved within
one or two cycles, make no further
adjustments.
❑d. If stability is not achieved, adjust R16 as
follows:
❑1. If response is erratic and dancer is
extremely jerky, rotate R16 CW.
❑2. If response is sluggish and dancer
hunts, rotate R16 CCW.
NOTE: If proper response is not achieved with R16
at maximum CW setting, the next higher differentiator
response range should be used.
CAUTION: When switching to higher response ranges,
R16 should be set full CCW.
Factory Settings:
“P” (R32) = 100% CW
“I” (R24) = 60-70% CW
“D” (R-16) = 75% CW
Dip switch #1 on (only)
❑e. Repeat steps b through d above to
insure optimum response.
NOTE: To insure optimum performance, the system
should be checked at or near full roll diameter.
❑f. Remove jumper on anti-drift input
(connecting terminal to DC common
terminal 9).
❑3. T - Integrator gain adjustment, R24.
CAUTION: The”l” gain adjustment controls how far
the dancer must move to compensate
for unwind roll diameter changes. Any
adjustment must be made strictly in
accordance with the instructions below:
❑a. With the system running and
stabilized, observe the amount of
dancer movement.
❑b. If the dancer arc is less than 5
degrees and movement is smooth,
do not make any adjustments.
❑c. If dancer arc is greater than 10
degrees, but movement is smooth,
adjust the “1” gain potentiometer
CW in small increments, observing
the results, until stability is achieved.
❑d. If dancer arc is within 5 to 10
degrees, but movement is choppy
and rough, adjust the “I” gain
potentiometer CCW in small
increments, observing the results,
until stability is obtained.
❑4. After completing P-l-D adjustments,
recheck main gain adjustments per steps
C4 through C8.
This completes the start-stop and adjustment of the
MCS-166/MCS-203 Dancer Control System.
If difficulties are encountered which cannot be
resolved using this manual, contact your local
Warner Electric Representative or the factory.

16 Warner Electric • 800-825-9050 P-0257-WE • 819-9027
Figure 13. Control Adjustment Locations MCS-166/MCS-203

Warner Electric • 800-825-9050 P-0257-WE • 819-9027 17
System Start-Up and Adjustment
MCS-166/MCS-204
Once set, most MCS-166/MCS-204 adjustments
require no further attention. The exception is the
torque/span adjust which sets the maximum output
limit. Please follow the set-up and adjustment
procedure below for trouble free start-up.
Refer to Figure 14, page 19, for exact location of
adjustments and indicators.
A. Preliminary Set-Up
❑1. Set voltage selector switch on MCS-166 for
proper input voltage range, either 120 VAC
or 220/240 VAC.
NOTE: An additional switch has been added to the
MCS-166 for selecting 220 or 240 VAC operation.
This switch is labeled Low-High. For older style units
with a single 120/220-240 VAC selector switch,
proceed to step 5 below.
❑2. Set the Low-High Switch as follows:
❑a. For 120 VAC, set to High Position.
❑b. For 240 VAC, set to High Position.
❑c. For 220 VAC, set to Low Position.
NOTE: The Low-High switch is used primarily for
selecting 220 or 40 VAC operation when the line
selector switch is set for 240*AC, but it can also be
used if low line input voltage exists.
❑3. Low line input: For 108 VAC input when set
on 120 VAC or 198 VAC input when set on
240 VAC, set the Low-High switch to the
Low position.
❑4. High line input: For 132 VAC input when set
on 120 VAC or for 268 VAC input when set
for 240 VAC, set the Low - High switch to
the High Position.
CAUTION: lmproperly setting the 120/240 VAC Selector
Switch and the High-Low Selector Switch
can damage the power supply and/or
control Module and void their Warranties.
❑5. Slide power module into its housing and
secure with the two captive fasteners on
the faceplate.
CAUTION: (OLD STYLE BACK BOARDS ONLY)
The connectors must mate properly when
inserting the control modules into the
housings. If the module does not slide in
smoothly, gently rock the module from side
to side until the connectors mate, but do
not apply excessive force.
(NEW STYLE UNITS WITH RIBBON CABLES)
Pull the ribbon cable forward so that the
connector end is in front of the housing
assembly. Fasten the ribbon cable
connector to the pin connector on the
control module. Pin 1 (Red Tracer) on the
ribbon cable must connect to pin 1 on
the control module as shown. This “Red
Tracer” will ALWAYS be toward the top of
the control.
❑6. Slide the MCS-204 Control Module into its
housing and secure with the two captive
fasteners on the faceplate.
CAUTION: (OLD STYLE BACK BOARDS ONLY)
The connectors must mate properly when
inserting the control modules into the
housings. If the module does not slide in
smoothly, gently rock the module from side
to side until the connectors mate, but do
not apply excessive force.
(NEW STYLE UNITS WITH RIBBON CABLES)
Pull the ribbon cable forward so that the
connector end is in front of the housing
assembly. Fasten the ribbon cable
connector to the pin connector on the
control module. Pin 1 (Red Tracer) on the
ribbon cable must connect to pin 1 on
the control module as shown. This “Red
Tracer” will ALWAYS be toward the top of
the control.
B. Static Adjustments and Check Out
❑1. Apply power to the Tension Control System
with the machine stationary. Check that the
“Power” indicators on both the MCS-166
and MCS-204 are illuminated.
❑2. Set the front panel ‘Torque/Span Adjust”
potentiometer to its full CCW positioning.
❑3. Brake-off/brake-on switch checks (optional)
❑a. Set brake-off switch to off position and
note that the “brake” indicator is off. The
0-100% indicator may be on at this time.
❑b. Return the brake-off switch to its normal
running position.
❑c. Place the brake-on switch (if used) in
the brake on position and note that the
“brake” indicator is on. The 0-100%
indicator may also be on at this time.
❑d. Return the brake-on switch to its normal
running position.
NOTE: If operation of the brake-off and brake-on
is reversed, the wiring is reversed. Refer to MCS-
166/MCS-204 wiring section for proper wiring
connections.

18 Warner Electric • 800-825-9050 P-0257-WE • 819-9027
❑4. Anti-residual adjustment
❑a. Activate the brake-off switch, if used,
or jumper the brake-off terminal to DC
common.
❑b. Check that the brake armature floats
away from the magnet with no sticking.
❑c. If the armature sticks, adjust the anti-
residual potentiometer CW or CCW until
the armature is free with no sticking.
❑d. Reapply the brake by either activating
the brake on switch or jumpering the
brake-on input to DC common. Brake-
off input must be open.
❑e. Repeat steps 4a through 4d above.
❑f. If brake releases freely, the anti-residual
is set.
NOTE: CCW adjustment decreases anti-residual
output while CW adjustment increases it. Setting the
anti-residual too far CW can cause brake engagement.
❑5. Frequency adjust
The frequency adjust changes the
modulation frequency to eliminate brake
“hum” or “howl” when the brake is
stationary. The frequency is factory set and
normally requires no adjustment.
❑a. Turn CW if a low pitch hum is
present or CCW if the hum is high
pitched.
*CAUTION: To set the frequency, the control must be
unplugged from its housing. Do not unplug
control unless power is off. Failure to turn
power off before unplugging will result in
damage to control module and/or power
module.
C. Input Calibration
NOTE: The following calibration procedures assume
that the maximum input corresponds to the maximum
(24VDC) output to the brake. An accurate digital
voltmeter is required to properly set up this system.
❑1. Local torque adjust mode
❑a. Insure power is on and torque
adjust/span is set fully CCW.
❑b. Set the “zero adjust” potentiometer
(through front panel) so the 0-100%
indicator illuminates. This is a true
zero output to the brake.
❑c. Now rotate the “torque/span”
potentiometer toward its maximum
setting. As the pot is turned, the
0-100% indicator goes out and
the “brake” indicator comes on. At
100% output (24VDC), the 0-100%
indicator will come on.
NOTE: Depending on the accuracy of the initial
“zero” setting, steps a through c above may have to
be repeated to achieve full range adjustment of the
“torque/span” potentiometer.
❑2. Remote torque adjust
❑a. Insure that power system is on.
❑b. Set the remote torque adjust
potentiometer to maximum.
❑c. Set the front pane “torque/span
adjust” to maximum output (24VDC).
The 0-100% indicator will be
illuminated.
❑d. Set the remote torque adjust
potentiometer to minimum.
❑e. Set the “zero adjust” potentiometer
so the 0-100% indicator illuminates.
❑f. Repeat steps b through e above as
these two adjustments will interact
on each other.
NOTE: When the remote torque adjust pot is at
minimum, the brake should be fully released. When the
pot is set to maximum, the brake should be fully on.
❑g. After the proper “span” adjustment
is obtained, remove the “torque/
span” knob and insert the cap plug
into the hole to prevent tampering.
❑3. Current source adjust
❑a. Insure that system power is on.
❑b. Adjust the external current source
for minimum input current, based on
the operating range selected.
❑c. Adjust the “zero adjust”
potentiometer so the 0-100%
indicator is illuminated.
❑d. Set the external current source
to maximum input based on the
operating range selected.
❑e. Adjust the “torque/span”
potentiometer for full output
(24 VDC) and 0-100% indicator
illumination.
❑f. Repeat steps b through e to insure
there is no interaction between
adjustments.
NOTE: Set-up adjustment is the same for all three
current range inputs.

Warner Electric • 800-825-9050 P-0257-WE • 819-9027 19
❑g. After set-up has been completed,
the “torque/span” knob should be
removed and the hole plugged with
the insert provided.
❑4. Voltage source adjust
❑a. Insure that system power is on.
❑b. Set the external voltage source for
maximum input level.
WARNING: The maximum input level must not exceed
14.5 VDC or damage may occur to control
logic circuits.
*Applies only to “older style” units without ribbon cable
assemblies.
❑c. Adjust the “torque/span”
potentiometer for maximum output
(24VDC) as indicated by the 0-100%
indicator illumination.
❑d. Adjust the external voltage source
for the minimum input level to be
used.
❑e. Set the “zero adjust” potentiometer
or zero output until the 0-100%
indicator illuminates.
❑f. Repeat steps b through e until no
Interaction is seen between the two
adjustments.
❑g. After set up adjustments have been
completed, the “torque/span” knob
should be removed and the hole
plugged with the insert provided.
❑5. Roll follower adjustment
❑a. Insure that system power is on.
❑b. Connect a DC voltmeter between
the wiper and DC common on the
follower potentiometer.
❑c. Adjust the roll follower arm for a true
zero position which corresponds
to the exact center of the roll shaft.
Adjust the roll follower potentiometer
to provide a DC input reading of 0.5
VDC ±0.1 VDC.
❑d. Remove the meter from the follower
potentiometer and connect across
the brake magnet.
❑e. Set the roll follower arm to
correspond to the maximum roll
diameter.
❑f. Adjust the “torque/span”
potentiometer to provide the desired
output level to the brake as indicated
by the voltmeter.
❑g. Set the roll follower arm back to its
true zero position.
❑h. Set the “zero adjust” potentiometer
for a zero output as indicated by the
0-100% indicator illumination.
❑i. Repeat steps e through h until no
interaction is evident between the
two adjustments.
NOTE: At maximum roll diameter, the output of the
MCS-204 should be set for the required tension. This
may not correspond to the full output level of the
control, depending on tension, speed, and torque
available.
D. Dynamic Adjustments
❑1. Remove any meter connections, etc., that
were made during set-up adjustments.
❑2. Start system and draw web through the
machine.
❑3. Make any adjustment necessary to provide
the required tensions based on the type of
input used.
This completes the start-up and adjustment of the
MCS-166/MCS-204 Remote/Analog Control System.
If any difficulties are encountered that cannot be
resolved through this manual, contact your local
Warner Electric Representative or the factory.

20 Warner Electric • 800-825-9050 P-0257-WE • 819-9027
Figure 14. Control Adjustment Locations MCS-166/MCS-204